Caviblaster 2040-D Manual

CAVIDYNETM, LLC
5077 Fruitville Road
Suite 109 - 157
Sarasota, FL 34234 USA
Phone: [phone]
Web Site: www.caviblaster.com
Model 2040-D

2040-D O&M Manual Ver 3.0 CaviDyneTM 5077 Fruitville Rd.; Suite 109 –157 Sarasota, FL 34234 U.S.A. Phone [phone]
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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®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 psi (8 bar) when
starting the equipment. Serious damage to the
equipment will occur.

2040-D O&M Manual Ver 3.0 CaviDyneTM 5077 Fruitville Rd.; Suite 109 –157 Sarasota, FL 34234 U.S.A. Phone [phone]
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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

2040-D O&M Manual Ver 3.0 CaviDyneTM 5077 Fruitville Rd.; Suite 109 –157 Sarasota, FL 34234 U.S.A. Phone [phone]
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LIST OF FIGURES & TABLES
Figure 1.1 –CaviBlaster®2040-D Specifications............................................................5
Figure 2.1 –CaviBlaster®2040-D General Features ......................................................7
Figure 2.2 –CaviBlaster®2040-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
Figure 6.3 –Inspection / Zero Thrust Gun..................................................................... 32
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1.0 UNIT SPECIFICATIONS
The CaviBlaster®2040-D power unit consists of a 67HP (50 kW) Kubota V3600 diesel
power-pack and a CAT 3560 triplex plunger pump. Detailed performance and
specifications are listed below:
CaviBlaster®2040-D Specifications
Nominal Pump Flow
20 GPM (76 LPM)
Nozzle Operating Pressure
3,700-PSI (255 BAR)
Engine
67 HP (50 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” 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®2040-D Specifications
This space intentionally left blank
(EOS)

2040-D O&M Manual Ver 3.0 CaviDyneTM 5077 Fruitville Rd.; Suite 109 –157 Sarasota, FL 34234 U.S.A. Phone [phone]
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2.0 GENERAL DESCRIPTION
The CaviBlaster®2040-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®2040-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
belt-driven 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 3,700-psi (255 bar).

2040-D O&M Manual Ver 3.0 CaviDyneTM 5077 Fruitville Rd.; Suite 109 –157 Sarasota, FL 34234 U.S.A. Phone [phone]
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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

2040-D O&M Manual Ver 3.0 CaviDyneTM 5077 Fruitville Rd.; Suite 109 –157 Sarasota, FL 34234 U.S.A. Phone [phone]
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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

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2.1 Using this Manual (Version 2.0)
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®
2040-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
LPM
Liters Per Minute
PPE
Personal Protective Equipment
PSI
Pounds Per Square Inch (without suffix, assumed to be gauge pressure).
PTO
Power Take-Off
(EOS)

2040-D O&M Manual Ver 3.0 CaviDyneTM 5077 Fruitville Rd.; Suite 109 –157 Sarasota, FL 34234 U.S.A. Phone [phone]
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3.0 SAFETY INFORMATION
The CaviBlaster®2040-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 2040-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®2040-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.

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Ensure that there is a safe area to work while operating
the CaviBlaster®2040-D.
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.
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.

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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.
This space intentionally left blank
Unauthorized replacement of any part may lead to
catastrophic equipment failure and serious personal
injury.
(EOS)

2040-D O&M Manual Ver 3.0 CaviDyneTM 5077 Fruitville Rd.; Suite 109 –157 Sarasota, FL 34234 U.S.A. Phone [phone]
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4.0 INSTALLATION
The CaviBlaster®2040-D must be installed in accordance with the requirements
outlined below. The unit can be installed in a vehicle to allow for maximum mobility and
flexibility.
4.1 Uncrating and Lifting
Unpack the equipment and inspect 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 weight listed in Section 1.0 UNIT
SPECIFICATIONS and that the unit is stable before lifting.
Figure 4.1 –Lifting Guidelines
Lift unit using
lifting eyes
Lift Unit from
Underneath
Frame

2040-D O&M Manual Ver 3.0 CaviDyneTM 5077 Fruitville Rd.; Suite 109 –157 Sarasota, FL 34234 U.S.A. Phone [phone]
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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 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, belts and fuel tank.
Figure 4.2 –Installation Guidelines
Fuel tank
filling port
Allow access to
control panel &
ignition panel
Allow access to
PTO and to
service belts
Allow access for
general service
Access required far
side for emergency
air shut off
(Chalwyn) valve.

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4.3 Initial Set-Up
After first receiving the CaviBlaster®power unit, the following must be checked
and completed:
1) Add engine oil (See Engine Manual located in the APPENDIX)
2) Add engine coolant (See Engine Manual located in the APPENDIX)
3) Add pump oil (See Pump Manual located in the APPENDIX)
4) Connect the feed or suction hose (See Section 4.3.1)
5) Connect the bypass hose (See Figure 2.2)
6) Connect the pressure hose (See 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.
The CaviBlaster®2040-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 result in increased wear and tear on
components and in decreased service life.
Engine and/or pump fluids may have been removed
for shipment. Check fluid levels prior to starting.

