2.1 ES4 brukermanual_ENG

OPERATING INSTRUCTIONS
AQUAJET - ES 4
The highly automated control system for high-pressure pump units
Manual number: Content revised: Language:

00.00038.0051 05.2021 English
Before commencing work, the product manual must be
read and understood and, in particular, the Chapter on
“Safety”.
Always keep this manual close to the product.
Only carry out those activities which are described in this
manual.
Manufacturer and customer service address:

Carl Zeiss Strasse 6 - 8 • 59302 Oelde • Germany
P.O. Box 33 09 • 59282 Oelde • Germany
Telephone: +49 (0) 25 22 76-0
Telefax: +49 (0) 25 22 76-4 44
E-mail: mail@hammelmann.de
http://www.hammelmann.com
Original operating instructions
Copyright of this manual remains with Hammelmann GmbH. This manual

contains regulations and drawings of a technical nature that must neither be
completely nor partly duplicated, distributed, utilised or made accessible to
third parties without our authority.
Contravention is culpable and obligates compensation for damages.
Copyright © 2021 Hammelmann GmbH, Oelde, Germany.
Subject to technical modifications.

Preface 3
Contents
1 Preface ..................................................................................................................... 5
1.1 Software version ............................................................................................... 5
1.2 Safety ............................................................................................................... 5
1.3 Abreviations ...................................................................................................... 5
1.4 View of warning notices.................................................................................... 6
1.5 Symbols ............................................................................................................ 6
1.5.1 Orientation elements ............................................................................ 6
2 Safety ....................................................................................................................... 7
2.1 Technical Condition of the Product .................................................................. 7
2.2 Use as intended ............................................................................................... 7
2.3 Information on use ............................................................................................ 7
2.4 Incorrect application ......................................................................................... 8
2.5 Operating personnel qualifications ................................................................... 8
2.5.1 Duties of the contractor (Owner / Operator) ........................................ 8
2.5.2 Training the operating personnel ......................................................... 8
2.6 Safety Equipment ............................................................................................. 8
2.7 Personal protective equipment (PPE) .............................................................. 9
2.8 How to react in case of danger ........................................................................ 9
2.8.1 On-site first-aid ..................................................................................... 9
2.8.2 First-aid ID .......................................................................................... 10
2.9 Professional disposal ..................................................................................... 10
3 Design and description ........................................................................................ 11

3.1 User interface ................................................................................................. 11
3.1.1 Status bar ........................................................................................... 11
3.1.2 Display and control section ................................................................ 13
3.1.3 Touch buttons .................................................................................... 14
3.2 Additional control elements ............................................................................ 15
3.2.1 Key panel ........................................................................................... 15
3.3 EMERGENCY STOP switch and start button ................................................ 16
3.4 Control types .................................................................................................. 16
4 Operating ............................................................................................................... 17
4.1 Switching on the control unit .......................................................................... 17
4.2 Setting up the control unit............................................................................... 18
4.2.1 Establishing and setting the target value ........................................... 18
4.2.2 Checking and adjusting the settings .................................................. 19
4.3 Start engine .................................................................................................... 20
4.4 High-pressure operation ................................................................................. 20
Operating instructions ES 4 Aquajet

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4 Preface
4.4.1 Starting the operation .........................................................................21

4.4.2 Stopping the operation .......................................................................22
4.5 Stop engine ....................................................................................................23
4.6 Shut down the control unit ..............................................................................24
5 Setting and monitoring ........................................................................................25

5.1 User settings ...................................................................................................25
5.1.1 Selecting the control type ...................................................................26
5.1.2 Setting the pressure build-up .............................................................26
5.1.3 Adjusting the operating settings .........................................................26
5.1.4 Externally activate and read-off the target values ..............................27
5.1.5 Change time, date and language .......................................................27
5.1.6 Selection of the pressure step ...........................................................28
5.2 Pump ..............................................................................................................29
5.2.1 Additional inputs .................................................................................30
5.3 Engine ............................................................................................................31
5.3.1 Regeneration of Volvo and Deutz engines Stage 5 ...........................31
5.4 General ...........................................................................................................33
5.4.1 Nozzle calculation ..............................................................................34
5.4.2 Fault memory .....................................................................................39
5.5 Gearbox ..........................................................................................................40
5.5.1 Engage the gear .................................................................................41
6 Correcting malfunctions ......................................................................................42

6.1 Procedure .......................................................................................................42
6.2 Fault list ..........................................................................................................43

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Preface 5
1 Preface
1.1 Software version

These operating instructions describe the operation of the ES 4 control unit
starting with the software version: ES 4 V1.1.
1.2 Safety
This manual allows the machine to be safely and efficiently handled.
The manual is an integral part of the machine and must be kept at all times
accessible for the personnel in the immediate vicinity of the machine. The
personnel must have studied this manual before starting any work and must be
in a position to follow the manual. The basic requirement for safe working is
adhering to all the safety and handling instructions indicated in this manual.
Also of validity are the local accident prevention provisions and the operator’s
general safety requirements for the operative range of the machine.
The figures in this manual act as an aid in understanding matters and may differ
from the actual design of the machine.
1.3 Abreviations
Abreviation Meaning
bar bar (pressure)
°C Degree Celsius (temperature)
kg Kilogram (weight)
N Newton (force)
kW Kilowatt (power rating)
1/min (or: RPM) Revolutions per minute (speed)
m/s² Acceleration
l Liter (volume)
m Meter (length)
min Minute (time)
mm Millimeter (length)
AF (or: SW) Wrench size in mm (across the flats).
Fig. Figure
PPE Personal protective equipment
V Volume (l/min; m3/h)
HD High pressure
HDP High pressure pump
DN Nominal diameter in mm

