Enerpac AquaJack EAJ1 Series User manual

© 2022 Enerpac, All Rights Reserved. 1
1.0 INTRODUCTION
Overview
The aim of the AquaJack Bolt Tensioning
System is to quickly and accurately apply a pre-
determined load to a nut and bolt assembly.
It has been primarily developed for use in the
underwater environment where speed, ease of
operation and reliability are paramount.
In use, AquaJack Bolt Tensioners are attached
to every stud bolt in the joint assembly allowing
simultaneous and uniform bolt tightening.
AquaJack Bolt Tensioners are to be used as
part of a complete hydraulic system, alongside
a pump, hose arrangement and reaction nuts.
The AquaJack series can used on a wide range
of bolt size and pressure requirements.
Delivery Instructions
Upon delivery all components must be
inspected for damage incurred during shipping.
If damage is found the carrier should be notified
at once. Shipping damage is not covered by
the Enerpac warranty.
Warranty
• Enerpac guarantees the product only for the
purpose for which is intended.
• Refer to the Enerpac Global Warranty
document for terms and conditions of the
product warranty.
Any misuse or alteration invalidates the
warranty.
• Observe all instructions as communicated in
this manual.
• When replacement parts are needed, use only
genuine Enerpac replacement parts.
Modification to any part of the equipment
outlined in this manual should not be attempted,
nor any component part be replaced without
first consulting Enerpac. Modifications may
render the equipment dangerous. Component
parts are each rated to suit the demands of
the overall equipment design and replacement
with similar items without provenance may
lead to unexpected and dangerous accidental
features.
If any equipment abuse is evident, the warranty
will be invalidated and Enerpac will not be
made responsible for an injury due to misuse or
failure to comply with the above safety notes.
L4374 Rev. C 03/22
Instruction Sheet
AquaJack®Bolt Tensioners
CONTENTS
1.0 INTRODUCTION.......................................1
2.0 SAFETY ....................................................2
3.0 SPECIFICATIONS.....................................4
4.0 FEATURES AND COMPONENTS.............4
5.0 SETTING UP.............................................5
6.0 INSTALLATION .........................................5
7.0 TENSIONING AND DE-TENSIONING .......15
10.0 STORAGE.............................................23
11.0 TROUBLESHOOTING ..........................24
12.0 TECHNICAL DATA ................................26

2© 2022 Enerpac, All Rights Reserved.
Conformance to National and International
Standards
Enerpac declares that the product(s) have been
tested and conforms to applicable standards
and the product(s) are compatible to all EU and
UK Requirements.
Copies of the EU Declaration as well as the
UK Self-Declaration are enclosed with each
shipment.
2.0 SAFETY
Read all introductions carefully. Follow all
recommended safety precautions to avoid
personal injury as well as damage to the
product and / or damage to other property.
Enerpac cannot be responsible for any damage
or injury from unsafe use, lack of maintenance,
or incorrect operation. Do not remove warning
labels, tags, or decals. In the event of any
questions or concerns arising, contact Enerpac
or a local Enerpac distributor for clarification.
If you have never been trained on high-pressure
hydraulic safety, consult your distributor or
service centre for information about Enerpac
Hydraulic Safety Courses.
This manual follows a system of safety alert
symbols, signals, words, and safety messages
to warn the user of specific hazards. Failure to
comply with these warnings could result in
death or serious personal injury, as well as
damage to the equipment or other property.
The Safety Alert Symbol
appears throughout this
manual. It is used to alert
you to potential physical
injury hazards. Pay close
attention to Safety Alert Symbols and obey
all safety messages that follow this symbol to
avoid the possibility of death or serious injury.
These tools conform with
the requirements for CE
and UKCA.
•EAJ1 •EAJ2 •EAJ3 •EAJ4 •EAJ5
•EAJ6 •EAJ7 •EAJ8
Safety Alert Symbols are used in conjunction
with certain Signal Words that call attention
to safety messages or property damage
messages and designate a degree or level of
hazard seriousness. The Signal Words used
in this manual are WARNING, CAUTION, and
NOTICE.
Indicates a hazardous
situation that, if not avoided, will
result in death or serious personal injury.
Indicates a hazardous situation
that, if not avoided, could result in death or
serious personal injury.
Indicates a hazardous situation
that, if not avoided, could result in minor or
moderate personal injury.
Indicates information considered
important, but not hazard related (e.g.
messages relation to property damage). Please
note that Safety Alert Symbol will not be used
with the signal word.
2.1 Safety Precautions - AquaJack
Tensioners
Failure to observe and comply with the
following precautions could result in death
or serious personal injury. Property damage
could also occur.
• Read and completely understand the
safety precautions and instructions in this
manual before operating the tensioners
or preparing them for use. Always follow
all safety precautions and instructions,
including those that are contained within
the procedures of this manual.
• When the system is under pressure DO
NOT STAND IN LINE with the direction of
force of the tensioners. Keep this area clear
of personnel at all times when the system
is under pressure. If the bolt should fail,
serious personal injury or death could result
if loose or broken parts become projectiles.
DANGER
WARNING
CAUTION
NOTICE
WARNING

