CAVIDYNE CaviBlaster 1228-G Manual

CAVIDYNE LLC
5077 Fruitville Road
Suite 109 - 157
Sarasota, FL 34232 USA
Phone [phone]
www.caviblaster.com
www.caviblaster.cl
Operation & Maintenance
Manual
Model 1228-G

WA NING
TO ENSU E OPE ATO SAFETY AND EFFICIENT USE OF THE
CAVIBLASTE SYSTEM IT IS ESSENTIAL TO FOLLOW THESE
INST UCTIONS
Table of Contents
I . Preparing the System Before Operation ……………………………… 03
II . Starting the CaviBlaster …………………………………………….. 05
III . Shooting Down the CaviBlaster …………………………………….. 06
IV. Recommendations for Safety Operation of the System ……………... 07
V. Recommendations for Better Results …………………………...…… 08
VI. Adjusting the System for Maximum Performance …………………. 09
VII. Routine Maintenance for the CaviBlaster System …………………... 10
VIII. Oil Change(s) of the CaviBlaster System …………………………... 11
IX. Summarizing Daily Operation Instructions ………………………... 12
X. List of Figures ………………………………………………………. 13
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CaviBlaster 1228-G Operations Manual
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I - Preparing the System Before Each Operation
1.- Inspect the CaviBlaster power unit, hoses and gun for any signs of damage.
2.- Inspect the inlet strainer (figure # 1) to ensure that it is not clogged, clean if
necessary.
3.- Check oil and fuel levels, proper oil level in pressure pump (figure # 2) and engine
(figure # 3), gasoline level in detachable fuel tank (figure # 4).
NOTE If Needed, fill lubricating oil(s) to proper level in the pressure pump
(figure # 5) and engine (figure # 6) per manufacturers operating manual.
Pressure pump oil is SAE 30W-Non Detergent (figure # 7)
Honda engine oil is SAE 10W 30 (figure # 8)
The new Honda engine has a Low Oil Level Warning Light (figure # 24)
5.- Connect the 1” red rubber by-pass hose (figure # 9) to the cam-lock plug on the
pressure regulating unloader (Figure # 10) The by-pass hose has a cam-lock socket
on one end, direct the other end away from the working area and secure the hose.
6.- Connect the ½” High Pressure Hose (figure # 11) to the quick-connect plug
under the pressure regulating unloader (figure # 12).
NOTE Do not attach the ZT Gun (figure # 21) to the high pressure hose, this
hose has to be cleaned before connecting the gun. This unit can deliver the
required pressure up to 300 feet or 100 mts with a ½” thermoplastic hose,
using greater lengths or smaller diameters may degrade its performance.
7.- Connect the dual ¼” black rubber fuel lines (Figure # 13) from the external fuel
tank to the fuel lines of the unit (figure #14), these connections are made with a
quick connect fitting .
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8.- Connection of the water source.
A.- Feeding water with the Feed Pump:
Connect the 1” diameter clear PVC feed hose (figure # 15) to the cam-lock
plug on the inlet strainer (Figure # 16), This feed hose has the feed pump on
one end and a cam-lock socket on the other end.
Insert the electrical plug powering the feed pump into the waterproof
electrical outlet on the handle of the power unit cart (figure # 17), The plug
cannot be wrongly connected because it will fit only in the correct position.
Drop the feed pump one or two feet into the water and tie to something to
avoid going any deeper, make sure the wiring splice is kept dry prior to
starting the feed pump. Either fresh water or see water can be used with this
system.
NOTE The feed pump has a neoprene check valve installed in the
discharge, this valve will prevent water from draining out of the feed hose
through the feed pump when the pump is turned off, however, this valve
somewhat restricts the flow of water from the pump, if maximum water
flow is required, this valve can be removed by removing the black hose barb
fitting.
B.- Feeding with an alternate water source: This source must supply water at a
volume grater than 12 gallons per minute at a maximum pressure of 70 psi.
Connect the water source to the inlet of the pressure pump (Figure # 16), make
sure the feed hose is connected to the pressure pump and water is present prior to
starting the unit.
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II - Starting the CaviBlaster
The preparing steps (Checking and Connections) must be already done before this point.
1.- When using the feed pump, start the feed pump by pulling the feed pump switch
(figure # 18) on the cart handle, to the ON position, when using a supplied water source,
open the valve to supply water to the system.
NOTE Make sure the system is primed and that there are no leaks, this is a
positive displacement pump and water must be supplied under pressure.
Failure to feed water may result in damage to the pump.
2.- Hold the end of the high pressure hose away before starting the unit.
3.- Once the system is primed, turn the key (figure # 19) to the right for ignition, let the
unit run for a few minutes to warm up / clean the interior of the high pressure hose, to
avoid particles of dirt going to the gun.
NOTE If the unit does not start at first, wait for 10 seconds before trying again.
4.- Once the unit is warm and the hose is clean, turn off the unit and turn off the feed
pump.
5.- Connect the ZT Gun (figure # 21), and submerge it into water, make sure the diver
has the trigger pressed in the ON position before starting the unit again, this will prevent
a pressure chock wave from damaging the pump in the instant that the engine is restarted.