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6 Preface
1.4 View of warning notices

DANGER
Personal injury from a source of danger
Specifically defined source of danger.
Non-observance leads to severe or fatal injury.
 Take countermeasures
WARNING
Non-observance can lead to severe or fatal injury.
CAUTION
Non-observance can lead to (minor) injury.
Notice
Material damage
These cases of material damage result from non-observance
of the here defined source of danger.
SIGNAL WORD! Embedded note with safety-relevant information
1.5 Symbols
1.5.1 Orientation elements

Symbol Meaning
 Listing
 Guidelines on how to act
 Results of an action taken
 Requirements to fulfill the guidelines
 Reference

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Safety 7
2 Safety
2.1 Technical Condition of the Product

The Hammelmann products produced in modern technical manufacturing
systems are subject to a strict quality, function and safety check. Nevertheless,
it can be assumed that the described product harbours risks if incorrectly used
or not used as intended, or is operated by untrained personnel.
Only adherence to all safety instructions and warnings enables the personnel to
be optimally protected and or for the product to be operated safety and trouble-
free.
Any non-authorized retrofitting or changes to the product are not permitted.
The operating company is committed to solely running the product in a flawless
and fail-safe condition.
There are separate manuals on certain system components (e.g. high-

pressure pump unit). It is mandatory for them to be followed.
2.2 Use as intended

The control unit described is solely for operating, setting and monitoring
HAMMELMANN high-pressure pump installations.
2.3 Information on use

Handling
• Only use the control unit at ambient temperatures between -20 °C and +70
°C.
• The control unit components are sealed as a protection against
unauthorised opening. Bear in mind that any non-authorised opening leads
to component failure.
• The control unit is maintenance-free across its entire service life and needs
no particular upkeep.
• The unit should only be operated with the supplied electrical accessories
(e.g. key-operated switch, high-pressure spray guns and radio remote
controls).
Storage and dispatch

• Only store the control unit at ambient temperatures between -30 °C and
+80 °C.
• Any dispatching should only be in the original packaging or in an
appropriately stable packaging form.

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8 Safety
2.4 Incorrect application

The product must neither be used for work nor run under operating conditions
which the manufacturer has not laid down for the product.
Predictable incorrect applications:

• Operations with system components (such as high-pressure pumps) which
have not been cleared by the manufacturer
• Operations with electrical accessories which were not supplied with the
product
• Operations with spare parts which the manufacturer has not cleared for the
product
• Operating undertaken by non-trained personnel
• Cleaning the control unit with the high-pressure cleaner
• Using sharp or pointed objects (e.g. knife or screwdriver) to operate the
control unit
• Inserting objects into openings of the device which are not envisaged for
this purpose
Prohibited operating conditions:

• Working without personal protective equipment on the product
• Operations in explosive environments
• Operations within the range of powerful electromagnetic fields
• Operations at an ambient temperature under -20 °C and over +70 °C
2.5 Operating personnel qualifications

2.5.1 Duties of the contractor (Owner / Operator)
The contractor is understood to be the person who authorises other persons to
operate the product.
The contractor bears the responsibility that the product is operated in
accordance with national legal requirements an within the context of the
operating instructions.
The contractor must ensure that only qualified personnel operate the
equipment.
2.5.2 Training the operating personnel

Training for operating the product can be carried out by the contractor or the
manufacturer.
Untrained personnel are considered unqualified and may not undertake any
activity with or on the product.
2.6 Safety Equipment

The safeguards for the high-pressure lines are found at the high-pressure pump
installation. The operating mode of the safeguards and scope for liquids to
escape in the event of malfunctioning are described in the high-pressure pump
installation manual.
Before any start-up, the user is to assure himself of the correct functioning of all
safety equipment of the system components.

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Safety 9
2.7 Personal protective equipment (PPE)

WARNING Only protective equipment designed for the application protects
against high-pressure water jets. Observe local and national safety at
work regulations.
Always wear the stipulated personal protective equipment when working with
the product.
PPE for the high pressure spray gun operator:
• Protective gloves
• Protective clothing
• Safety footwear
• Facial protection
• Ear protection
PPE when handling harmful substances:

• PPE for operating the high pressure
spray gun
• Respiratory protection
2.8 How to react in case of danger

WARNING
Incorrectly assessing injuries from high-pressure water
High-pressure water may result in injection injuries and cuts.
Only a doctor can determine how serious an injury caused by
high-pressure water actually is.
 Call in a doctor even in the case of apparently slight
injuries.
In case of danger or accidents, shut down the high-pressure pump unit by

immediately operating the EMERGENCY STOP switch.
2.8.1 On-site first-aid

Given an injury:
1. Elevate the injured body part
2. Cover wound in a sterile manner or bandage
3. Apply a pressure dressing given marked bleeding
4. Keep an eye on the person injured
5. If required, wrap up any severed body parts and preferably keep cool
6. Transfer as rapidly as possible to an accident surgery unit
7. Point out to the doctor that an accident with high-pressure water is
involved

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10 Safety
2.8.2 First-aid ID
During the operation, have a first-aid ID for water-jet injuries with you at all
times.
Printing first-aid ID
 Scan QR code
or
 Visit:
https://www.hammelmann.com
 Click on Service
 Click on Safety
 Click on PDF download under first-
aid ID
 Select your national language
2.9 Professional disposal

Important
Professional disposal
The product is made up of various materials (metal, plastic)
 Sort the parts by materials before their disposal
 Ensure that all materials are properly disposed of
Adhere to the following when disposing of components and parts of the product:
• Follow the national and local disposal regulations.
• Have the parts and components disposed of by a qualified specialist firm.