© 2022 Enerpac, All Rights Reserved. 3
• Operating procedures will vary, depending
on the system arrangement. Always read,
follow and completely understand all
manufacturers’ instructions when operating
pumps, valves and all other devices used
with the tensioners. Follow all safety
precautions contained in the manufacturer’s
manuals. Use only for intended purpose.
• Wear personal protective gear when
operating hydraulic equipment. Always wear
eye protection. Safety equipment such as
dust mask, non-skid safety shoes, hard
hats, gloves or hearing protection (used as
appropriate) will reduced personal injuries.
• Ensure that the strengths of the bolts
are known and that the recommended
tensioning applied loads are well within the
safe limits.
• Do not handle pressurized hoses. Escaping
oil under pressure can penetrate the skin. If
oil is injected under the skin, see a doctor
immediately.
• Do not pressurize disconnected couplers.
• The system operating pressure must not
exceed the pressure rating of the lowest
rated component in the system.
• Install pressure gauge(s) in the system
to monitor operating pressure. It is your
window to see what is happening in the
system.
• Never set a relief valve to a higher pressure
than the maximum rated pressure of the
pump and tensioner. If ratings are different,
relief valve setting should not exceed the
setting of the lowest rated component
(pump or tensioner).
• Do not exceed equipment ratings. Never
attempt to apply more load to a bolt than
the maximum capacity of the tensioner.
Overloading may cause equipment failure
and possible personal injury.
Failure to observe and comply with the
following precautions could result in minor
or moderate personal injury. Property
damage could also occur.
• Be careful to avoid damaging hydraulic
hoses. Avoid sharp bends and kinks when
routing hydraulic hoses.
• Do not bend beyond the minimum bend
radius specified by the hose manufacturer.
Using a bent or kinked hose will cause
severe back-pressure. Sharp bends and
kinks will internally damage the hose,
leading to premature hose failure.
• Do not lift hydraulic equipment by the
hoses or couplers. Use the tensioner lifting
eyes-bolts and appropriately rated lifting
equipment, where appropriate.
• Keep hydraulic equipment away from
flames and heat. Excessive heat will soften
packings and seals, resulting in fluid leaks.
Heat also weakens hose materials and
packings.
• For optimum performance, do not expose
hydraulic equipment to temperatures of
150˚F [65˚C] or higher.
• Immediately replace worn or damaged parts
with genuine Enerpac parts. Enerpac parts
are designed to fit properly and to withstand
high loads. Non-Enerpac parts may break or
cause the product to malfunction.
• Use hydraulic tensioners only in a coupled
system. Never use a tensioner with
uncoupled couplers.
• Hydraulic equipment must only be serviced
by a qualified hydraulic technician. For repair
service, contact the Enerpac Authorized
Service Centre in your area.
• Rope off working area and place warning
signs.
• To help ensure proper operation and best
performance, use of Enerpac oil is strongly
recommended.
NOTICE
CAUTION

4© 2022 Enerpac, All Rights Reserved.
3.0 SPECIFICATIONS
Major tensioner specifications, such as
maximum working pressure, maximum load
and maximum stroke are stamped into the side
of the hydraulic tensioner body. See
Figure 1. Be aware of these specifications
during installation and set-up.
FIGURE 1, TENSIONER DATA
4.0 FEATURES AND COMPONENTS
Refer to Figure 2 for a diagram of AquaJack
Series tensioner major components.
FIGURE 2, TENSIONER MAJOR
COMPONENTS
ENERPAC
EAJXX DATE CODE
MAX WP 1500 bar (21,750 psi)
MAX LOAD xx kn (xxx.xx lbf )
MAX STROKE xx mm (x.xx in)
7
1
3
4
2
5
6
Key:
1 - Quick-Fastening Reaction Nut
2 - Piston
3 - Grip Tape
4 - Body
5 - Coupler (2)
6 - Lifting Eye
Bolts (2)
7 - Tommy Bar
4.1 Maximum Stroke Indicator
Maximum allowable tensioner stroke is visually
indicated by a painted groove located on the
puller’s circumference.
Continually watch for the maximum stroke
indicator during tensioning procedures. Stop
pressurizing the system immediately if the
indicator becomes visible.
If during any tensioning procedure, the
maximum stroke indicator appears before the
desired hydraulic pressure is reached: STOP
the pump, tighten nut(s) at the tensioner(s) and
release hydraulic pressure. Then, turn down
the quick fastening nut(s) to return the piston(s)
back into the tensioner(s).
To ensure proper tensioning, always repeat the
tensioning stage (start over) if the maximum
stroke indicator appears before the desired
hydraulic pressure is reached.
Continuing to pressurize the
system after the maximum stroke indicator
becomes visible may result in high pressure
hydraulic oil leakage. Serious personal injury
could result if a stream of pressurized hydraulic
oil penetrates the skin. Damage to tensioner
components and joint may also occur if
maximum stroke is exceeded.
FIGURE 3, MAXIMUM STROKE INDICATOR
WARNING
Maximum
Stroke
Indicator

