APS 55K DIESEL HUSKY User manual

55K DIESEL HUSKY
ADVANCED PRESSURE SYSTEMS
OPERATION AND MAINTENANCE MANUAL
32-755-500.M - APRIL 2023

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© 2023 Advanced Pressure Systems. All rights reserved.
NOTICE
This document contains subject matter in which Advanced Pressure Systems has proprietary
rights. Recipients of this document shall not duplicate, use, or disclose information contained
herein, in whole or in part, for other than the purpose for which this manual was provided.
Advanced Pressure Systems believes the information described in this manual to be accurate and
reliable. Much care has been taken in its preparation; however, the Company cannot accept any
responsibility, financial or otherwise, for any consequences arising out of the use of this material.
The information contained herein is subject to change, and revisions may be issued advising of
such changes and/or additions.
ADVANCED PRESSURE SYSTEMS 2023
ADVANCED PRESSURE SYSTEMS
701 S. PERSIMMON ST.
TOMBALL, TEXAS 77375
PHONE: [phone]
TOLL FREE: 877-290-4277
[e-mail]
WWW.ADVANCEDPRESSURESYSTEMS.COM

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CONTENTS
About This Content............................................................................................................ 5
Overview ............................................................................................................................ 5
Safety ................................................................................................................................ 9
Safety Precautions........................................................................................................................................... 9
Safety Messages............................................................................................................................................12
Safety Labels...................................................................................................................................................13
Personal Protective Equipment (PPE)........................................................................................................ 14
Emergency Medical Information................................................................................................................. 15
Lockout/Tagout..............................................................................................................................................16
Operation......................................................................................................................... 17
Overview...........................................................................................................................................................17
Transporting....................................................................................................................................................17
Before Starting the System ..........................................................................................................................17
Startup.............................................................................................................................................................. 18
Shutdown.........................................................................................................................................................19
Operating the User Interface........................................................................................................................ 19
Decommissioning .......................................................................................................................................... 23
System Storage .............................................................................................................................................. 23
Operation Safety Guidelines ............................................................................................ 25
Overview........................................................................................................................................................... 25
General Safety Guidelines............................................................................................................................. 25
Pressure Relief Devices................................................................................................................................. 26
High Pressure Hose and Lance Assemblies.............................................................................................27
Control Gun and Control Device Safety .....................................................................................................28
Rigid Tube Cleaning Lance Safety .............................................................................................................. 29
Flexible Tube Cleaning Lance Safety..........................................................................................................29
Nozzles.............................................................................................................................................................30
Personal Protective Equipment ...................................................................................................................31
Maintenance.................................................................................................................... 33
Overview........................................................................................................................................................... 33
Maintenance Precautions.............................................................................................................................33
Gland Nut Torque Specification ..................................................................................................................34
Daily Inspection ..............................................................................................................................................35
Monthly Maintenance....................................................................................................................................35

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High Pressure Fittings and Connections ...................................................................................................36
Filters and Strainers.......................................................................................................................................36
Nozzles, Holders, and Lance Connections................................................................................................ 36
Trigger and Valve Controls........................................................................................................................... 36
High Pressure Hoses.....................................................................................................................................37
Proper Hose Storage ..................................................................................................................................... 37
Preventative Maintenance Schedule ..........................................................................................................37
ECV Rebuild.....................................................................................................................................................38
ECV Installation ..............................................................................................................................................40
Safety Valve Service ......................................................................................................................................41
Water Filter Element Replacement .............................................................................................................43
Hydraulic Filter Element Replacement.......................................................................................................44
Dynamic Seal Temperature Sensor Replacement................................................................................... 45
Calibrations ..................................................................................................................... 46
Calibration Overview......................................................................................................................................46
Calibrating the Dynamic Seal Temperature Sensor ................................................................................ 46
Calibrating the External Control Valve........................................................................................................47
Calibrating the Safety Valve ......................................................................................................................... 48
55K Fluid End Assembly .................................................................................................. 51
Maintenance Overview.................................................................................................................................. 51
Maintenance Precautions.............................................................................................................................51
Gland Nut Torque Specification ..................................................................................................................52
Using the Loading Tool ................................................................................................................................. 54
Installing the Minor Maintenance Kit..........................................................................................................60
Installing the Major Maintenance Kit..........................................................................................................68
Troubleshooting .............................................................................................................. 74
Overview........................................................................................................................................................... 74
Troubleshooting Guide.................................................................................................................................. 74
High Dynamic Seal Temperature ................................................................................................................76
Low Inlet Water Pressure..............................................................................................................................77
High Oil Temperature ....................................................................................................................................77
Low Oil Pressure.............................................................................................................................................78
Low or High Output Pressure.......................................................................................................................78
High Water Filter Differential Pressure....................................................................................................... 79
Specifications.................................................................................................................. 80
General .............................................................................................................................................................80