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Design and description 11
3 Design and description

The ES 4 is a control unit for operating, monitoring and setting HAMMELMANN
high-pressure pump installations.
Inputting is done by means of a touch display. In addition, keys facilitate
operating the control unit during the operation.
The control unit is supplied ready-configured to the system and ready for start-
up ex-works.
3.1 User interface
Fig. 1: Layout of the user interface
1 Status bar 3 Touch buttons

2 Display area 4 Key panel
3.1.1 Status bar

Current status information is shown in the status bar.
Fig. 2: Status bar
1 Battery voltage 3 I/O touch button

2 Status information

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Touch button
Switch off control unit
Consumers
Status of the consumer: Off
A consumer has been connected and detected.
Status of the consumer: On
High-pressure water is not supplied to the consumer.
The system is possibly still not operable.
Status of the consumer: On
High-pressure water is supplied to the consumer.
Fault: There is no feedback from the consumer.
The connection between control unit and consumer has possibly
been interrupted.
Fault: The consumer issues a faulty feedback.
The connection between control unit and consumer has possibly
been disrupted (e.g. by a short-circuit).
Engine warning lamps

The description is for orientation purposes. For a precise description, consult
the engine operating instructions.
Critical engine fault. The engine is stopped.
Critical oil pressure. The engine is stopped.
General engine malfunction. Can result in a power reduction.
The engine is pre-glowing. The engine can be started as soon as the

lamp is extinguished.
Under engine stoppage conditions, engine ignition was manually

switched on with the key.
Low fill level of the diesel tank. Replenish with diesel fuel.
The particle filter ash load is too high.
A common particle filter malfunction.

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A common malfunction of the exhaust gas treatment system.
Low DEF (Diesel Exhaust Fluid) fill level. Replenish with AdBlue.
Particle filter regeneration has been manually suppressed. Carry out

regeneration.
Raised exhaust gas temperature (occurs when the particle filter is

being regenerated).
3.1.2 Display and control section

In this area, the menu determines which system information is displayed and
which settings are undertaken.
The start screen indicates the most important information on operating.
Fig. 3: Display and control section of the start screen
1 Engine rev. counter [rpm] 3 Diesel fill level [%]

2 Pressure gauge [bar] 4 DEF / AdBlue® level [%]
Indicate target value

To display the set target value, press once on the rev. counter or pressure gauge
(depending on control type set).
Display DEF / AdBlue® level

To display the set DEF / AdBlue® level, the engine controller must be switched
on .
 Press the key to switch on the engine controller.

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3.1.3 Touch buttons

Use the touch keys at the bottom edge of the user interface to navigate to the
sub-menus.
Fig. 4: Touch buttons

Menu touch buttons on the front page:
User menu Info
Pump Gearbox
Engine
General touch buttons:

Back
Return to the previous menu.
OK
Confirm input.
ESC
Abort / Discard the input.
Further information in chapter "Setting and monitoring" on page 25.

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3.2 Additional control elements
3.2.1 Key panel

The key panel under the user interface allows the most important functions to
be operated - even when protective gloves are worn.
Fig. 5: Key panel
Stop engine
Start engine
Switch on engine ignition

Switch on engine ignition to obtain engine information during an
engine stoppage.
Home key
Press home key to get to the start screen.
Raise speed or pressure
Reduce speed or pressure

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3.3 EMERGENCY STOP switch and start button

The EMERGENCY STOP switch and start button are fitted within the reach of
the touch display.
Fig. 6: Key panel
EMERGENCY STOP Start button

switch
3.4 Control types

Control type: Speed
Speed control allows the engine speed to be controlled irrespective of the
outputted pressure.
In contrast to pressure control, the speed control does not automatically adjust
the speed in order to maintain the pressure given a pressure drop (e.g. as a
result of nozzle wear).
Control type: Pressure
Pressure control establishes an operating pressure which the control unit
automatically maintains. The engine speed is correspondingly adjusted.

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Operating 17
4 Operating
WARNING
Risk of injury
Working with high-pressure water is dangerous.
 Always wear the prescribed protective equipment when
handling high-pressure water.
 Refer to chapter "Personal protective equipment (PPE)",
page 9.
WARNING
Accident risk
The product may only be operated by trained personnel.
 Refer to chapter "Operating personnel qualifications ", page
8.
4.1 Switching on the control unit

Switch on the control unit to undertake settings and then start the engine.
 Switch on the battery main switch of the system.
 Unlock emergency stop switch
 Press the control unit start button. The start button is next to
the EMERGENCY STOP switch.
 “HAMMELMANN loading” appears on the display. The control unit starts.