© 2022 Enerpac, All Rights Reserved. 5
6.0 INSTALLATION
6.1 Before You Begin
1. Be sure that ALL calculations (bolt load,
hydraulic pressure, etc.) have been made
prior to starting the tensioning process
and that they have been reviewed and
approved by a qualified engineer with
bolting experience.
2. Be sure all personnel involved in this
procedure are trained in joint tightening
procedures and the tensioning equipment
being used. Ensure that all personnel read
and understand the safety information
contained in sections 2.1 and 2.2 of this
document.
3. Be sure that the pump reservoir oil capacity
is adequate for the number of tensioners to
be used in the circuit. Refer to Table 1 for
tensioner oil volumes.
4. Be sure all personnel are aware of the
maximum working pressure and maximum
stroke applicable to the tensioner(s) being
used. This information is stamped on
the tensioner body. See Section 3.0 for
additional information.
5. Inspect the studs to verify that they contain
no obvious damage or defects, and that
they appear capable of withstanding the
force that will be applied by the tensioners.
5.0 SETTING UP
5.1 Hydraulic Oil
Oil requirements will vary, depending on
pump model and type. Refer to your pump
instruction manual for oil specifications. Failure
to use genuine Enerpac hydraulic oil may void
warranty.
5.2 Hoses and Fittings
All hydraulic hoses and fittings used in the
circuit must be rated at or above the maximum
working pressure of the tensioner - 1500 bar
[21,750 psi].
To ensure safe and reliable operation, use
of Enerpac approved high pressure hoses is
strongly recommended. Refer to the Enerpac
Bolting Solutions Catalogue for a complete
list of available hoses, fittings and related
accessories.
5.3 Pump Requirements
This bolt tensioning equipment has been
designed to be used in conjunction with a
hydraulic pump unit. Enerpac can offer a range
of pump options to suit particular applications
and thus operators should refer to the specific
instruction manual for the pump to be used.
The safety rationale used in the design of this
tensioner has assumed a pump maximum
working pressure appropriate for the tool and
using hydraulic oil Enerpac HF oil ISO32.
Enerpac HF oil is available at your local Enerpac
Distributor or Authorized Service Centre.
Hydraulic connection is made using quick
disconnect male & female couplers. In the event
an alternative pump unit is used, additional
safety measures such as pressure relief valves
or bursting discs must be considered to ensure
over-pressurisation cannot occur.
The following are recommended pump
parameters:
AIR SUPPLY : 1/2” nominal bore supply line
AIR CONSUMPTION: 50 CFM
AIR PRESSURE: 75 psi
See pump manual for operating instructions.
Table 1 - Tensioner Oil Volumes
Series
Maximum Oil Volume at Maximum
Stroke (each tensioner)
fluid ounces (US) cubic
mm
EAJ1 0.7 20.2
EAJ2 1.7 49.8
EAJ3 2.6 75.7
EAJ4 3.7 110.6
EAJ5 6.0 177.3
EAJ6 8.4 249.4
EAJ7 12.5 371.1
EAJ8 15.7 464.2
Note: To determine total oil volume required, multiply
the oil volume for your tensioner series by the number of
tensioners to be used in the circuit. Oil volumes shown
are approximate. Additional oil will be contained inside
hoses and fittings.