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Standard Operating Parameters .................................................................................................................80
High Pressure Pump......................................................................................................................................80
Recommended Environmental Conditions ...............................................................................................80
Diesel Engine...................................................................................................................................................80
Fuel....................................................................................................................................................................81
Service Connections......................................................................................................................................81
Component Identification.............................................................................................................................82
Inlet Water........................................................................................................................................................83
References....................................................................................................................... 84
Engineering Drawings....................................................................................................................................84
Spare Parts ......................................................................................................................................................84
Appendix.......................................................................................................................... 86

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About This Content
Disclaimer
Due to continuing product improvement, the information contained in this document is subject to
change without notice. Advanced Pressure Systems shall not be held liable for technical or editorial
omissions made herein, nor for any incidental or consequential damage resulting from the use of
this material.
Copyright
This content contains information protected by copyright. No part of this document shall be
reproduced in any manner without prior written consent from Advanced Pressure Systems.
©2023 Advanced Pressure Systems. All rights reserved. ORIGINAL INSTRUCTIONS.
Overview
The Husky pump is a powerful positive displacement, ultrahigh-pressure (UHP) triplex plunger
pump system. These waterjet cleaning pumps are designed and manufactured to operate in
continuous service at a designed flow and pressure. With pressures ranging from 2,758 bar (40,000
psi) to 3,793 bar (55,000 psi), the Husky is an extremely versatile pump. The Husky pump is
designed for full-scale industrial use with minimal maintenance and reliable performance.
Features include:
A triplex, direct-drive, high-pressure pump with easy access to seals and check valves.
Multiple prime mover options:
o302 hp Caterpillar C7.1 Tier 4
o335 hp Caterpillar C9.3 Tier 3 engine (export only)
o275 hp Caterpillar C7.1 Tier 3 engine (export only)
Sensor lights and automatic shutdown for low inlet water pressure, high engine or pump
temperature, and low engine or pump oil pressure.
A closed-loop oil lubrication system.
An inlet water booster pump with water filtration to 10 microns absolute.
An over-pressure protection valve.
Adhering to the recommended procedures for operation and maintenance outlined in this manual
will ensure optimum benefit from the high-quality components used in the design and construction
of the Husky pump system.

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How It Works
Several items work together to operate the UHP fluid end. These items are the inlet water, the diesel
engine, the pump, and the cooling system. When all of these items work together high pressure
water is created.
Inlet water is the first item. The inlet water flows through a water filter to ensure it is clean enough
to flow through the rest of the system. From there, the water continues to the inlet check valve.
For the water to continue through the system, the diesel engine must run. When the diesel engine
runs, it turns the crankshaft of the pump. In turn, the crankshaft moves the plungers.
The pump is connected to the engine and operates in a two-stroke cycle: the inlet stroke, and the
pressure stroke.
The sequence of the inlet stroke has four steps:
1. The outlet check valve closes.
2. The plunger moves back.
3. The inlet check valve opens.
4. Water enters the pump.
(image is used as reference only)

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After the inlet stroke is the pressure stroke which has five steps:
1. The inlet check valve closes.
2. The plunger moves forward.
3. The water is pressurized.
4. The outlet check valve opens.
5. High pressure water goes to the manifold.
At this point, the two-stroke cycle repeats.
(image is used as reference only)

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The cooling system is the last item. It operates to make sure that the rest of the systems are at the
correct temperature. The charge pump supplies low-pressure water to cool the UHP fluid end. The low-
pressure water also lubricates the plungers and the plunger bearings.
A failed dynamic seal causes high-pressure water to leak into the low-pressure water that cools the
bearing, cools the plunger, and lubricates the plunger. The symptoms of a failed dynamic seal are heat
and pulsing water at the cooling water outlet line of the manifold. The temperature sensors on the
cooling water outlet line measure the heat in that circuit.
(image is used as reference only)