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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). A belt-driven self-priming centrifugal water pump is supplied to
provide positive inlet water pressure to the main pressure pump. Two
water supply conditions are acceptable for the CaviBlaster®power unit.
Forced inlet water condition using the 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 the 1-1/2” clear PVC feed hose to the
water inlet connection on the control panel (See Figure 2.2).
Submerse the feed hose into the water source.
Prime the pump by filling the body with water.
It is important to keep the feed hose in the water source when the
engine is running and the clutch is engaged or damage to the pressure
pump will result.
Water level
Pump inlet must be
below the tank bottom

2040-D O&M Manual Ver 3.0 CaviDyneTM 5077 Fruitville Rd.; Suite 109 –157 Sarasota, FL 34234 U.S.A. Phone [phone]
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To use force feed from an alternate source:
When feeding the CaviBlaster®with an alternate water source, the
source must supply water at a volume of greater than 25 gallons (95
liters) per minute at a maximum pressure of 70-psi (4.8 bar).
Connect a 1-1/2” cam-lock socket on the water supply hose to the
water inlet connection on the control panel (See Figure 2.2).
Turn on the alternate water source.
It is important to keep the water source on when the engine is running
or damage to the feed pump shaft seal will result.
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 water to
the pressure pump will cause damage to the 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 water is supplied to the water supply tank
to maintain the water level several inches above the tank outlet. 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 required pump flow of 20
GPM (75 LPM). A minimum delivery of 25 GPM (95 LPM) is recommended to
ensure that the pump is not starved of water. If connecting to a gravity feed tank,
locate the tank outlet above the water inlet connection on the power unit to
ensure a flooded suction line. (See Figure 4.4)
(EOS)

2040-D O&M Manual Ver 3.0 CaviDyneTM 5077 Fruitville Rd.; Suite 109 –157 Sarasota, FL 34234 U.S.A. Phone [phone]
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5.0 OPERATION
The CaviBlaster®2040-D should be operated by two (2) properly trained individuals.
One, the diver, operates the zero-thrust gun, while the other operates the power unit.
Both operators should be in constant audio or visual communication with each other.
The CaviBlaster®2040-D 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 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 engine Owner’s Manual found in the
Appendix). Add lubricating oil (SAE 10W40) if necessary.
4) Check for proper pressure pump oil level (See pump Owner’s Manual found
in the Appendix). Add lubricating oil (SAE 30W non-detergent) if necessary.
5) Check fuel tank (See Figure 2.1) for proper diesel fuel level. Add diesel fuel
(ASTM Grade No. 1-D or 2-D, or EN 590) if necessary.
Incorrect fuels should not be used as they may prove
hazardous and cause damage to the engine.

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5.2 Startup of the CaviBlaster®
Before starting the CaviBlaster®2040-D 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) Verify that the unit has been properly prepared for operation as described
in Section 4.
2) Connect the gun to the high-pressure hose and unroll sufficient length of
hose to reach the operating location.
3) Verify that the Emergency Air Shut-Off valve is open by pulling the handle
up.
4) Verify that the throttle cable is at more than half throttle.
5) Verify that 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 starter
again. Once the engine starts, turn off the air supply to the air starter.
Warning –air supply to the starter should not exceed 120psi (8 bar).
8) Run the engine at idle speed for a minimum of 20 seconds (20”) at
operating temperatures above 41◦F (5◦C). For lower operating
temperatures, run at idle speed for a minimum of one minute (1’).
The engine must be run at full throttle / full speed. If
partially throttled, the engine will stall, creating an
undesirable running condition for the belt drive system.
DO NOT THROTTLE UP THE ENGINE UNTIL THE
DIVER IS READY FOR UNDERWATER OPERATION.

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5.3 Normal Operation
Normal operation of the CaviBlaster®system is defined as user control of water
flow via the gun trigger. Control of the power unit from the gun trigger is
accomplished by a mechanical shut-off valve in the gun. Should a problem
develop with the control valve, discontinue using the CaviBlaster®until fixed.
The CaviBlaster®2040-D power unit is designed to operate at full throttle. Less
than full throttle will result in malfunction of the belt drive system and less than
optimum cleaning performance.
Review the safety requirements for PPE and safe
operation before proceeding.
1) Startup the power unit as described in Section 5.2.
2) Verify that the gun is properly connected and that the mechanical trigger is
released.
3) When the diver is ready to commence cleaning operations, ensure that the
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 follow all safety
regulations that may be applicable to the work being performed.
5) The gun trigger should be in open or “ON” position (See Figure 5.3) when
engaging the PTO and throttling up the engine. 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.
6) Pull the PTO handle to the on position to engage the pressure pump.
7) Throttle the engine completely up by pulling the black throttle cable knob
all the way out and twisting the knob to lock it (See Figure 5.1).
8) 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.