 The starting procedure is concluded once the front page is displayed.
Fig. 7: Front page

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18 Operating
4.2 Setting up the control unit
4.2.1 Establishing and setting the target value

The target value establishes which engine speed [rpm] or which pressure [bar]
the high-pressure pump is to be operated with.
The control type determines whether the control is effected by means of the
speed or the pressure.
The control type can be set in the user settings.
 Refer to chapter "User settings", page 25.
Establishing the target value

Nozzle calculator
Link:
https://www.water-jetting-
calculator.com/nozzlecalculation
 The HAMMELMANN nozzle

calculator can be used to establish
the target value.
Another way is to calculate the target value in the control unit.

 Refer to chapter "Nozzle calculation", page 34.

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Operating 19
Setting the target value

Set the target values appropriate for your application. Proceed as follows:
Fig. 8: Setting the target values
1 Engine rev. counter 3 Raise speed / pressure

2 Pressure indicator 4 Reduce speed / pressure
 Press the key to get to the start screen.

 Using speed control: Touch the value 2 x in the middle of the rev. counter (1).
 Using pressure control: Touch the value 2 x in the middle of the pressure
indicator (2).
 An entry mask appears.
 Enter the target value established beforehand.
 Confirm the input with “OK”.
 The input is set as the target value.
The target value can be raised and lowered by pressing the and keys.
4.2.2 Checking and adjusting the settings

Before starting the engine, check the following settings and, if necessary, adjust
them:
• User settings
 Refer to chapter "User settings", page 25.
• Gearbox (select gear/performance range)
 Refer to chapter "Gearbox", page 40.

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20 Operating
4.3 Start engine

Ensure that the following is carried out before starting the engine:
• The control unit is set up. All the required settings have been undertaken.
• All the connected pressure-retaining parts (consumers, high-pressure
hoses, …) are designed for the maximum loads (pressure, flow rate,
temperature) and are operable.
Fig. 9: Starting/stopping engine
Start the engine as follows:

 If necessary, press the key (1) to get to the start screen.
 The start screen appears on the touch display.
 Briefly press (for 0.5 seconds) the key (2).
 If the engine does not immediately start, then keep the key (2) pressed a
little longer. Note: A delayed start indicates a weak battery.
 The engine starts automatically.
Fig. 10: Start-up phase

 A countdown for the start-up phase is shown after an effective start.
Fig. 11: Countdown status “OK”

 An “OK” is shown once the start-up phase is over.
The system is now ready for the high-pressure operation.
4.4 High-pressure operation

You can start the operation when the following conditions are met:
• The engine has been started.
• No fault messages have been shown. Any faults have been identified and
corrected.
• All operating personnel are wearing their personal protective equipment
(Refer to chapter "Personal protective equipment (PPE)", page 9.).

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Operating 21
4.4.1 Starting the operation

WARNING: As the consumer operator (e.g. of the high-pressure spray
gun), do not undertake any settings on the control unit. The control unit
must be operated by another trained operator.
 The consumer operator switches on the consumer (e.g.: activates the spray
gun trigger)
Fig. 12: Starting the operation

 The consumer colour changes from white to green in the status bar.
 The engine speed keeps increasing until the set target value is reached.
The high-pressure pump installation generates high pressure.
 High-pressure water is supplied to the consumer.
Control type: Speed Control type: Pressure

Fig. 13: Control types during the operation
A Idle running speed C Max. speed / pressure

B Target value
 Press the or key on the key panel to raise or lower the target value.
 The system shuts itself off if you exceed HP-Max (or fall short of HP-Min)
(see User settings).

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22 Operating
4.4.2 Stopping the operation

 Stop the operation at the consumer (e.g. release the spray gun trigger)
 The effect of setting the idle running delay (see User settings) is for the
system to hold the high speed for the time set.
 The consumer operator remains at his operating position until the engine is
shut down.
Fig. 14: Stopping the operation

 The consumer colour changes from green to white in the status bar.
 The engine speed drops to the idle running speed.
 High-pressure water is no longer supplied to the consumer.
 Shut off the engine to stop the operation.

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Operating 23
4.5 Stop engine

Stop the engine to stop the operation.
 If necessary, press the key (1) to get to the start screen.
 The start screen appears on the touch display.
Fig. 15: Starting/stopping engine
 Briefly press the key (3).

 The engine shuts down once the cooling time (countdown in the status bar)
has expired.
Note: The turbocharger can be damaged by shutting down the engine
before the cooling time is over. In an emergency, the engine can be
immediately stopped by again pressing the key (3).
Fig. 16: Countdown
Shut down the control unit to fully take the system out of service.

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24 Operating
4.6 Shut down the control unit

 Press the key to get to the start screen.
Fig. 17: Shut down the control unit
 Press this touch button on the start screen to shut down the
control unit.
 The control unit shuts down.
Only when the engine is completely shut down does the touch
button appear.

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Setting and monitoring 25
5 Setting and monitoring
5.1 User settings
Press this touch button on the start screen to get to the “Settings”
menu.
The control unit is adjusted to the operating conditions and your personal
requirements in the settings.
Fig. 18: User settings
1 Control type 5 Operating settings

2 Pressure build-up 6 Date and time
3 Pressure level (optional) 7 Language
4 External target values
Switch: On Switch: Off
Selection: On Selection: Off

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5.1.1 Selecting the control type

The system is controlled either through the speed or pressure.
 Further information in chapter "Control types" on page 16.
 Touch a selection button to change the setting.
 The activated setting is marked with a symbol.
5.1.2 Setting the pressure build-up

This setting option affects the speed with which the system builds up pressure.
As a rule, the following applies:
• Long high-pressure hose (100 m) = slow pressure build-up
• Short high-pressure hose (20 m) = rapid pressure build-up
Rapid Moderate Slow