6© 2022 Enerpac, All Rights Reserved.
Table 1 - Hexagon Nut Drilling
Metric Heavy Series
BOLT
DIA.
Ø A Ø B Ø C NUT A/F TOMMY
BAR
DIAMETER
mm mm mm mm
M16 5.2 7 4* 24 5
M20 5.2 7 4* 30 5
M22 5.2 7 4* 32 5
M24 6.2 9 5* 36 6
M27 6.2 9 5* 41 6
M30 8.2 12 6* 46 8
M33 8.2 12 7* 50 8
M36 10.2 15 8* 55 10
M39 10.2 15 8 60 10
M42 10.2 15 9 65 10
M45 10.2 15 9 70 10
M48 12.4 18 11 75 12
M52 12.4 18 12 80 12
M56 14.4 21 12 85 14
M60 14.4 21 12 90 14
M64 16.4 24 14 95 16
M68 16.4 24 14 100 16
M72 16.4 24 14 105 16
6. Be sure that all nuts and threaded pullers are
free running on the studs over the entire stud
length protruding through the joint.
6.2 Application Preparation
Hexagonal Nut Drill Details:
In order to allow the rotation of the standard
hexagonal nut, tommy bar holes are required to
be drilled into the flat of each nut. Drilling details
are shown below in Figure 4.
1. TABLES 1.0 AND 2.0 are for use with
imperial heavy series nuts and metric series
hexagon nuts to ANSI B18.2.2 only. (Where
the nut height = the stud diameter).
2. Dimension ‘C’ denotes maximum hole depth
to drill point. Unless otherwise specified.
* Indicates the use of a Flat Bottom Drill
NOTICE
FIGURE 4, DRILLED NUT

© 2022 Enerpac, All Rights Reserved. 7
Table 2 - Hexagon Nut Drilling
Imperial Heavy Series
BOLT
DIA.
Ø A Ø B Ø C NUT A/F TOMMY
BAR
DIAMETER
mm mm mm inch
5/8” 6.2 7 4* 1.1/16” 6
3/4" 6.2 9 5* 1.1/4” 6
7/8" 6.2 9 5* 1.7/16" 6
1" 6.2 9 6* 1.5/8" 6
1.1/8" 6.2 9 6* 1.13/16" 6
1.1/4” 8.2 12 8* 2” 8
1.3/8" 8.2 12 8* 2.3/16" 8
1.1/2” 10.2 15 9 2.3/8” 10
1.5/8" 10.2 15 9 2.9/16" 10
1.3/4" 10.2 15 10 2.3/4" 10
1.7/8" 10.2 15 10 2.15/16" 10
2” 12.4 18 12 3.1/8" 12
2.1/4" 12.4 18 12 3.1/2" 12
2.1/2” 14.4 21 14 3.7/8” 14
2.3/4" 14.4 21 14 4.1/4" 14
3” 16.4 24 16 4.5/8” 16
3.1/4" 16.4 24 17 5" 16
3.1/2" 16.4 24 18 5.3/8" 16
3 3/4" 16.4 24 18 5 3/4" 16
4” 16.4 24 18 6 1/8” 16
Table 2 - Hexagon Nut Drilling
Metric Heavy Series (continued)
BOLT
DIA.
Ø A Ø B Ø C NUT A/F TOMMY
BAR
DIAMETER
mm mm mm mm
M76 16.4 24 15 110 16
M80 16.4 30 15 115 16
M85 16.4 30 15 120 16
M90 16.4 30 18 130 16
M95 16.4 30 18 135 16
M100 16.4 30 18 145 16

8© 2022 Enerpac, All Rights Reserved.
6.3 Bolt Preparation
Simple bolt preparation, carried out topsides,
will significantly reduce the risk of problems
occurring during tensioner application and
operation. Therefore, we would recommend
that the following preparations and checks are
adopted whenever possible.
1. To accommodate the AquaJack tensioner an
extended portion of bolt is required above
the drilled hexagonal nut (Figure 5). It is
recommended that this extension (length
A) be pre-set before lowering the bolts
underwater.
2. The required bolt protrusion must be through
a drilled hexagonal nut and nut washer
faces must point inwards. Visibly check that
the nut drilled holes are nearest to the nut
washer face.
3. The drilled hexagonal nut must be free-
running on all bolts over the entire length
A and especially over the 30 mm length B
(Figure 5).
4. Assemble the Quick-Fastening reaction nuts
to the end of the bolt protrusions, length C
(Figure 5), ensuring that the Quick-Fastening
reaction nut locking mechanism fully and
easily engages.
Alternatively, if solid reaction nuts are used,
ensure free running over bolt protrusion,
length C.
5. Protect the bolt protrusion using sleeves,
adhesive tape, etc. This will not only protect
the threads from knocks and damage during
installation but prevent movement of the
pre-drilled nut, which may alter the pre-set
length A.
Table 3 - AquaJack Bolt
Protrusion
AquaJack BOLT
DIA.
LENGTH
A
EAJ1 3/4”
7/8” 119
EAJ2 1”
1 1/8” 152
EAJ3 1 1/4”
1 3/8” 163
EAJ4 1 1/2”
1 5/8” 176
EAJ5
1 3/4”
1 5/8”
2”
189
EAJ6 2 1/4”
2 1/2” 206
EAJ7 2 3/4”
3” 235
EAJ8 3 1/4”
3 1/2” 252
FIGURE 5, BOLT PREPARATION

