Caviblaster 2040-D Operation & Maintenance Manual Download

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2040-D O&M Manual Ver 3.0 CaviDyne



5077 Fruitville Rd.; Suite 109

– 157 Sarasota, FL 34234 U.S.A.



Phone 352.275 5319

Page 3/38

TABLE OF CONTENTS

1.0 UNIT SPECIFICATIONS ............................................................................................5

2.0 GENERAL DESCRIPTION ........................................................................................6

2.1 Using this Manual .......................................................................................................8

2.2 Conventions ................................................................................................................9

2.3 Scope .........................................................................................................................9

2.4 Terms and Abbreviations ............................................................................................9

3.0 SAFETY INFORMATION ......................................................................................... 10

3.1 Personal Safety ........................................................................................................ 10

3.2 Personal Protective Equipment................................................................................. 11

3.3 Modification to the Equipment................................................................................... 12

4.0 INSTALLATION ....................................................................................................... 13

4.1 Uncrating and Lifting ................................................................................................. 13

4.2 Installation Location .................................................................................................. 14

4.3 Initial Set Up ............................................................................................................. 15

4.3.2 Connecting the Water Source ............................................................................ 15

5.0 OPERATION ............................................................................................................ 18

5.1 Preparing the Unit for Operation ............................................................................... 18

5.2 Startup ...................................................................................................................... 19

5.3 Normal Operation ..................................................................................................... 20

5.4 Gun Pressure Calibration ......................................................................................... 22

5.5 Recommendations for Effective Results ................................................................... 25
5.6 Shutting Down the CaviBlaster

............................................................................... 25

5.7 Emergency Shutdown Systems ................................................................................ 25

6.0 MAINTENANCE ....................................................................................................... 28

6.1 Basic Preventive Maintenance Recommendations ................................................... 29

6.2 Diesel Engine Service ............................................................................................... 30

6.3 Pump Service ........................................................................................................... 30

6.4 Inspection/Cleaning of water inlet strainer ................................................................ 30

6.5 Inspection / Maintenance of the belt drive system .................................................... 32

7.0 WINTERIZATION ..................................................................................................... 34

8.0 TROUBLESHOOTING ............................................................................................. 35

9.0 REPLACEMENT PARTS ......................................................................................... 37

APPENDIX - COMPONENT LITERATURE ................................................................... 38

Summary of Contents for 2040-D

Page 1: ...CAVIDYNE TM LLC 5077 Fruitville Road Suite 109 157 Sarasota FL 34234 USA Phone 352 275 5319 Web Site www caviblaster com Model 2040 D ...

Page 2: ...ntire manual carefully before use The CaviBlaster 2040 D 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 Proper commercial diver s protective equipment should be used to operate the CaviBlaster system Do not use air pressure in excess of 120 p...

Page 3: ...Installation Location 14 4 3 Initial Set Up 15 4 3 2 Connecting the Water Source 15 5 0 OPERATION 18 5 1 Preparing the Unit for Operation 18 5 2 Startup 19 5 3 Normal Operation 20 5 4 Gun Pressure Calibration 22 5 5 Recommendations for Effective Results 25 5 6 Shutting Down the CaviBlaster 25 5 7 Emergency Shutdown Systems 25 6 0 MAINTENANCE 28 6 1 Basic Preventive Maintenance Recommendations 29 6...

Page 4: ...D Control Panel 8 Figure 2 3 CaviBlaster 2040 D PTO Operation 8 Figure 4 1 Lifting Guidelines 13 Figure 4 2 Installation Guidelines 14 Figure 4 3 Gravity Feeding Source 16 Figure 5 1 Emergency Shut Down and Throttle Control 21 Figure 5 2 Gun Pressure Calibration 21 Figure 5 3 Gun Position for Best Results 21 Figure 6 1 Inspection Cleaning Water Filter 30 Figure 6 2 Inspection Belt tension 31 Figur...

Page 5: ...kW Diesel Powered Kubota V3600 Installation Environment 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 ...

Page 6: ...re hose and a diesel powered high pressure pumping unit The zero 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 bel...

Page 7: ...asota FL 34234 U S A Phone 352 275 5319 Page 7 38 Radiator Lifting eyes Forklift slots Fuel tank Fuel level gauge Control panel see Figure 2 2 Figure 2 1 CaviBlaster 2040 D General Features For more information on the CaviBlaster system please visit us at www caviblaster com ...

Page 8: ...5 5319 Page 8 38 Figure 2 2 CaviBlaster 2040 D Control Panel PTO Disengaged PTO Engaged Figure 2 3 CaviBlaster 2040 D PTO Operation By pass hose 1 cam lock Pressure hose 3 4 JIC Gauge Panel Engine Start push to start Engine Stop push to stop Throttle Control Air Hose engine start Water Inlet 1 1 2 cam lock ...

Page 9: ...re 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 ...

Page 10: ... 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 2040 D underwater cleaning system must only be attempted by commercial divers or other personnel who have been trained in its us...

Page 11: ...cinity 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 Proplugs or equivalent for diver hearing protection The operators of the CaviBlaster system should always wear neoprene or heavy rubber gloves to provide prote...

Page 12: ...re 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 of any part ...