 Touch one of the 3 buttons to change the setting.
 The activated setting is marked with a symbol in the touch button.
Note: The pressure build-up can only be set when the “Pressure” control type is
activated. The setting has no effect on pressure build-up under the “Speed”
control type.
5.1.3 Adjusting the operating settings

The operating settings are for adjusting the control unit to the operating
conditions.
Minimum high pressure Establish a minimum value for the pressure. The
system shuts itself off if the value is fallen short of
during the operation.
Minimum high pressure The system shuts itself off when the user-defined
time time span is fallen short of.
Maximum high pressure Establish a maximum value for the pressure. The
system shuts itself off if the value is exceeded.
Standby time The systems shuts off the engine if no high-
pressure water is requested in the specified time
span.
Idle running delay On stopping the high-pressure operation, the
system keeps to the high speed during the user-
defined time span.
 Switch the options on/off by touching the switch .

 Touch a value to change it.

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5.1.4 Externally activate and read-off the target values

Target values can be externally read in and read off as follows.
Analogous interface Activation:
• Target values for pressure and speed
BUS control Reading off and activating:
• Target values for pressure and speed
• Starting and stopping the system
• Control type
• Gearbox stage
Reading off:
• Pump operating parameters
(backing pressure, oil pressure, …)
 Switch the interface on/off by touching the switch .
5.1.5 Change time, date and language

Time and date  Touch a value to change it.
Language  To change the language, touch the national
flag.
 Touch the flag of the language required.

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5.1.6 Selection of the pressure step

This is an optional function only available to systems with more than one
pressure level.
In the “Settings” menu, press on the pressure level value (6) to

select the pressure step.
Fig. 19: Pressure level selection
1 Password 3 Confirm / Quit

2 Pressure levels
Selection: On Selection: Off
Change the pressure step as follows:

 Touch the pressure step value.
 The selection window (see Fig.) appears.
 Touch the password button (1).
 An input window appears.
 Enter the password “123” and confirm the input.
 Touch the selection button to select the required pressure level (2).
 The activated pressure step is marked with a symbol.
 Close the window by touching “OK/Esc” (3).

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5.2 Pump
Press this touch button on the start screen to get to the “Pump”
menu.
This menu allows for monitoring of the pump operating parameters.
Fig. 20: Pump
1 Flow rate 8 Oil pressure

2 Operating pressure 9 Oil temperature
3 Backing pressure 10 Conductivity of the water
4 Solenoid valve 11 Pre-pressure pump
5 Air pressure 12 Supply tank full / empty
6 Filter differential pressure 13 Additional inputs
7 Water temperature
The values are shown in traffic light colours. The colours signify the following:
White: Normal value
Yellow: Near-limit value
Red: Fault / Limit exceeded

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5.2.1 Additional inputs
Press this touch button in the “Pump” menu to get to the

“Additional inputs” menu.
Here you can read off the readings of any additional sensors which have been
installed.
Fig. 21: Additional inputs

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5.3 Engine
Press this touch button on the start screen to get to the “Engine”
menu.
In this menu you can:

• Monitor the engine operating parameters
• Read-off the controller output
• Start/suppress regeneration of the particle filter (if present)
Fig. 22: Engine
1 The engine operating 4 Start regeneration

parameters
2 Engine warning lamps 5 Suppress regeneration
3 Engine fault list
5.3.1 Regeneration of Volvo and Deutz engines Stage 5

The most frequent reason for the “Common particle filter malfunction” warning
lamp appearing is an increased soot load.
Regenerate the particle filter to reduce the soot load.
The regeneration control unit might automatically start if the engine is running at
idle.
Fig. 23: Common particle filter malfunction

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Carry out the regeneration as follows:

Bear in mind that the regeneration can last up to 45 minutes. No high-pressure
operation is possible during the regeneration.
NOTE: Constantly drain the water from the feed tank to stop the pump from
overheating.
 Press this touch button on the start screen to get to the

“Engine” menu.
 Press this touch button to start the regeneration.

 To clean the particle filter, the exhaust gas temperature is
artificially raised.
 Once the required exhaust gas temperature is reached, the
regeneration starts automatically.
It is usual for the “Increased exhaust gas temperature” warning
lamp to appear during regeneration.
The appearance of the “Engine regeneration finished” note means that

regeneration has been successfully carried out.
 Confirm note with “OK”.
The high-pressure operation can now be continued.
Not carrying out any regeneration results in the soot load continuing to increase.
The following information appears when a critical soot load is reached.
Fig. 24: Regeneration required

 Start regeneration
 Regeneration will be carried out.
 Ignore regeneration
 Ignoring enables a further 10min of operations.
NOTE: Ignoring the warning too often makes any further regeneration
impossible due to the high loading condition. The engine will then be
permanently shut down until authorised Service personnel replace the filter.

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5.4 General
Press this touch button on the start screen to get to the “General”
menu.
In this menu you will find:

• General system information
• Nozzle calculation
• Fault memory
Fig. 25: General
1 Hour meter 4 Nozzle calculator

2 Machine number 5 Fault memory
3 Software version 6 Service access
Service access
Only HAMMELMANN service personnel are entitled to undertake settings in the
service menu.

