Table of Contents
Related Manuals for CAVIDYNE Caviblaster 4030-D
Summary of Contents for CAVIDYNE Caviblaster 4030-D
- Page 1 CAVIDYNE LLC 5077 Fruitville Rd. Sarasota, FL 34232 Phone: (352) 275-5319 www.cavidyne.com Operation & Maintenance Manual Model 4030-D Page 1 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com...
- Page 2 Injuries Resulting From A Failure To Comply With Instructions In This Manual. Please Read And Study The Entire Manual Carefully Before Use. The CaviBlaster 4030-D Must Only Be Operated And Maintained By Trained Personnel. This Equipment Generates High Pressure Water Jet And Is Intended For Underwater Use Only.
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Page 3: Table Of Contents
5.6 Shutting Down the CaviBlaster ........................27 6.0 MAINTENANCE ..............................27 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 Page 3 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com... -
Page 4: Unit Specifications
APPENDIX - COMPONENT LITERATURE .........................37 LIST OF FIGURES & TABLES Figure 1.1 – CaviBlaster 4030-D Specifications ..........…..... 5 Figure 2.1 – CaviBlaster 4030-D General Features ........…..... 7 Figure 2.2 – CaviBlaster 4030-D Control Panel..........…..... 8 Figure 4.1 – Lifting Guidelines ..................13 Figure 4.2 –... - Page 5 The CaviBlaster 4030-D power unit consists of a 99HP (74 kW) Kohler KDi 3404 TCR diesel power-pack and a UDOR VXX-B 160/180-R triplex plunger pump. Detailed performance and specifications are listed below: CaviBlaster 4030-D Specifications Nominal Pump Flow 40 GPM (153 L/M)
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Page 6: General Description
Stall, Creating An Undesirable Running Condition For The Belt Drive System. The CaviBlaster 4030-D power unit is a complete “plug and play” system built into a selfsupporting frame that allows quick deployment and/or installation of the unit. Water can be supplied from either a pressurized source, directly from the natural source via a beltdriven booster pump supplied with the power unit, or from a gravity feed storage tank. - Page 7 NOTE: New generation Diesel engines with emission control requirements at a level “Tier 4F” in USA and “Stage V” in EU governed by computer systems with better electric control and higher redundancy of safety features DO NOT require an Emergency Stop Button. Page 7 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com...
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Page 8: Using This Manual
“Stage V” in EU governed by computer systems with better electric control and higher redundancy of safety features DO NOT require an Emergency Stop Button. 2.1 Using this Manual Page 8 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com... -
Page 9: Conventions
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. -
Page 10: Safety Information
(EOS) 3.0 SAFETY INFORMATION The CaviBlaster 4030-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 4030-D must only be operated by personnel that have read and understand this manual. -
Page 11: Personal Protective 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. -
Page 12: Modification To The Equipment
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. -
Page 13: Uncrating And Lifting
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. -
Page 14: Installation Location
NOTE: New generation Diesel engines with emission control requirements at a level “Tier 4F” in USA and “Stage V” in EU governed by computer systems with better electric control and higher redundancy of safety features DO NOT require an Emergency Stop Button. Page 14 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com... -
Page 15: Initial Set-Up
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. Page 15 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com... - Page 16 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). Page 16 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com...
- Page 17 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) Page 17 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com...
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Page 18: Operation
(EOS) 5.0 OPERATION The CaviBlaster 4030-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. -
Page 19: Startup Of The Caviblaster
5.2 Startup of the CaviBlaster Before starting the CaviBlaster 4030-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. -
Page 20: Normal Operation
Should a problem develop with the control valve, discontinue using the CaviBlaster until fixed. The CaviBlaster 4030-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. - Page 21 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. Wear neoprene or rubber gloves to protect the hands and follow all safety regulations that may be applicable to the work being performed.
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Page 22: Adjusting The Caviblaster For Maximum Performance
With the power unit turned off, pull the gun trigger to discharge any residual pressure in the hose lines. Disconnect the whip hose with the gun from the pressure hose. Page 22 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com... - Page 23 Do Not Adjust The Pressure At The Gun To More Than 3,000-Psi (206 Bar). Higher Pressure Will Not Improve Peformance. Hoses Are Rated For Maximum 5,000-Psi (345 Bar). Pressures Above 5,000-Psi Could Result In Hose Failure. Page 23 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com...
- Page 24 Figure – PTO Lever Page 24 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com...
- Page 25 Figure 5.3 – Gun Pressure Calibration Page 25 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com...
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Page 26: Recommendations For Effective Results
CaviBlaster system. 3. Follow all safety regulations that may be applicable to the work being performed. Figure 5.4 – Gun position for best results Page 26 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com... -
Page 27: Shutting Down The Caviblaster
6. It is now safe to remove the gun from the water. 7. Flush the system and rinse the power unit with fresh water at the end of the day. (EOS) 6.0 MAINTENANCE Page 27 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com... - Page 28 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 Page 28 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com...
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Page 29: Basic Preventive Maintenance Recommendations
4) The initial pump oil change is required after 50 hours of operation. The oil change interval is every 300 hours if oil other than recommended pump oil is used. See pump manufacturer’s literature in the Appendix for additional recommendations Page 29 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com... -
Page 30: Diesel Engine Service
APPENDIX for further information. 6.4 Inspection/Cleaning of water inlet strainer The CaviBlaster 4030-D is equipped with a water strainer before the water feed pump and a media ‘sock’ filter system between the feed pump and the pressure pump. The process... - Page 31 ‘sock’ media. 3) Inspect cover o-ring for damage, replace if necessary. 4) Replace cap and tighten securely. Figure 6.1 – Water Filter Inspection / Cleaning Page 31 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com...
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Page 32: Inspection / Maintenance Of The Belt Drive System
6.5 Inspection / Maintenance of the Belt Drive System The CaviBlaster 4030-D is equipped with belt power transmission. The driver shaft has a manually operated power take-off. Full Engine Speed Is Required For Proper Operation Of The Gun. To inspect the belt: 1. -
Page 33: Inspection / Maintenance Of The Zero-Thrust Gun
This will allow oil to reach the positioning pin and valve cone and minimize the possibility of corrosion or mineral crystals forming that would freeze the pin or valve cone. Figure 6.3 – Zero-Thrust Diver Gun Page 33 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com... -
Page 34: Winterization
10 seconds. 6. Stop the unit. Following this procedure will ensure that all the critical system components exposed to water have been flushed with antifreeze. (EOS) 8.0 TROUBLESHOOTING Page 34 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com... - Page 35 Check the plungers for cracks Check the plunger rod O-ring for damage Page 35 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com...
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Page 36: Replacement Parts
Inlet filter housing O-ring Viton Inlet filter basket - stainless steel L44 BT-4-SR-9/64 Inlet filter bag – multifilament Nylon KO100K4S Engine air filter P828889 Engine oil filter HH1C0-32430 Page 36 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com... -
Page 37: Appendix - Component Literature
Valve seal kit 5019.0139.00 Pressure regulating unloader 8116.2543.00 Pressure regulating unloader repair kit Relief/Safety valve 8116.2538.00 Trigger valve repair kit 20 3600 490 (EOS) APPENDIX - COMPONENT LITERATURE Page 37 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com... - Page 38 Pump Exploded View Pump Capacity PACER Pumps Curve Centrifugal Series “I” Suttner Trigger Gun Gun Schematic Drawing Model ST-3600 Warranties Cavidyne Kohler Engines NACD UDOR VXX Suttner (EOS) Page 38 CaviDyne LLC – Operating Manual for CaviBlaser 4030-D www.cavidyne.com sales@cavidyne.com...
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