Page 13: ...t for damage If damage is found immediately contact CaviDyneTM 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 weigh...

Page 14: ...r 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 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 ...

Page 15: ... Figure 2 2 7 Connect the air starter hose See Figure 2 2 8 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 4 3 1 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 ...

Page 16: ...r condition using the centrifugal water pump or an outside water source capable of supplying at least 20 GPM 95 LPM at a maximum pressure of 70 PSI 4 8 BAR Gravity feeding water source See Figure 4 4 Use a hose with a diameter of at least 1 1 2 to connect the water tank to the power unit Figure 4 3 Gravity Feeding Source To use the feed pump supplied with the system Connect the cam lock socket on ...

Page 17: ... pump To use gravity feed Locate the water supply tank so that the tank outlet is higher than the water inlet on the control panel See Figures 2 2 and 4 4 Connect a minimum 1 1 2 hose to the water inlet 1 1 2 cam lock plug Connect the other end of the hose to the water supply tank outlet Make sure the lowest point in the hose line is the connection with the power unit It is essential that adequate...

Page 18: ... 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 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 engin...

Page 19: ...hat the PTO lever is in the disengaged position 6 Apply appropriate hearing protection prior to starting engine 7 Open the air supply valve at the source being used to power the air starter Push the black Engine Start knob See Figure 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 starte...

Page 20: ... gun 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 4 Wear neoprene or rubber gloves to protect the hands and...

Page 21: ...e water pressure in the hose s by squeezing the gun 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 Figure 5 1 Engine Shut Down and Throttle Control Although the CaviBlaster system is safe to use when submerged in water the system generates a high pressure up to 3 700...

Page 22: ...uge to the pressure hose and tighten the JIC connections Reattach the whip hose with the gun to the calibration gage 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 ...

Page 23: ...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 3 750 psi 258 Bar Pressure adjustments are made by turning the knob on top of the pressure regulating valve in the same manner as described above Figure 5 2 Pressure Regulating Valve DO NOT ADJUST THE PRESSURE AT THE GUN TO MORE THAN 3 700 PSI 255 ...

Page 24: ...2040 D O M Manual Ver 3 0 CaviDyneTM 5077 Fruitville Rd Suite 109 157 Sarasota FL 34234 U S A Phone 352 275 5319 Page 24 38 Figure 5 3 Gun Pressure Calibration Test gauge Whip hose Main hose Whip hose ...

Page 25: ...the black knob to lock 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 m...

Page 26: ... the pressure pump 3 Shut off the engine by pushing the red E Stop button on the control panel 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...

Page 27: ...gine In addition manual emergency shutdowns are provided in the form of an E stop button on the main control panel and an air shut off Chalwyn valve in the air intake system Pressing either of these buttons will result in immediate engine shutdown In the event of an emergency resulting in vaporized fuel being present in the air use only the emergency air shut off Chalwyn valve See Figures 5 6 and ...

Page 28: ...ssure released from all hoses prior to performing any service 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 DECREAS...

Page 29: ...r X Replace engine oil filter 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 af...

Page 30: ...ed on a regular basis The pump crankcase holds 4 2 qt 4 L of SAE 30 weight 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 2040 D is equipped with 2 water strainers one before the water feed pump and one between the water feed pump and the pressure pump Th...

Page 31: ...2040 D O M Manual Ver 3 0 CaviDyneTM 5077 Fruitville Rd Suite 109 157 Sarasota FL 34234 U S A Phone 352 275 5319 Page 31 38 Figure 6 1 Inspection Cleaning Water Strainer Water Filter Water Strainer ...

Page 32: ...ated power take off FULL ENGINE SPEED IS REQUIRED FOR PROPER OPERATION OF THE GUN To inspect the belt 1 Remove the belt guard cover supported by 7 bolts See Figure 6 2 2 If belts need tightening use the tightening nut to adjust See Figure 6 2 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 Inspection Belt tension Belt...

Page 33: ...er if it will be used in the next 24 hours Ensure the gun is completely 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 poss...

Page 34: ...ons To winterize the CaviBlaster 2040 D power unit 1 Fill a 5 gallon or larger tank with appropriate antifreeze solution 2 Insert a feed pump 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 ...

Page 35: ...TER DOES NOT GO OUT THE GUN Verify inlet water supply is functioning 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...

Page 36: ... is operating at the correct pressure 3 700 psi Remove the gun 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 Rem...

Page 37: ...artridge stainless steel 1 1 Engine air filter 2 1 Engine oil filter HH1C0 32430 1 1 Engine fuel filter 16631 42560 1 1 Engine fan belt 2 1 Pressure pump drive belt 2 1 Feed pump drive belt 1 1 Pump seal kit 31280 1 1 Pump valve kit 31292 1 1 Pressure regulating unloader repair kit UB 402 K 1 1 Relief valve repair kit UB 402 K 1 1 Trigger valve repair kit 20 3600 490 All parts can be ordered from ...

Page 38: ...ec Sheet Engine Operator s Manual NACD Power Take Off PTO Drawing CAT Pumps Model 3560 Pump Spec Sheet Pump Service Manual Crankcase Oil Data Sheet and MSDS Udor Unloader Relief Valve Model UB 402 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 CAT Pumps Suttner EOS ...

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