100% Coverage
(typical arrangement)
Note: Using this method of assembly,
all studs are tightened simultaneously
in one operation. To allow room for all
tensioners, the protruding studs must
be staggered over each side of the
joint (see above).
Interconnecting hose
Feed Hose to
Pump
Note: In stage one,
50 % of the studs are
tensioned, In stage
two, the remaining
50% of the studs are
tensioned.
Note: This method of assembly
is often used where studs can be
tensioned from only one side of the
joint due to an access restriction on
the opposite side. The studs must
be assembled with the protrusions
on the same side of the joint (see
below).
50% Coverage
(typical arrangement)
Interconnecting hose
Interconnecting hose
Feed Hose to
Pump
© 2022 Enerpac, All Rights Reserved. 9
6.4 Flange and Bolt Assembly
Prior to installation of the flange bolts, it is recommended that the flange is squared and brought
into close contact using methods such as the Enerpac flange puller. Once the flange faces are
square and in close proximity the bolts and gasket may then be installed.
The bolts must be installed in a specific manner depending upon whether 100% tensioner coverage
or 50% coverage is adopted.
FIGURE 6, HYDRAULIC TENSIONER MOUNTING ARRANGEMENTS (TYPICAL)

10 © 2022 Enerpac, All Rights Reserved.
6.5 Assembling AquaJack Tensioners
Note: If de-tensioning, refer to Section 7.3.
1. Ensure that all pistons are fully retracted, i.e.
pistons flush with the top of the body. See
Figure 7.
2. Assemble one tensioner onto every bolt
(every other bolt for 50% coverage) by
sliding them over the bolt protrusions. See
Figure 8.
3. Slide the Quick-Fastening reaction nut
over the remaining bolt thread protrusion,
tapered side toward the AquaJack, and
squeeze the nut halves together until
the locking mechanism engages. See
Figure 9.
4. Whilst supporting the weight of the tool, if
located horizontally, and ensuring the bridge
access window points radially outward, using
a Tommy bar, screw the Quick-Fastening
reaction nut down until it firmly seats against
the piston taper. Do not advance the piston
to the Quick-Fastening reaction nut as
this does not ensure correct engagement.
This, in eect, will centralise the assembly,
retain the AquaJack and lock the Quick-
Fastening reaction nut in position. See
Figure 10
Note: If solid reaction nuts are used, ensure that
they do not bind on the bolt threads causing
the bolt to turn through the hexagonal nut on
the opposite side of the flange. Should this
occur, then upon application of tensioning load,
insucient thread engagement may exist and
could lead to stripping of the bolt threads.
5. The AquaJack Tensioners are now
assembled, ready for hose connection.
FIGURE 7, FULLY RETRACT PISTON
FIGURE 8, PLACE TENSIONER ONTO TO
STUDBOLT
FIGURE 9, SLIDE QUICK-FASTENING
REACTION NUT INTO PLACE
FIGURE 10, COMPLETE QUICK-FASTENING
REACTION NUT INSTALLATION