05.2021
5.4.1 Nozzle calculation
Press this touch button in the “General” menu to get to the

“Nozzle calculation” menu.
Note: The nozzle calculation refers to HAMMELMANN nozzles. The calculation

results may vary if the nozzles of other manufacturers are used.
This menu allows the following to be calculated:

• Nozzle diameter
• Capacity
• Number of nozzles
Calculated values are coloured. The colours signify the following:

Green: Normal value
Red: Limit exceeded / fallen short of

05.2021
Calculating the nozzle diameter

 Press this touch button.
Fig. 26: Calculating the nozzle diameter
 Press on a grey box to adjust the value in question.

 An input box appears.
 Adjust the values to your application.
 Confirm the input with “OK”.
WARNING: Note the maximum recoil forces for hand-operated high-

pressure jet appliances.
Max. permitted recoil force [N]

without body support 150
with body support 250

05.2021
 Touch the grey box (1) to adjust

the nozzle factor.
 Choose the nozzle type by
touching the appropriate button.
 Choose the nozzle type diameter
by touching the button (2).
 An input mask appears.
 Type in a value for the nozzle
diameter and confirm the input
with “OK”.
Fig. 27: Nozzle selection
HAMMELMANN Max. pressure

Jet form Nozzle factor
nozzle type [bar]
A Round 0.95 2000
B Flat 0.67 2000
C Round 0.92 400
D Flat 0.67 400
E Round 0.92 2500
G Round 0.92 2500
H Round 0.75 2500
I Round 0.70 3000
K Round 0.75 3000
L Round 0.95 1600
M Round 0.95 2500
N Round 0.63 2500
O Round 0.63 2500
P Round 0.71 3000
R Flat 0.67 3000
S Round 0.92 3000
T <= 0.45 mm Round 0.92 3500
T >= 0.50 mm Round 0.72 3500
U Round 0.70 4000
W Round 0.92 3000
Directly drilled As per nozzle
Round 0.65
nozzle marking

05.2021
Calculating the capacity

Fig. 28: Calculating the capacity

 Adjust the nozzle factor (1) as described above.
 If you do not need a column for your calculation, then position the number of
nozzles to “0”.

05.2021
Calculating the number of nozzles

Fig. 29: Calculating the number of nozzles

 Adjust the nozzle factor (1) as described above.

05.2021
5.4.2 Fault memory
Press this touch button in the “General” menu to get to the “Fault
memory” menu.
There is a list of the most recent faults in this menu.
Fig. 30: Fault memory
1 The most recent faults 5 Failure Mode Identifier *

(the latest one first)
2 Number acc. to fault list 6 Time when it occurred
3 Fault wording 7 Scroll up the list
4 Subject Parameter Number * 8 Scroll down the list
* Service personnel make use of the SPN together with the FMI to obtain
specific information on a fault.
Possible causes of malfunctions and their correction can be found here:

 Refer to chapter "Correcting malfunctions", page 42.

05.2021
5.5 Gearbox
Press this touch button on the start screen to get to the “Gearbox”
menu.
In this menu you can:

• Monitor the gearbox operating parameters
• Engage the gear
Fig. 31: Gearbox
1 Possible speed range 6 Air pressure

2 Engaged gear 7 Pressure cylinder direction of
movement
3 Possible flow rate 8 Output speed
4 Gears 9 Gearbox temperature
5 Pressure cylinder direction of
movement
The gears are coloured. The colours signify the following:

Green: Gear engaged, system in operation
Yellow: Gear engaged, system not in operation
Grey: Gear not engaged
Red: Gear engaged, fault
Light red: Gear not engaged, fault

05.2021
5.5.1 Engage the gear

The required flow rate determines which is the correct gear to engage.
The gear can only be changed when the engine is shut down.
Proceed as follows in changing the gear:
 Shut off the engine.
 Refer to chapter "Stop engine", page 23.
 Open the menu - “Gearbox”
 Press the touch button of the gear required (5).
 The gear is engaged as soon as the engine is started.
 When starting the engine, the touch button colour changes to

green. The gear is engaged.
NOTE: A red touch button may indicate a problem with the air
pressure supply of the gearbox. Check the air pressure supply.
The air pressure (6) measured must be highlighted in green.

05.2021
42 Correcting malfunctions
6.1 Procedure
In the case of faults (malfunctions) a fault message appears on the display.
Fig. 32: Fault message

The high-pressure pump installation is immediately stopped in the case of faults
(malfunctions) which could cause damage to it.
 Establish the possible reasons for the fault
 Refer to "Fault list", page 43.
 Correct the fault, if possible
Reset fault
 Press the reset touch button to reset the fault.

 The fault is re-evaluated
 The operation can be continued as before given correction of the fault.
 Contact HAMMELMANN Customer Service if the fault message reappears
and the reason for it cannot be established.

