Cavidyne, LLC Caviblaster 3040-D Manual

CAVIDYNETM, LLC
5077 Fruitville Rd.
Sarasota, FL 34232
Phone: [phone]
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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(EOS)

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 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 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 hasbeen made to ensurethat 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
(EOS)

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 usingthis equipment. Refer to theapplicable 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 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.

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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(EOS)

4.0 INSTALLATION
The CaviBlaster®3040-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 notbe 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 from
Underneath
Frame
Lift unit using
lifting eyes

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
Allow access to
control panel &
ignition panel
Allow access to
service belts
Allow access for
general service

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) *Offshore unit* Connect the air starter hose (See Figure 2.2)
8) *Electric Start unit* Connect battery terminals.
9) 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).
Engine And/Or Pump Fluids May Have Been
Removed For Shipment. Check Fluid Levels
Prior To Starting.
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®3040-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.
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 45 GPM (170 L/M)
(flow plus 50%) at a maximum pressure of 70-PSI (4.8 BAR).
•Gravity feeding water source (See Figure 4.3). 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
Water level
Pump inlet must be
below the tank bottom

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 pump body with water.
•It is important to keep thefeed hose in the water source when the engine isrunning
and the clutch is engaged or damage to the pressure pump will result.
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 45 gallons (170 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 supply tank outlet is higher than the water
inlet on the power unit control panel (See Figures 2.2).
•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 more than the required pump flow of 30
GPM (114 L/M). A minimum delivery of 45 GPM (170 L/M) is required 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 2.2)
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(EOS)

5.0 OPERATION
The CaviBlaster®3040-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 audio or visual communication with each other.
The CaviBlaster®3040-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 of operation, so that the unit is
always ready for immediate use. This should be completed after each use.
1) 1.- Inspect the CaviBlaster®power unit, hoses, JIC fittings and gun for any signs of damage.
2) 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) 3.- Check for proper engine oil level (See engine Owner’s Manual found in the Appendix). Add
lubricating oil (SAE 10W40) if necessary.
4) 4.- Check for proper pressure pump oil level (See pump Owner’s Manual found in the Appendix). Add
lubricating oil (SAE 30 non-detergent) if necessary.
5) 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.

5.2 Startup of the CaviBlaster®
Before starting the CaviBlaster®3040-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) *Offshore units* Verify that the Emergency Air Shut-Off valve is open by pulling the
handle out. Verify that the throttle cable is at more than half throttle and the clutch
(PTO) is disengaged by pulling the PTO lever back.
4) Apply appropriate hearing protection prior to starting engine.
4a) *Offshore units* 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).
4b) “Electric Starter units” Disengage the PTO clutch. Insert the key into the ignition switch
on the ignition panel. 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 “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.
5) 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’).
Do Not Throttle Up The Engine Until The Diver Is
Ready For Underwater Operation.