© 2022 Enerpac, All Rights Reserved. 11
• Internal pressure within the AquaJack due
to over tightening the reaction nut during
assembly. In such a case, the reaction nut
must be released, the hose connected, and
the reaction nut re-tightened.
• Internal pressure within the hose itself
caused by previous use at a greater depth.
This may be remedied by returning the
hose to the surface and venting the internal
pressure as described in Section 9.5.
6.6 Hose Connections - Restricted Access
In certain situations, where access is restricted,
it may not be possible to attach the hydraulic
hoses to the AquaJack as shown in Figure 12
and 13. In such situations, it may be necessary
to attach the hoses at 90° to that shown. This is
achieved using banjo assemblies.
Assembly of Banjo Fittings
Banjo fittings are used as a method of re-
orientating the quick disconnect couplings when
access is dicult. The general configuration is
shown below:
1. Remove the standard male quick disconnect
coupling and associated adaptor from the
AquaJack.
2. The banjo block is fitted with a male quick
disconnect coupling, ¼” BSP adaptor and
O-ring seal with steel back up ring. If these
items are not already fitted to the banjo
block, then the block should be gripped
in a soft jawed vice and the coupling /
adaptor assembled in accordance with
the instructions above entitled ‘QUICK
DISCONNECT COUPLING SEALS’.
3. Ensure that the AquaJack body counter-
bore is clear of dirt and debris and insert an
O-ring and back-up ring.
4. Insert an O-ring and back-up ring into the
counter-bore on the outside face of the
banjo block, before inserting the banjo bolt
through the bore of the banjo block.
5. The threads on the banjo bolt should be
coated with Omega 95 (or similar lubricant
with a coecient of friction (mu) = 0.12).
6. Insert the banjo bolt into the port on the
AquaJack body and when the banjo block
is in the desired orientation, the banjo bolt
should be tightened to a torque of 45 lb-ft
(61 Nm).
6.6 Hose Connections
Note: Refer to Section 6.4 for an explanation of
100% Coverage and 50% Coverage.
Hose Connection Notes
1. Ensure the pump hydraulic oil return valve is
fully open.
2. Always link AquaJack together working
either in a clockwise or anticlockwise
direction around the flange. This will
minimise incorrect connections.
3. Ensure that a link hose exists connecting
tensioners on one side of the flange to the
other. (100% tensioner coverage only).
4. Both feed hoses must always be used with
the down-line manifold.
5. The female quick disconnect coupling
on down-line hoses only, are equipped
with locking collars which when screwed
up behind the coupling sleeve prevents
disengagement. The locking collar on the end
of the down-line must be backed o before
the down-line hoses can be disconnected.
6. Should an interconnecting or feed hose be
missing or damaged then the down-line is
equipped with a ‘sacrificial hose’ which is
connected between the manifold and the end
of the down-line. This may be disconnected,
the manifold re-connected to the end of the
down-line and the sacrificial hose used to
replace the damaged or missing hose.
After removing the sacrificial hose,
before the down-line can be re-connected the
adapter coupling (chained to the end of the
down-line) must first be disconnected. See
Figure 6.
7.When the hydraulic circuit is complete, no
unconnected couplings should exist.
8. All hoses are fitted with self-sealing quick
disconnect couplings ensuring that hydraulic
fluid will not flow through the coupling unless
fully connected. Therefore it is extremely
important to check for complete coupling
connection prior to pressurisation of the
system.
Should any of the quick disconnect
couplings prove dicult to fully assemble,
then it may be due to the following:
• Coupling locking collars not fully screwed
back (on down-line hoses only).
NOTICE

12 © 2022 Enerpac, All Rights Reserved.
FIGURE 11, COMPLETE QUICK-FASTENING REACTION INSTALLATION
FIGURE 13, 100% TENSIONING HYDRAULIC CIRCUIT WITH A BANJO FITTING
FIGURE 12, DOWN-LINE
ADAPTER COUPLING

© 2022 Enerpac, All Rights Reserved. 13
6.6 Air Drive Pump Unit
Refer to Section 3.3for pump requirements.
Also refer to the pump operation manual.
Pump Unit Description
1. Pump
An air operated reciprocating piston type
pump, which operates on the principle of
pressure intensification via differential areas,
i.e. a large, low pressure air piston drives a
much smaller hydraulic piston to provide oil
flow at high pressure.
2. Air Filter/ Regulator
A combined unit consisting of an air filter, air
pressure gauge and air pressure regulator
assembly. The air filter removes water and
foreign particles from the inlet air supply, and
should be periodically cleaned and drained.
The air regulator is used to regulate the
incoming air pressure and can be used to
set the pump to stall when a predetermined
hydraulic pressure is attained.
The inlet air supply is connected directly
to the air filter/regulator unit via a quick
disconnect coupling.
3. Air Lubricator
Connected directly onto the air filter/
regulator unit, it is used to lubricate the
incoming air supply and hence lubricate the
pump unit.
4. Pump Start/ Stop Valve
A simple manual on/off valve to start and
stop the air supply to the pump. The speed
of operation of the pump can be finely
regulated using this valve.
5. Hydraulic Oil Return Valve
A high pressure valve allowing hydraulic
pressure to be built up when closed,
and released when opened, diverting the
hydraulic oil back to the reservoir.
6. Pump Exhaust/ Silencer
A muffle/filter connected to the pump
exhaust port to reduce the operating noise
level.
7. Pressure Gauge
A Budenberg 0-25000 psi hydraulic oil
pressure gauge positioned behind a
protective wire guard.
8. Hydraulic Reservoir
A tank of approximately 9 litres (2 gallons)
capacity incorporating an external
transparent tube type level indicator. Filters
are fitted into the filler neck and the oil outlet
port.
Pump Unit Ancillary Equipment
1. Pump Unit
A high delivery air powered pump unit used
to supply hydraulic oil to the AquaJack
tensioner.
2. Feed Hose
3 metres long, used to connect pump unit to
hose reel/down-line and down-line manifold
to AquaJack tensioner/ hydraulic circuit.
3. Interconnecting Hose
1 metre long, used to link the AquaJacks
together constructing a ring main hydraulic
circuit.
4. Down Line
Made up in 30 metre lengths, used to
connect the AquaJack hydraulic circuit to
the topsides pump unit.
FIGURE 14, AIR OPERATED PUMP UNIT
ARRANGEMENT

