Cavidyne, LLC Caviblaster 3040-D Operation & Maintenance Manual
CAVIDYNETM, LLC
5077 Fruitville Rd.
Sarasota, FL 34232
Phone: (352) 275-5319
www.cavidyne.com
Operation &
Maintenance
Manual
Model 3040-D
CAVIDYNETM LLC Is Not Responsible For Damages Or
Injuries Resulting From A Failure To Comply With
Instructions In This Manual. Please Read And Study The
Entire Manual Carefully Before Use.
The CaviBlaster® 3040-D Must Only Be Operated And
Maintained By Trained Personnel.
This Equipment Generates High Pressure Water Jet And
Is Intended For Underwater Use Only. Serious Personal
Injury Or Death May Result From Improper Use.
Commercial Diver’s Gear Should Be Used When
Operating The Caviblaster® System.
*Offshore Unit* Do Not Use Air Pressure In Excess Of
120 Psi (8 Bar) When Starting The Equipment. Serious
Damage To The Equipment Will Occur.
CAUTION:
DO NOT USE THIS EQUIPMENT TO CLEAN
SENSITIVE SURFACES as LED-Lights,
Underwater Lights, Electronic Equipment, Etc.
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 ............................................................................................................. 19
5.1 Preparing the Unit for Operation ............................................................................... 19
5.2 Startup........................................................................................................................ 20
5.3 Normal Operation ...................................................................................................... 21
5.4 Adjusting the CaviBlaster for Maximum Performance ……………............................. 23
5.5 Recommendations for Effective Results .................................................................... 27
5.6 Shutting Down the CaviBlaster® ................................................................................ 28
6.0 MAINTENANCE ........................................................................................................ 29
6.1 Basic Preventive Maintenance Recommendations ................................................... 30
6.2 Diesel Engine Service ............................................................................................... 31
6.3 Pump Service ............................................................................................................ 31
6.4 Inspection/Cleaning of water inlet strainer ................................................................ 31
6.5 Inspection / Maintenance of the belt drive system .................................................... 33
6.6 Inspection / Maintenance of the Zero Thrust Gun ……….......................................... 34
7.0 WINTERIZATION ..................................................................................................... 35
8.0 TROUBLESHOOTING ............................................................................................. 36
9.0 REPLACEMENT PARTS ......................................................................................... 38
APPENDIX - COMPONENT LITERATURE ................................................................... 39
LIST OF FIGURES & TABLES
Figure 1.1 – CaviBlaster® 3040-D Specifications ............................................................ 5
Figure 2.1 – CaviBlaster® 3040-D General Features ...................................................... 7
Figure 2.2 – CaviBlaster® 3040-D Control Panel............................................................. 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 Up Control ....................................... 23
Figure 5.2 – PTO Lever………………............................................................................ 25
Figure 5.3 – Gun Pressure Calibration .......................................................................... 26
Figure 5.4 – Gun Position for Best Results ................................................................... 27
Figure 6.1 – Water Filter Inspection / Cleaning ............................................................. 32
Figure 6.2 – Belt Inspection / Tension …………............................................................ 33
Figure 6.3 – Zero Thrust Gun ………………….............................................................. 34
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1.0 UNIT SPECIFICATIONS
The CaviBlaster® 3040-D power unit consists of a 99HP (74 kW) Kubota V3800 diesel
power-pack and a Comet HPP GL 109/290 triplex plunger pump. Detailed performance
and specifications are listed below:
CaviBlaster® 3040-D Specifications
Nominal Pump Flow
30 GPM (76 L/M)
Nozzle Operating Pressure
4,000-PSI (275 BAR)
Engine
99 HP (74 kW), Diesel Powered (Kubota V3800)
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” x 55” x 62” (163 cm x 140 cm x 157 cm)
Maximum Pressure Hose Length
600 LF (200 meters) of 3/4” diameter
Power Unit Weight (Dry)
2,400 LBS (1,100 KG)
Zero-Thrust Gun Weight
11 LBS (5 KG)
Figure 1.1 – CaviBlaster® 3040-D Specifications
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2.0 GENERAL DESCRIPTION
The CaviBlaster® 3040-D 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 gun, connecting high-pressure 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 Belt
Drive System.
The CaviBlaster® 3040-D 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 a beltdriven booster pump supplied with the power unit, or from a gravity feed storage tank.
The unit is equipped with many features to maintain operator safety while operating at
pressures of 4,000-psi (275 bar).
Figure 2.1 – CaviBlaster® 3040-D General Features
For more information on the CaviBlaster
®
system please visit us at:
www.caviblaster.com
Figure 2.2 – CaviBlaster® 3040-D Control Panel
2.1 Using this Manual
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 CaviDyneTM or other personnel familiar with the
operation of this equipment.
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®
3040-D. It is essential that personnel who will operate and/or service this equipment
familiarize themselves with this manual. Standard components, such as the unit
engine and pump, are covered by the manufacturer’s literature found in the
Appendix.
2.4 Terms and Abbreviations
CCW
Counterclockwise
CW
Clockwise
EOS
End of Section
GPM
Gallons Per Minute
HP
Horsepower
L/M
Liters Per Minute
PPE
Personal Protective Equipment
PSI
Pounds Per Square Inch (without suffix, assumed to be gauge pressure).
PTO
Power Take-Off
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3.0 SAFETY INFORMATION
The CaviBlaster® 3040-D power unit is an inherently powerful and potentially
dangerous piece of equipment; however, with proper care and training it can be
operated safely. The 3040-D 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® 3040-D underwater cleaning system must only be
attempted by commercial divers or other personnel who have been trained in its
use. Appropriate protective equipment should always be worn. Operation of the
system without the proper equipment and training can result in personal injury.
CaviDyneTM, LLC Is Not Responsible For Damages Resulting
From A Failure To Comply With Instructions In This Manual.
Please Read Carefully Before Use.
If Inspection Or Calibration Of The Caviblaster® Gun Is Being Conducted Out
Of The Water, Remember That The Zero-Thrust Gun 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.
Ensure That There Is A Safe Area To Work While
Operating The Caviblaster® 3040-D.
Seek Immediate Medical Attention If The Operator Suffers
An Injury As The Result Of Contact With The HighPressure 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. CaviDyneTM
suggest wearing vented earplugs, such as “Doc’s Proplugs” or equivalent, for diver
hearing protection.
The operators of the CaviBlaster® system should always wear neoprene or heavy
rubber gloves to provide protection to the hands and, in particular, to the nails. The
gloves will absorb most of the energy produced by bursting cavitation bubbles and
prevent the cavitation bubbles from contacting the operators’ hands. The gloves will
also protect operators’ hands from the initial shockwave when the gun is activated.
Failure to wear
appropriate PPE
may result in
serious
personal injury.
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 CaviDyneTM. Any unapproved modifications will
void the equipment warranty. Unauthorized modification or part substitution can
result in serious personal injury or property damage.
Unauthorized Replacement Of Any Part May Lead To
Catastrophic Equipment Failure And Serious
Personal Injury.
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