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Safety
Advanced Pressure Systems designed this high-pressure waterjet cutting system and related equipment
with safety in mind. Although the waterjet can appear harmless, it is a high-energy cutting tool capable
of cutting many materials such as composites, metals, plastics, and wood products. Misuse of this
equipment or carelessness in its application is extremely hazardous to personnel. Always treat the
waterjet system with respect.
READ CAREFULLY BEFORE USE. KEEP FOR FUTURE REFERENCE!
Safety Precautions
Follow all safety precautions to ensure safe operation of the equipment.
 Only trained, qualified personnel shall service and maintain the equipment.
 Safety glasses and ear protection shall be worn when operating or working near the pump.
 Do not allow the waterjet stream to touch any part of the body—it will cause serious injury.
 Never point a waterjet cutting or cleaning tool at oneself or any person. Do not aim any
waterjet tool at anything not intended to be cut.
 During equipment maintenance, take the system out of service. Lock and mark the controls
with a warning sign. See section ‘Lockout/Tagout’ for details.
 All personnel required to do any system operation or service function must pay particular
attention to all warning signs and notices posted in the plant and on the equipment.
 All protective guards, shields, and covers must be in place on the equipment at all times.
 First aid facilities shall be provided in convenient locations throughout the plant. All
personnel must know the locations of the first aid facilities.
 Always keep the work area around the equipment clean and free of debris. Fluid spillage
results in slippery floors. Clean up spills immediately.
 Any unfavorable conditions that can result in injuries must be reported to the plant
supervisor immediately.
 Do not wear loose clothing or jewelry while working around equipment with moving parts.
 Pressurized air can drive particles into the eyes and skin if handled incorrectly. Use
appropriate personal protective equipment and exercise caution.
 Only use water-based solvents for cleaning parts.

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Diesel Engines
Do not allow the engine to exhaust into a closed work area. Provide either adequate
ventilation or vent the exhaust outdoors.
Do not overfill the fuel tank.
Do not operate the engine in an explosive or flammable environment.
Do not allow flammable liquids to touch the engine while it is hot.
Do not operate the engine without its protective covers in place.
Do not attempt to service the engine while it is in operation.
Do not allow moving parts to contact clothing or body.
Do not allow fuel to contact exposed portions of the body.
Electrical
Only a certified electrician shall do electrical and/or electronic troubleshooting and servicing
of electrical devices.
Always assume that power is ON in all electrical systems. Always examine and lockout the
main power switches before servicing the equipment. Post a sign, “Maintenance in
Progress—Do Not Energize.”
Be aware that live electrical circuits are present in the control console whenever the master
disconnect switch is in the ON position, regardless of whether the E-Stop is engaged.
Turn off the circuit breakers located inside the electrical enclosure before servicing the
electrical system. If this is not possible, have someone stand by to prevent someone from
powering up the system.
Take extra precautions when servicing the power system in a damp environment.
Never alter or bypass protective interlocks or devices.
Never use jumper wires across fuses, fuse holders, or breakers.
Never use metal rulers, flashlights, pencils, or tools that have exposed conductive material
when working near electrical/electronic components.
Ensure all tools are correctly insulated for the job. Use only correct test apparatus; regularly
examine to ensure they are working correctly. Use caution when connecting a test probe to
test points.
When connecting a voltmeter to terminals for measurement, use a range higher than the
expected voltage.
All replacement wires shall conform to the manufacturer’s specifications, including color-
coding, wire numbers, and size.
Close and latch the control panel doors or junction box covers after servicing.
Maintain all electrical components, protective guards, and shutdown devices according to
approved practices.

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High-Pressure Cleaning Tools
Turn off equipment and relieve water pressure before replacing nozzles, tips, or bits.
Hang a warning sign on the control panel that states that the equipment is being serviced
and is not available for use until servicing is complete.
Install all protective covers and shielding on equipment before starting the pump.
Examine for leakage after nozzle or tip replacement and correct the leak immediately.
Use only APS manufactured or approved waterjet nozzles, cleaning tips, and drilling or
cutting bits.
Mechanical
Do not start the system unless the operator can properly shut it down.
Never maintain, service, or clean around the equipment while it is operating.
Do not use incorrect tools—they can cause injury or costly damage to equipment.
Use only approved test equipment. Examine the equipment regularly for correct operation
and calibration.
Never climb on or around the equipment on makeshift devices. Use only approved catwalks,
ladders, or platforms.
Do not exceed specified pressure setting limits for pneumatic or hydraulic components.
Exceeding these limits may result in serious injury to personnel or damage to the
equipment.
Shield and bundle equipment hoses and cables so they do not obstruct the operator’s
freedom of movement.
Always be alert when working around the equipment.
Remove all tools, parts, and rags from moving parts after servicing the equipment.

