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CAVIDYNE Caviblaster 2570-D, Operation & Maintenance Manual, Page: 1 / 35

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CAVIDYNE LLC

5077 Fruitville Road
Suite 109 - 157
Sarasota, FL 34232
Phone: (352) 275-5319
Email: [email protected]
www.caviblaster.com

Operation &

Maintenance

Manual

Model 2570-D

Summary of Contents for Caviblaster 2570-D

Page 1: ...CAVIDYNE LLC 5077 Fruitville Road Suite 109 157 Sarasota FL 34232 Phone 352 275 5319 Email sales cavidyne com www caviblaster com Operation Maintenance Manual Model 2570 D ...

Page 2: ...el 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 Do not use air pressure in excess of 120 psi 8 bar when starting the equipment Serious damage to the equipment will occur Page 2 CaviBlaster 2570 D Operations Manual For more in...

Page 3: ...ration 18 5 2 Startup of the CaviBlaster 19 5 3 Normal Operation 20 5 4 Adjusting the CaviBlaster for Maximum Performance 22 5 5 Recommendations for Effective Results 23 6 0 MAINTENANCE 25 6 1 Basic Preventive Maintenance Recommendations 26 6 2 Diesel Engine Service 27 6 3 Pump Service 27 6 4 Inspection Cleaning of water inlet strainer 27 6 5 Inspection Maintenance of the Belt Drive System 28 6 6 ...

Page 4: ...5 1 Engine Shut Down and Throttle Control 21 Figure 5 2 Pressure Regulating Valve 22 Figure 5 3 ZT Gun Positioning for Best Results 23 Figure 5 4 Control Panel Ignition Key 24 Figure 6 1 Inspection Cleaning Water Strainer 28 Figure 6 2 Inspection Belt tension 29 Figure 6 3 Diver Gun 2570 ZT DumpGun 30 This space intentionally left blank Page 4 CaviBlaster 2570 D Operations Manual For more informat...

Page 5: ...ion 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 75 psi Minimum to 100 PSI Maximum 5 2 BAR to 6 9 BAR See Section 4 for further requirements Overall Unit Dimensions L x W x H 97 x 57 x 63 247 cm x 145 cm x 160 cm Maximum Pressure Hose Length 600 LF 200 meters of 3 4 19mm diameter Power Unit Weight...

Page 6: ...to control the water stream on and off 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 2570 D power unit is a complete plug and play system built into a self supp...

Page 7: ...al Features Page 7 CaviBlaster 2570 D Operations Manual For more information please email sales cavidyne com or call 1 352 275 5319 For more information on the CaviBlaster system please visit us at www caviblaster com ...

Page 8: ...Figure 2 2 Control Panel Figure 2 3 PTO Lever Hose Connections Page 8 CaviBlaster 2570 D Operations Manual For more information please email sales cavidyne com or call 1 352 275 5319 ...

Page 9: ...r 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 2570 D It...

Page 10: ...ion in this manual for the correct procedures prior to any installation setup or maintenance work 3 1 Personal Safety Operation of the CaviBlaster 2570 D underwater cleaning system must only be attempted by commercial divers or other personnel who have been trained in its use Appropriate protective equipment should always be worn Operation of the system without the proper equipment and training ca...

Page 11: ...earing a diving helmet hearing protection is recommended CaviDyne 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 will absorb most of the energy produced by bursting cavitation bubbl...

Page 12: ...ecommended 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 This space intentionally left blank Page 12 CaviBlaster 2570 D Operations Manual For more information please email sales cavidyne com or call 1 352 275 5319 EOS Unauthorized replacement of any par...

Page 13: ...e 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 Figure...

Page 14: ...e 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 frequ...

Page 15: ... 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 The CaviBlaster 2570 D must be flushed and rinsed with fresh water after every use in seawater Failure to flush and rinse the power unit after use in seawater will re...

Page 16: ...g the channel water pump or an outside water source capable of supplying at least 30 GPM 114 LPM at a maximum pressure of 100 PSI 6 9 BAR Gravity feeding water source See Figure 4 4 Use a hose with a diameter of at least 1 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 the 1 1 2 feed hose to...

Page 17: ...et on the control panel See Figures 2 3 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 water is supplied to the water supply tank to maintain the water level several inches above the tank outle...