6.- At this point is recommended to apply hearing protection to the operator and people
near the unit prior to starting the engine.
7.- Restart the feed pump again and restart the unit again, let the diver go to the desired
position to work.
8.- Once the diver is ready and in position, move the throttle to the MAX position (figure
# 20) so the diver can start the cleaning process.
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III - Shutting Down the CaviBlaster
1.- Move the throttle to the MIN position (figure # 29)
2.- Shut off the engine by turning the key to the OFF position to the left.
3.- Stop the feed pump by pushing down the pump switch.
4.- Squeeze the trigger on the gun to make sure all pressure is released while the
gun is still submerged.
5.- Now is safe to remove the gun from the water.
6.- If its the end of the day, flush and rinse the unit with fresh water for 5 minutes
to clean all hoses and the complete system.
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IV – ecommendations for Safety Operation of the System
1.- When the diver is ready to commence cleaning operations, make sure that the gun is
submerged in water, before moving the throttle lever up to “MAX” (Figure # 20).
2.- Ensure that the power unit operator and other persons working in the vicinity of the
unit wear appropriate hearing protection when the engine is running. If the diver is
not wearing a helmet, hearing protection is recommended. CaviDyne recommends
“Doc’s Pro-plugs” vented earplugs or equivalent for diver hearing protection.
3.- To activate the cleaning cavitation stream squeeze the trigger to the open or “ON”
position, use the most efficient operating technique as explained in next chapter.
4.- The diver must wear neoprene or rubber gloves to protect the hands and follow all
safety regulations that may be applicable to the work being performed.
5.- Ensure that the gun is submerged all the time the engine and pressure pump are
operating.
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V – ecommendations for Better esults
1.- Once the engine is throttled up to operating speed and the trigger on the gun is pulled,
the diver has to find the most effective distance between the gun nozzle and the surface
to be cleaned.
The most efficient technique is to hold the tip of the nozzle 2-5 inches (5 – 12 cm) away
from the surface to be cleaned at a 25 degree angle (figure # 28). The diver needs to
observe the shape of the cavitation jet cone, at greater depths the pressure will make it
smaller, please have in mind that the wider zone of the cone is the most efficient part of
the cavitation jet. Placing the nozzle in less than 2 inches from the surface will not allow
for efficient cavitation performance and will degrade the cleaning capability of the
system.
Follow the safety regulations that may be applicable to the work being performed.
3.- If the diver operating the system must be replaced of the cleaning operation
terminated, disengage the pressure pump by pulling down the throttle to the MIN
position (figure # 29) and then release the remaining pressure in the hose by pressing the
trigger of the gun to the open position, revert to step 1 of operating instructions to start
the cleaning again.
WA NING Although the CaviBlaster system is safe to use when submerged in water,
the system generates a high- pressure (up to 2,800-psi) water stream, which can cause
injury when the gun is out of the water. ALWAYS keep the gun submerged when the
pressure pump is engaged.
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VI – Adjusting the System for Maximum Performance
1. Using the pressure gauge included with the CaviBlaster power unit, (figure # 30)
the water pressure will need to be higher to account for sidewall friction loss in the
pressure hose. The pressure at the pump should be 2,800-psi plus 0.75-psi per foot of
pressure hose.
For example, if using the CaviBlaster with 100 feet of pressure hose, the pressure gauge
located next to the pump should indicate 2,875-psi. Pressure adjustments are made in
the pressure regulator by turning the nuts of the green spring. There should always be a
trickle of water through the bypass when the gun trigger is in the open or “ON” position.
2. Using a calibration pressure gauge between the pressure hose and the
CaviBlaster gun, (figure # 34) (Not included with the unit) the water pressure should be
2,800-psi with the gun submerged and the gun trigger in the open or “ON” position.
The pressure is adjusted by turning the nuts on the end of the pressure-regulating
unloader (Figure # 30). This adjustment increases or decreases the flow of water through
the bypass hose when the CaviBlaster gun trigger is in the open or “on” position.
The flow of water through the bypass hose, in turn, determines the flow of water
through the pressure hose and the gun. Less flow through the bypass hose means more
flow through the gun which translates to higher velocity and pressure. There should
always be a trickle of water through the bypass when the gun trigger is in the open or
“ON” position, this ensures that the bypass will open without a pressure shock wave
damaging the pump when the gun trigger is released to the closed position.
3. Without a pressure gauge, close the pressure-regulating unloader until there is just
a trickle of water (less than ¼ gallon per minute) coming out of the bypass with the gun
trigger in the open or “ON” position.
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VII – outine Maintenance of the CaviBlaster System
1. Empty and clean the inline strainer every day. (figure # 1).
2. Check the oil level and consistency in the engine and pressure pump every day. (figure
# 2 and Figure # 3)
3. Flush the system and rinse the power unit with fresh water after each days use, for at
least 5 minutes, to make sure all inside residuals are removed.