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Safety Messages
Safety messages are highlighted with the safety alert symbol and a signal word or a signal word panel.
Pay particular attention to these safety messages and all safety precautions posted on the equipment.
Safety Alert Symbol
This is the safety alert symbol. The safety alert symbol indicates a
potential physical injury hazards. Obey all safety messages that follow
this symbol to avoid possible injury or death.
Signal Words
WARNING! WARNING indicates a hazardous situation, which if not avoided, can
result in death or serious injury.
CAUTION! CAUTION indicates a hazardous situation, which if not avoided, can
result in minor or moderate injury.
Signal Panel Words
DANGER indicates a hazardous situation, which if not avoided,
will result in death or serious injury.
CAUTION emphasize operating or service procedures, or
conditions that can result in equipment damage or impairment
of system operation.
NOTICE indicates a non-hazardous situation, which if not
avoided, can result in property damage.

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Safety Labels
The section describes the safety labels and their locations.
High-Pressure Hose
This label indicates the minimum pressure rating of the hose to be used with the unit.
(Item 1 in the image below) This label is located on the high-pressure tubing assembly.
Forklift
This label indicates the location of the forklift pockets to properly lift the pump on the diesel Husky.
(Item 2 in the image below)

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Personal Protective Equipment (PPE)
Personal protective equipment (PPE) is equipment worn to minimize exposure to serious workplace
injuries and illnesses.
Helmets must be worn at all times by all personnel within the work area.
Helmet material must withstand a mechanical shock to 10 G in 8 m.s.
without fracturing.
Operators must wear safety glasses with side shields and a visor, or
goggles and a visor, to guard against spray and flying debris.
Operators and other personnel must wear safety footwear with steel
toecaps a minimum of 5 mm (0.02-in.) thick. The toecap must cover at
least 30% of the footwear length. Footwear must have metatarsal
guards to provide instep protection.
The operators and other personnel exposed to noise levels of more than
90 dBa for more than 1 hour must wear suitable ear protection. Earplugs
and muffs are usually adequate.
The operators must wear gloves at all times; leather gloves are
preferred.
Waterproof garments only protect the operator from spray and flying
debris. They do NOT deflect direct jet impact.

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Emergency Medical Information
WARNING! Obtain medical treatment immediately for ANY high-pressure
waterjet injuries.
It is vital that medical personnel have information about this type of injury. We recommend that all
personnel working with waterjet equipment carry a medical alert card or tag that describes their work
and the nature of injuries inherent in using waterjets.

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Lockout/Tagout
The water supply and electrical systems can be locked out separately. Under most circumstances, both
systems should be locked out.
This lockout/tagout procedure is designed to protect all employees from injuries caused by the
unexpected energizing or startup of the machine, or the release of stored energy during service and
maintenance.
This is accomplished with energy isolating devices that prevent the transmission or release of energy.
An energy source is any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or
other energy source that could cause injury to personnel.
A lockout device utilizes a lock and key to hold an energy isolating device in the safe position and
prevents the machine from being energized. A tagout device is a prominent warning device that can be
securely attached to the machine warning personnel not to operate the energy isolating device. This
procedure requires the combination of a lockout device and a tagout device.
Water Supply
1. Shut down the pump using the ‘Standard System Shutdown’ procedure below.
2. Look at the gauges on the display to ensure that the fluid end pressure is bled down.
3. Turn off the water supply to the charge pump.
4. Close the inlet water valve, and then install a lockout/tagout device.
5. Open the top and bottom petcocks on the water filter canister to drain the filter canister. If
the draining water appears to be under pressure, ensure that the inlet water valve is closed.
6. Ensure isolation of the inlet water by looking at the Pre-Filter and After-Filter pressure on the
Pump Data screen. Both readings should be at zero.
Electrical
1. Shut down the pump using the ‘Standard System Shutdown’ procedure below.
2. Remove the battery box cover.
3. Use a 9/16-in. wrench to remove the negative (black) lead from the battery. This cable goes
from the battery to the battery disconnect.
4. Install a lockout/tagout device over the negative battery cable.
5. Use a 9/16-in. wrench to remove the positive (red) lead from the positive battery post. This
wire goes from the battery to the engine starter motor.
6. Install a lockout/tagout device over the positive battery cable.