11.Blank Female Quick-Disconnect Coupling *
Used to blank the pump hydraulic oil
outlet when pre-setting the pump hydraulic
pressure.
* Included in standard accessory kit
Pump Unit Operation
It is always good practice to regulate the pump
to stall at the pre-determined hydraulic pressure
required to achieve the desired bolt load. The
recommended pump operating procedure is
indicated as follows.
1. Connect blanked-o female quick
disconnect couplings to the pump hydraulic
oil outlets, or connect feed hose between
the couplings.
2. Open the hydraulic oil return valve to tank.
Ensure the valve is fully open.
3. Close the pump start/stop valve (handle in
vertical position).
4. Connect an external air supply line to the
pump unit.
5. Turn the air pressure regulator adjusting
screw anti-clockwise until zero pressure
reads on the air pressure gauge.
6. Open the pump start/stop valve. The pump
should not operate as the regulator has been
set to produce zero air pressure. Should
the pump operate, then re-adjust the air
pressure regulator until the pump stops.
7. Close the hydraulic oil return valve.
8. Turn the air pressure regulator adjusting
screw slowly clockwise until the pre-
determined hydraulic oil pressure reads on
the oil pressure gauge.
9. Close the pump start/stop valve.
10.Slowly open the hydraulic oil return valve
to release the system pressure. Ensure the
valve is fully opened.
The pump is now ready to be operated by
using the pump start/stop valve. When the pre-
determined required hydraulic oil pressure is
reached then the pump will automatically stall.
FIGURE 15, PUMP ANCILLARY EQUIPMENT
ARRANGEMENT
14 © 2022 Enerpac, All Rights Reserved.
5. Hose Reel
Used to carry the 30 metre lengths of down-
line.
6. Down-line Manifold
A 3 way manifold used to connect the down-
line to the AquaJack tensioner hydraulic
circuit.
7. Sacrificial Hose
A 3 metre feed hose connected between
the down-line and the down-line manifold -
used as an emergency replacement feed or
interconnecting hose.
8. Down-line Adaptor Coupling
Used to connect the sacrificial hose to the
down-line.
9. Open Ended Female Quick-Disconnect
Coupling *
Used for AquaJack piston retraction.
10.Open Ended Male Quick-Disconnect
Coupling *
Used for hose venting following use at
depth.

Safety Notes On Pump Operation
1. Although the pump has been set to stall at
the desired hydraulic pressure, it is always
advisable to monitor the pressure as it is
applied.
2. Never pressurise the pump unit without
either a blank quick disconnect coupling or
the system hoses attached. (The maximum
disconnected coupling pressure is 1000 psi).
3. Wear safety glasses at all times during pump
operation.
4. Always de-pressurise the system when
leaving unattended.
7.0 TENSIONING AND DE-TENSIONING
Never stand in-line with the bolt
axis while the system is pressurized. If the bolt
should fail, serious personal injury or death
could result if loose or broken parts become
projectiles. All personnel must be aware of this
potential hazard at all times.
Ensure that the maximum
working pressure is not exceeded. Refer to the
specifications stamped on the tensioner body.
Also see Table 2 at the end of this document.
7.1 Tensioning Instructions - 100%
Coverage (tensioner installed on each stud)
IMPORTANT: Read precautions and instructions
at beginning of Section 7.0 before beginning the
following steps. Also refer to safety information
contained in Section 2.1.
For each flange/joint to be tensioned a ‘Subsea
Bolt Tensioning Data Sheet’ will be provided by
Enerpac (see appendix C for a sample sheet).
This data sheet will show relevant flange and
bolt details together with a calculated hydraulic
tool pressure to achieve the required bolt load.
In order to correctly apply this required residual
bolt load a controlled tensioning procedure
must be adopted.
A general sub-sea tensioning procedure, for
100% tensioner coverage is described below.
1. Ensure that the gap between the flange
faces is uniform around the entire perimeter.
Assemble the AquaJack and hydraulic
circuit as per sections 6.4 and 6.6. Obtain
final confirmation from the diver at the work
site that he is satisfied with the set-up and
ready for pressurisation to begin.
WARNING
WARNING
2. Apply a nominal hydraulic tool pressure
of 1000 psi. Check AquaJack tensioners
for squareness and centralisation. Ensure
reaction nuts are firmly engaged.
3. Apply the hydraulic tool pressure as specified
on the ‘Subsea Bolt Tensioning Data Sheet’,
and check to ensure that all pistons project
from the AquaJack body. Turn down the pre-
drilled hexagonal nuts within the AquaJack
bridge window using a tommy bar, firmly
seating each nut against the flange surface.
Do not use intermediate hydraulic
tool pressures as this may interfere with the
primary over-stroke elimination feature (see
Section 7.4).
4. Release the system pressure and repeat
Step 3 twice further, i.e., the hydraulic tool
pressure is applied and the nuts turned
down three times.
5. As a final check, ensure the gap between
the flange faces is still uniform, apply the
hydraulic tool pressure once more and
attempt to further tighten the nuts using
a tommy bar. If the nuts cannot be turned
then tensioning is complete and the system
may be de-pressurised and the AquaJack
removed.
If the nuts can be turned, then Steps 4 AND
5must be repeated until the nuts cannot be
rotated any further. Should repeated cycling
be necessary, check that the correct grade
of studbolt/nut is being used.
The above tensioning procedure is typical only.
Should the operator wish to adopt their own
‘tried and tested’ subsea tensioning procedures
with the AquaJack equipment then Enerpac will
be pleased to advise accordingly.
7.2 Tensioning Instructions - 50%
Coverage (tensioner installed on every other
stud)
IMPORTANT: Read precautions and instructions
at beginning of Section 7.0 before beginning the
following steps. Also refer to safety information
contained in Section 2.1.
For each flange/joint to be tensioned a ‘Subsea
Bolt Tensioning Data Sheet’ will be provided by
Enerpac (see appendix C for a sample sheet).
This data sheet will show relevant flange and
bolt details together with a calculated hydraulic
tool pressure to achieve the required bolt load.
NOTICE
© 2022 Enerpac, All Rights Reserved. 15