05.2021
Correcting malfunctions 43
6.2 Fault list

Fault code Possible reason Remedy
Emergency stop switch
1 Emergency stop actuated Unlock emergency stop switch.
actuated.
Oil level too low. Top up with oil or change it.
Change oil filter,
Oil filter clogged.
change oil, if necessary.
2 Pump oil pressure too low Check oil temperature.
Oil temperature too high Check cooling water.
(viscosity drop). Monitor oil pressure manometer
(oil pressure approx. 5 bar).
Check sensors
Oil pressure pump signal
3 Oil pressure defective. (Sensor current ≥ 4 mA),
error (<4mA)
Replace sensor, if necessary.
Check water supply or water tank
Water tank fill level too low.
fill level.
Pre-pressure pump Backing pressure manometer -
Medium backing pressure
4 defective. check (backing pressure > 3 bar).
too low
V-belt of the pre-pressure Check, re-tension V-belt tension or
pump loose or defective. possibly replace.
Water filter clogged. Replace water filter.
Check sensors
Medium backing pressure
5 Sensor defective. (Sensor current ≥ 4 mA),
signal error (<4mA)
6 Medium filter soiled Medium filter clogged. Replace medium filter.
Check sensors
Medium filter sensor fault Differential pressure sensor
7 (Sensor current ≥ 4 mA),
(<4mA) defective.
Medium filter differential Filter differential pressure is Replace sensor cable (backing
8
pressure negative negative. pressure and filter pressure).
Supply medium
Check supply medium.
temperature > 30 °C.
Pump medium temperature Water temperature in the
9 Top up with cold water.
too high feed tank too high.
Operation with a lot of Possibly drain bypass water
bypass water. separately.
Sensor defective (< 4mA). Replace sensor.
Medium temperature signal
10 Cable or plug connection Check cable and plug connection,
error (<4mA)
loose or defective. replace if required.

05.2021
Cooling water temperature too high,

allow cooling water to cool / supply
fresh water.
Cooling water quantity too low,
Pump oil temperature too
11 Oil temperature too high. Increase the flow rate.
high
Capacity impaired by the heat
exchanger,
check heat exchanger, if necessary
repair/replace.
Pump oil temperature
signal error (<4mA)
Check compressed air supply.
Min. air pressure fallen
Check pneumatic installation.
13 Air pressure too low short of.
Check sensor (also see Fault 14).
Air filter soiled. See note.
A soiled air filter gives rise to a reduction in the air flow rate.
This results - given high pressure activation - in a brief collapse of the air pressure
downstream of the filter due to only a low air volume being able to flow through the filter.
Should the time needed for the air pressure to stabilise downstream of the filter become
too long, then a system with air pressure monitoring shuts itself off with the “Over-low air
pressure” fault message.
If provided for in the software configuration, a warning appears on the control unit display
and the high pressure is shut off. The engine continues to run at idle (no air pressure can
be built up without the engine running!).
The warning disappears when the air pressure is again OK.
Replace air filter.
Air pressure signal error
(<4mA)
Do not use any water with low
Conductivity too low Water conductance has water conductances (demineralised
15
(demineralised water) fallen to under 150µS. water). There is a risk of damage to
the pump.
Conductivity signal error
(<4mA)
Cooling water temperature too high.
Oil temperature of the
Gearbox oil temperature Cooling water quantity too low.
17 intermediate gearbox too
too high Capacity impaired by the heat
high.
exchanger.
Gearbox oil temperature
signal error (<4mA)
Gearbox oil pressure too
19 Oil level not high enough. Replenish with gearbox oil.
low

05.2021

Gearbox oil pressure signal
error (<4mA)
Sensor high pressure
signal error (<4mA)
Medium tank fill level too The fill level in the water
22 Check water supply.
low tank is too low.
Diesel tank reserve fallen
30 Diesel tank fill level low Replenish with diesel.
short of.
Diesel tank signal error
(<4mA)
External target value signal
error (<4mA)
35 Excess current at output Output over-loaded. Check the output wiring.
Max. permitted high Examine nozzle selection:
pressure exceeded. Min. speed not to be fallen short of.
Maximum high pressure Incorrect nozzles. Replace nozzles.
50
exceeded Nozzles clogged. Clean or replace nozzles.
Change hose lengths in the
Hose length > 20 m.
settings.
High pressure target value The set HP target value Check target value (see User
51
exceeded has been exceeded. settings).
Set user maximum The set HP max value has Check HP max value (see User
52
pressure exceeded been exceeded. settings).
Check nozzles,
if necessary replace them.
Min. permitted high
WARNING Never retighten fittings
pressure fallen short of.
Set user minimum pressure when pressurized!
53
fallen short of Check high-pressure line.
High pressure not reached
Examine values and, if necessary
or fallen short of in the time
change them in the User menu.
set (User menu).
Pressure higher than the
value programmed for Examine parameters.
engine at idle.
Bypass valve or
54 Pressure at idle
changeover valve Check valves.
defective.
Pressure pickup defective,
Replace pressure pickup.
check sensor current.

05.2021
The set standby time has

Increase/shut off standby time (see
55 Set standby time expired expired under no-load
User settings).
conditions.
The valve current monitor
Bypass valve current not Check plug on the solenoid valve
56 has established a low or
within tolerance coil.
high current.
57, The valve current monitor
Changeover valve X Check plug on the solenoid valve
58, has established a low or
current not within tolerance coil.
59 high current.
The engine has been
Engine speed deviation too Contact the engine manufacturer’s
60 overloaded or a malfunction
large service department.
has developed.
Check gearbox.
Gearbox end positions The gearbox has lost the
61 Check sensor at the gearbox.
vacated in the operation end position.
Check air pressure at the gearbox.
Gearbox engaging gear at Try the operation again.
62 The gear is not engaged.
start failed Check gearbox and sensors.
Gearbox no start possible.
63 No end position, no air No gear engaged. Externally top up air pressure.
pressure
Battery voltage low, do not
64 The battery is too weak. Charge or replace battery.
start engine!
The control unit has a
65 Internal control fault Contact Service.
malfunction.
General engine fault type.
81 Engine fault Note SPN and FMI numbers / texts.
The engine is not stopped.
Cooling water level too low. Check cooling water level.
Cooler soiled. Check cooler.
Engine temperature too
81 Fan defective. Check fan.
high
Air supply and/or exhaust Check air supply and exhaust air
air obstructed. ports.
Level of the DEF / AdBlue®
82 DEF / AdBlue® level low Top up with DEF / AdBlue®.
tank is too low.
System examination diesel
The engine unit has a Contact the engine manufacturer’s
83 engine required by Service
malfunction. service department.
technician