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Operation
Overview
Commissioning requirements and procedures are detailed in this section. These procedures require a
thorough understanding of the individual components, safety issues, and the overall operation of the
system.
All personnel involved in the operation and/or service of the system must carefully review this manual
prior to commissioning and operating the machine.
The Technical Service Department at Advanced Pressure Systems is available to assist in the
commissioning and operation process. Service and repair training for maintenance personnel is also
available.
Transporting
The weight of the machine is not evenly distributed from one end to the other. Note the warnings
stamped on the unit. The forklift should be positioned accordingly.
When the machine has been removed from the crate, note the position of the fork pockets on the
bottom of the machine if so equipped. The pockets are positioned in relationship to the center of gravity
to balance the weight on the forklift.
Before Starting the System
Prior to starting the system review the manufacturer’s manuals included in the appendix covering the
operation of the engine and drive train.
1. Set unit on a level surface.
2. Check oil level and any water contamination in the hydraulic reservoir.
3. Check all electrical cables and connections.
4. Check fuel level, engine oil level, coolant level and engine belt tension.
5. Check the fuel/water separator for the presence of water.
6. If the pump is located in a closed space, make sure that the exhaust tubing connects to the
engine exhaust.
7. Verify all bolts are torqued to the specified level.
8. Verify connections on the manifold are tight and do not leak.

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Do not tighten high pressure connections when the system is pressurized.
Remove all pressure from the system before tightening connections.
9. Ensure the supply water and the filters and strainers are clean.
10. Verify the pressure relief valve has been calibrated. Procedures for this can be found in the
‘Calibrating the Safety Valve’ section later in this manual.
11. Ensure the supply water line to the pump is airtight. Air entering the suction side, supply line will
cause severe knocking and cavitation of the pump.
12. Check to ensure supply water is flowing to the system.
13. Inspect the pump for visible damage, debris, and cleanliness.
Startup
1. Ensure that supply line water is connected to the unit.
2. Turn on the pressurized supply line water.
3. Turn the inlet water valve to the ON position.
Failure to open the inlet water valve can severely damage the pump.
4. Open the top petcock on the water filter canister to purge the air from the filter canister. Close
the petcock after water begins flowing from the valve.
5. Examine the pump for leaks. Fix any leaks before starting the pump.
6. Turn the key switch to ON.
7. After the screen turns on, press the ignition button to start fuel pump. Once primed press and
hold the start button. Release the button after the engine starts.
8. Listen for unusual noises in the system. For diesel units, it is normal for the engine to make a
knocking noise while it warms up. The knocking noise should go away after the engine is warm.
9. With the pump operating at its rated full speed the maximum working pressure should be
reached easily. If the maximum working pressure cannot be reached at full speed, check the
nozzle size or the system plumbing for leakage. Refer to section ‘Troubleshooting’ later in this
manual if the issue is not resolved.
10. Ensure the suction and discharge valves remain fully open during operation.
Never close the suction or discharge valves while the pump is running.

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Shutdown
Standard System Shutdown
1. Use the rotary knob on the screen to dial back pressure as low as possible.
2. Push the idle button, and then let the engine run for a minimum of three minutes to cool down.
The engine should idle to allow the turbo to cool down.
3. Press the stop button to initialize shutdown. Engine may continue to run and indicate “DES” this
process is to comply with tier 4. DO NOT force a shutdown unless necessary.
4. Once engine has stopped turn the key off to shut down control system.
5. Switch the battery disconnect switch to the off position to disconnect electrical power.
Emergency System Shutdown
1. Push the red E-Stop button on the control panel.
Operating the User Interface
Run Screen
1. On the run screen shown below there are 12 boxes, 6 on each side. These indicate which
physical button to push on the display screen to activate the labeled function.
2. Starting from top left is the “Metric” /“English” units changer button. The text displayed in the
box will be the units shown AFTER the button is pressed.
3. Moving down, the next two buttons control the commanded engine RPM up and down. The
current engine speed is displayed graphically in the horizontal bar graph and the setpoint is
shown digitally below. These numbers may not match. Use the graph for reference when setting
RPM.