Page 18: ...1 Inspect the CaviBlaster power unit hoses fittings and zero thrust gun guns for any signs of damage 2 Inspect the inline filter cartridge to ensure that it is not clogged See Figure 6 1 Clean or change cartridge if necessary 3 Check for proper engine oil level See engine Owner s Manual found in the Appendix Add lubricating oil SAE 10W40 if necessary 4 Check for proper pressure pump oil level See ...

Page 19: ...nition start key to the on position and wait for the glow plugs to heat up Turn the ignition start key to the start position If the engine does not start within 10 seconds turn the ignition start key to the off position and wait at least 30 seconds before trying to start again Once the engine starts turn off the ignition start key to the on position 7 Run the engine at idle speed for a minimum of ...

Page 20: ... 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 follow all safety regulations that may be applicable to the work being performed 5 The zer...

Page 21: ...er 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 relatively safe to use when submerged in water the system generates a high pressure up to 7 000 psi 482 bar water stream which can cause injury when the zero thrust gun is out of the water ALWAYS keep the zero thrust gun submerged when the pres...

Page 22: ...merged and the gun trigger in the ON position The power unit operator should turn the knob on top of the pressure regulating valve See Figure 5 2 until pressure reads 7 000 psi 482 Bar on the test gauge Turning the knob clockwise will increase the pressure and turning it counter clockwise will decrease the pressure Figure 5 2 Pressure Regulating Valve EOS Page 22 CaviBlaster 2570 D Operations Manu...

Page 23: ...om 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 cle...

Page 24: ...e or if using gravity feed shut off the supply of water to the pressure pump 5 Squeeze the zero thrust gun trigger to the open or ON position See Figure 5 3 to release the water pressure remaining in the hose s while the zero thrust gun is submerged 6 It is now safe to remove the zero thrust gun from the water 7 Flush the system and rinse the power unit with fresh water at the end of the day 5 7 E...

Page 25: ... any other parts may lead to equipment failure and severe personal injury and will void all warranties 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 ...

Page 26: ... any hose damage if found replace hose immediately 2 Remove zero thrust 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 oil change interval is every 125 hours if oil of a quality lower than prescribed ...

Page 27: ...ty 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 2570 D is equipped with a water strainer located between the water feed pump and the pressure pump To inspect and clean the strainer follow the procedure below 1 Isolate or disconnect the water source from the inlet connec...

Page 28: ...t power transmission The driver shaft has a manually operated power take off PTO FULL ENGINE SPEED IS REQUIRED FOR PROPER OPERATION OF THE ZERO THRUST GUN Page 28 CaviBlaster 2570 D Operations Manual For more information please email sales cavidyne com or call 1 352 275 5319 Unscrew 3 bow screws Remove Lid Check Sock Filter Change if Needed ...

Page 29: ...ning 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 Page 29 CaviBlaster 2570 D Operations Manual For more information please email sales cavidyne com or call 1 352 275 5319 ...

Page 30: ...sed 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 freeze the pin or valve cone 4 Do not use WD 40 ...

Page 31: ... 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 zero thrust 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 all the critical system components expo...

Page 32: ...ump Check that feed pump inlet water strainer is 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 Pump drive belt failure 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 pre...

Page 33: ...igger 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 WARNING Ensure that neither the cleaning nozzle nor dump outlet of the gun is not pointing at any structure equipment power li...

Page 34: ...p oil seal kit 09554 1 1 Pump plunger packing kit 09707 1 1 Pump inlet valve kit 09709 1 1 Pump discharge valve kit 09710 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 CAVIDYNE LLC 507 Fruitville Rd Sarasota FL 34235 Phone 352 275 5319 Email support cavidyne com www caviblaster com EO...

Page 35: ...Crankcase Oil Data Sheet and MSDS Relief Valve Interpump S3 Spec Sheet FP Pump PC40B14 Channel Pump Pump Exploded View Pump Capacity Curve Gardner Denver Zero Thrust Tuf Gun 15K Gun Schematic Drawing Cavidyne JCB Engines NACD Clutch G Pumps FP Channel Pumps Gardner Denver Warranties EOS Page 35 CaviBlaster 2570 D Operations Manual For more information please email sales cavidyne com or call 1 352 ...

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