4. Inspect the pump drive belt every week and replace the belt when cracking appears.
5. Change the engine oil after the first month or 20 hours and every six months or 100
hours thereafter. Replace the oil filter every 200 hours. Use SAE 10W-30 oil for general
all- temperature use. (figure # 7 and figure # 8)
6. Clean the air cleaner cover, filter elements and base every three months or 50 hours.
Replace the paper filter element every twelve months or 300 hours or if damaged or
excessively dirty.
7. Change the oil in the pressure pump after the first 50 hours and every 500 hours
thereafter. Use single-weight lubricating oil (SAE 30 weight non-detergent)
8. Change the spring for the gun trigger every 12 months or less if required. (figure # 32)
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VIII – Oil Change(s) of the CaviBlaster System
A- Honda Engine Oil Change:
1. Remove top Oil cap from the engine
2. Set container to receive the used oil, under the engine
3. Open small hose at the foot of the engine
4. Let the engine oil drop, for about 20 minutes
5. Close small hose
6. Put in one ¼ Oil SAE 10W-30
7. Take measure of oil in engine
8. Place oil cap again
B- Pressure Pump Oil Change:
1. Set the unit in an inclined position, to easy drain the oil pump
2. Open oil cap from top of the pump
3. Set container to receive the used oil, under the pump
4. Remove oil cap from bottom of the pump
5. Let the oil drop for 20 Minutes
6. Close bottom cap
7. Set unit in a flat position
8. Put in one ¼ Non-Detergent SAE 30 ISO100
9. Place oil cap again and check the level in the pump, the middle is perfect.
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IX – Summarizing Daily Operating Instructions
1. Inspect the system for damage. Clean the inlet strainer. Check oil/fuel levels.
2. Attach all hoses to the unit and connect the feed pump electrical cable.
3. Start the feed pump or alternate water supply and ensure that the system is
primed.
4. Attach the gun to the pressure hose.
5. Make sure that the diver is ready to work and that the gun is submerged in the
water.
6. Apply hearing protection, start the engine and adjust the throttle to “MAX.”
7. Activate the cleaning cavitation stream by squeezing the gun trigger to open or
“on.”
8. Proceed with cleaning.
9. Stop the feed pump.
10. Release pressure from the hose(s) by squeezing the gun trigger to the open or
“ON” position while under water.
11. Remove the gun from the water.
12. Flush the system and rinse the outside of the power unit with fresh water.
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X – List of Figures
Figure # 1 – Inlet Water Strainer Figure # 2 – Oil level in pressure pump
Figure # 3 – Oil level in engine Figure # 4 – asoline Tank
Figure # 5 – Oil filling port in pump Figure # 6 – Oil filling port in engine
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Figure # 7 – SAE 30W Non-Detergent Figure # 8 – SAE 10W 30 Engine Oil
Figure # 9 – By-pass Hose Figure # 10 – By-pass hose connection
Figure # 11 – High Pressure Hose Figure # 12 – HP Hose Connection
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Figure # 13 – Dual fuel lines Figure # 14 – Fuel Lines Connection
Figure # 15 – PVC Feed Hose / Pump Figure # 16 – Feed hose connection
Figure # 17 – Feed pump connection Figure # 18 – Feed pump On / Off switch
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Figure # 19 – Ignition Panel Figure # 20 – Throttle to MAX Position
Figure # 21 – Zero Thrust un Figure # 22 – Surface lance
Figure # 23 – Battery in Marine Case Figure # 24 – Low Oil Level Warning
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Figure # 25 – Noise reduction muffler Figure # 26 – Pressure gauge / Manometer
Figure # 27 – CaviBlaster Complete System Assembled
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Figure # 28 – un position for best results Figure # 29 – Throttle in MIN position
Figure # 30 – Pressure regulating unloader Figure # 31 – Air filter on top of engine
Figure # 32 – ZT un Repair Kit Figure # 33 – ZT un Assembly
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Figure # 34 – Additional Calibration auge
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WA NING
While the CaviBlaster system is very safe, operators should exercise care when using
the equipment. The cavitation “flame” can be safely passed over the operators’ skin at
normal operating distances of 2” – 3” from the tip of the nozzle. However, at very
close distances (typically less than 1”) both nozzles are capable of causing harm to the
operator, particularly in the initial instant that the system is activated. For that reason,
operators should exercise caution when operating the gun with the nozzles in
close proximity to the body. The operators should also ensure that the reverse-
thrust nozzle guard is secured in the correct position prior to operating the gun.
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 shock wave when the gun is activated.
Serious harm and injury may result from the misuse of CaviBlaster system
equipment or improperly selected fittings, hoses or attachments. All components
of the system should be checked against the manufacturers’ instructions to ensure that
they are compatible with the pressures being used and of the correct thread type and
pressure rating for the intended service. Refer to these Operating Instructions and to
the engine and pressure pump manufacturers’ operation manuals for instructions or
call CaviDyne, LLC at [phone] with any questions.
CAUTION: DO NOT USE IT TO CLEAN SENSITIVE
SU FACES as LED-Lights, Underwater Lights, Electronic
Equipment, Etc.
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