05.2021
General engine fault type.

84 Engine fault Note SPN and FMI numbers / texts.
The engine is stopped.
The engine has a severe
Engine constant system malfunction. The engine Contact the engine manufacturer’s
85
blocking has been shut down to service department.
protect it from damage.
A serious fault has
Critical fault exhaust gas Contact the engine manufacturer’s
86 developed with exhaust gas
after-treatment process service department.
after-treatment.
Diesel particle filter ash Contact the engine manufacturer’s
87 The particle filter is full.
charge too high service department.
The control unit receives no Check power supply.
No feedback from safety
90 feedback from safety Check wiring.
control
control. Contact Service.
Check power supply.
No feedback from E32 No feedback from bus
91 Check wiring.
control unit coupler (E32).
Contact Service.
No feedback from Check power supply.
No feedback from gearbox
92 automatic gearbox bus Check wiring.
control unit
coupler. Contact Service.
Check power supply.
No feedback from heating No feedback from the
93 Check wiring.
control unit heater bus coupler.
Contact Service.
Check power supply.
No feedback from servo No feedback from the split
94 Check wiring.
split nozzles control unit nozzle servo-motor.
Contact Service.
Emergency stop cross- The emergency stop has
120 Check wiring.
circuit been incorrectly wired.
Servo-split nozzle engine General split nozzle type of Re-start system and control unit.
121
fault fault. Contact Service.
Electrical fault; precise
Check wiring of the corresponding
122 Safety control I/O fault reason is specified in the
sensor or actuator.
fault notification
The safety control and main Update appliances.

Safety control incorrect
123 control versions are
version Only use compatible software
incompatible.
versions.
Heater 1 temperature
160 Cable or sensor defective. Replace cable or sensor.
sensor signal error
Heater 2 temperature
161 Cable or sensor defective. Replace cable or sensor.
sensor signal error

05.2021

05.2021
Water Jetting
Calculator
The free Hammelmann app
For iOS, Android and your browser
Water Jetting Calculator: hammelmann.com/app
Hammelmann GmbH (0) 25 22 / 76 - 0

Carl-Zeiss-Straße 6-8 mail@hammelmann.de
59302 Oelde, Germany www.hammelmann.de
06/21 © Copyright Hammelmann GmbH, Oelde, Germany. Subject to technical modifications and error amendments.

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OPERATING INSTRUCTIONS

Manual number: Content revised: Language:

Manufacturer and customer service address:

Original operating instructions

Copyright of this manual remains with Hammelmann GmbH. This manual

Copyright © 2021 Hammelmann GmbH, Oelde, Germany.

Subject to technical modifications.

3 Design and description ........................................................................................ 11

Operating instructions ES 4 Aquajet

4.4.1 Starting the operation .........................................................................21

5 Setting and monitoring ........................................................................................25

6 Correcting malfunctions ......................................................................................42

Operating instructions ES 4 Aquajet

1.1 Software version

Operating instructions ES 4 Aquajet

1.4 View of warning notices

SIGNAL WORD! Embedded note with safety-relevant information

1.5.1 Orientation elements

Operating instructions ES 4 Aquajet

2.1 Technical Condition of the Product

There are separate manuals on certain system components (e.g. high-

2.2 Use as intended

2.3 Information on use

Storage and dispatch

Operating instructions ES 4 Aquajet

2.4 Incorrect application

Predictable incorrect applications:

Prohibited operating conditions:

2.5 Operating personnel qualifications

2.5.2 Training the operating personnel

2.6 Safety Equipment

Operating instructions ES 4 Aquajet

2.7 Personal protective equipment (PPE)

PPE when handling harmful substances:

2.8 How to react in case of danger

In case of danger or accidents, shut down the high-pressure pump unit by

2.8.1 On-site first-aid

Operating instructions ES 4 Aquajet

2.9 Professional disposal

Operating instructions ES 4 Aquajet

3 Design and description

3.1 User interface

Fig. 1: Layout of the user interface

1 Status bar 3 Touch buttons

3.1.1 Status bar

Fig. 2: Status bar

1 Battery voltage 3 I/O touch button

Operating instructions ES 4 Aquajet

Switch off control unit

Engine warning lamps

Critical engine fault. The engine is stopped.

Critical oil pressure. The engine is stopped.

General engine malfunction. Can result in a power reduction.

The engine is pre-glowing. The engine can be started as soon as the

Under engine stoppage conditions, engine ignition was manually

The particle filter ash load is too high.

A common particle filter malfunction.

Operating instructions ES 4 Aquajet

A common malfunction of the exhaust gas treatment system.

Particle filter regeneration has been manually suppressed. Carry out

Raised exhaust gas temperature (occurs when the particle filter is

3.1.2 Display and control section

Fig. 3: Display and control section of the start screen

1 Engine rev. counter [rpm] 3 Diesel fill level [%]