CAVIDYNE Caviblaster 2570-D Manual

CAVIDYNE LLC
5077 Fruitville Road
Suite 109 - 157
Sarasota, FL 34232
Phone: [phone]
Email: [email protected]
www.caviblaster.com
Operation &
Maintenance
Manual
Model 2570-D

CAVIDYNE 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 2570-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 deat 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 t e
equipment will occur.
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CaviBlaster 2570-D Operations Manual
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TABLE OF CONTENTS
1.0 UNIT SPECIFICATIONS........................................................................................5
2.0 GENERAL DESCRIPTION....................................................................................6
2.1 Using this Manual...................................................................................................9
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
4.3.1 Connecting the Water Source...........................................................................15
5.0 OPERATION........................................................................................................18
5.1 Preparing the CaviBlaster for Operation...............................................................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 Inspection / Maintenance of the Zero-Thrust Gun................................................30
7.0 WINTERIZATION.................................................................................................31
8.0 TROUBLESHOOTING.........................................................................................32
9.0 REPLACEMENT PARTS.....................................................................................34
APPENDIX - COMPONENT LITERATURE..............................................................35
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CaviBlaster 2570-D Operations Manual
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LIST OF FIGURES & TABLES
Figure 1.1 – Specifications…………………………………………………………………….5
Figure 2.1 – General Features.........................................................................................7
Figure 2.2 – Control Panel...............................................................................................8
Figure 2.3 – PTO Hose Connections............................................................................8
Figure 4.1 – Lifting Guidelines.......................................................................................13
Figure 4.2 – Installation Guidelines................................................................................14
Figure 4.3 – Gravity Feeding Source.............................................................................16
Figure 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
T is space intentionally left blank
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CaviBlaster 2570-D Operations Manual
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1.0 UNIT SPECIFICATIONS
The CaviBlaster 2570-D power unit consists of a 145HP (108 kW JCB diesel power-
pack and a Giant GP8135 triplex plunger pump. Detailed performance and
specifications are listed below:
CaviBlaster 2570-D Specifications
Nominal Pump Flow 25 gpm (95 LPM
Nozzle Operating Pressure 7,250-PSI (500 BAR
Engine 145 HP (108 KW , Diesel Powered (JCB DIESEL
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 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 (Dry 5,000 LBS (2270 KG
Zero-Thrust Gun Weight 11 LBS (5 KG
Figure 1. 1 – Specifications
T is space intentionally left blank
(EOS)
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2.0 GENERAL DESCRIPTION
The CaviBlaster 2570-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 and crushes concrete
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/guns, connecting high-pressure hose
and a diesel-powered, high-pressure pumping unit. The zero-thrust gun/guns uses a
trigger-operated valve 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-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 7,250-psi (500 bar .
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Figure 2.1 – General Features
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For more information on the CaviBlaster system please visit us at:
www.caviblaster.com

Figure 2.2 – Control Panel
Figure 2.3 – PTO Lever Hose Connections
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2.1 Using t is 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 CaviDyne 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 “T is 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 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
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3.0 SAFETY INFORMATION
The CaviBlaster 2570-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 2570 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 and maintaining 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 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 can result in personal injury.
CaviDyne 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 zero-thrust gun/guns
is being conducted out of the water, remember that the zero-thrust
gun/guns 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 2570-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. 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
bubbles and prevent the cavitation bubbles from contacting the operators’ hands.
The gloves will also protect operators’ hands from the initial shockwave when the
zero-thrust gun is activated.
Failure to wear appropriate PPE may result in serious
personal injury.
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3.3 Modification to t e 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 CaviDyne. Any unapproved
modifications will void the equipment warranty. Unauthorized modification or part
substitution can result in serious personal injury or property damage.
T is space intentionally left blank
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(EOS)
Unaut orized replacement of any part may lead to
catastrop ic equipment failure and serious personal
injury.

4.0 INSTALLATION
The CaviBlaster 2570-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 CaviDyne 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
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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 .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
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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 pressure hose (See Figure 2.3
6) 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 t e 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 result in increased wear and tear on
components and in decreased service life.
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Engine and/or pump fluids may ave been removed
for s ipment. C eck fluid levels prior to starting.

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 end panel (See Figure
2.3 . A self-priming channel 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 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 the water inlet
connection on the end panel (See Figure 2.3 .
Submerse the feed hose into the water source.
Prime the pump by turning on the engine.
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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.
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 30 gallons (114
liters per minute at a maximum pressure of 100-psi (6.9 bar .
Connect a 1-1/2” cam-lock socket on the water supply hose to the
water inlet connection on the end panel (See Figure 2.3 .
Turn on the alternate water source.
Ensure t at t e feed ose is connected to t e inlet
connection and t e water supply is on prior to
starting t e pressure pump. Failure to supply water
to t e pressure pump will cause damage to t e 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 2.3 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 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 25
gpm (95 LPM . A minimum delivery of 30 GPM (114 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)
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5.0 OPERATION
The CaviBlaster 2570-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.
T e CaviBlaster 2570-D s ould only be operated by
properly trained personnel w o are familiar wit t e
contents of t e manual. Review t e safety
requirements found in Section 3 before operating.
5.1 Preparing t e 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, 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 pump Owner’s Manual found
in the Appendix . Add lubricating oil (SAE 30 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 s ould not be used as t ey may prove
azardous and cause damage to t e engine.
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5.2 Startup of t e CaviBlaster
Before starting the CaviBlaster 2570-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 zero-thrust gun to the high-pressure hose and unroll sufficient
length of hose to reach the operating location.
3) Verify that the throttle control is at more than half throttle.
4) Verify that the PTO lever is in the disengaged position.
5 Apply appropriate hearing protection prior to starting engine.
6) Turn the ignition 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 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’ .
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DO NOT THROTTLE UP THE ENGINE UNTIL THE
DIVER IS READY FOR UNDERWATER OPERATION.
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.

5.3 Normal Operation
Normal operation of the CaviBlaster system is defined as user control of water
flow via the bypass gun trigger. Control of the power unit from the gun trigger is
accomplished by a mechanical shut-off valve in the gun/guns. Should a problem
develop with the control valve, discontinue using the CaviBlaster until fixed.
The CaviBlaster 2570-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 t e safety requirements for PPE and safe
operation before proceeding.
1) Startup the power unit as described in Section 5.2.
2) Verify that the zero-thrust gun is properly connected and that the
mechanical trigger is released.
3 When the diver is ready to commence cleaning operations, ensure that the
zero-thrust 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 zero-thrust 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 using the throttle control (See Figure
5.1 .
8 Activate the cleaning cavitation stream by squeezing the gun trigger to the
open or “ON” position (See Figure 5.3 . Release trigger to stop the water
flow at the nozzle and direct it to dump mode.
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