Do not use intermediate hydraulic
tool pressures as this may interfere with the
primary over-stroke elimination feature (see
section 7.4).
4. Release the system pressure and repeat
STAGE 3 twice further, i.e. Apply the 1st
pass pressure and turn down nuts three
times.
NOTICE
In order to correctly apply this required residual
bolt load a controlled tensioning procedure
must be adopted.
A general sub-sea tensioning procedure, for
50% tensioner coverage is described below.
1. Ensure that the gap between the flange
faces is uniform around the entire perimeter.
Assemble the AquaJack and hydraulic circuit
to the first 50% of the bolts as per Section
6.4. Obtain final confirmation from the diver
at the work site that he is satisfied with the
set-up and ready for pressurisation to begin.
2. Apply a nominal hydraulic tool pressure
of 1000 psi. Check AquaJack tensioners
for squareness and centralisation. Ensure
reaction nuts are firmly engaged.
3. Apply the 1st pass hydraulic tool pressure
as specified on the ‘Subsea Bolt Tensioning
Data Sheet’ and check to ensure that all
pistons project from the AquaJack body.
Turn down ALL of the pre-drilled hexagonal
nuts, including those without AquaJack’s
fitted, using a tommy bar, firmly seating each
nut against the flange surface.
See Figure 16 for typical tensioner
arrangement. Also refer to Section 6.4 for
additional tensioner installation and hook-up
instructions.
1 1
1 1
11
2
2
22
2 2
A
FIGURE 16, TENSIONER ARRANGEMENT, FIRST
PASS - TYPICAL (50% TENSIONER COVERAGE)
Apply Pressure “A”
(At all studs marked “1”)
1 1
1 1
11
2
2
22
2 2
B
FIGURE 17, TENSIONER ARRANGEMENT, SECOND
PASS - TYPICAL (50% TENSIONER COVERAGE)
Apply Pressure “B”
(At all studs marked “2)
FIGURE 18, RECHECKING FIRST PASS TENSION
(50% TENSIONER COVERAGE)
1 1
1 1
11
2
2
22
2 2
B
1
1
Apply Pressure “B”
(At two diametrically opposite
studs marked “1”)
16 © 2022 Enerpac, All Rights Reserved.

At this stage, if the AquaJack
pistons have advanced more than 3/4 of their
maximum stroke due to pulling in the joint, then
the tensioners must be manually retracted by
screwing down the reaction nut using a tommy
bar.
5. Transfer the AquaJack to the remaining 50%
of the bolts and apply a nominal hydraulic
tool pressure of 1000 psi. Check the
AquaJack tensioners for squareness and
centralisation. Ensure the reaction nuts are
firmly engaged.
6. Apply the 2nd pass hydraulic tool pressure
as specified on the ‘Subsea Bolt Tensioning
Data Sheet’ and turn down the pre-drilled
hexagonal nuts within the AquaJack bridge
using a tommy bar, firmly seating each nut
against the flange surface. See Figure 17.
7. Release the system pressure and repeat
Step 6 twice further. See Figure 18
8. As a final check, reassemble the AquaJack
to the initial 50% of the bolts.
9. Ensuring that the gap between the flange
faces is still uniform, apply the 2nd pass
hydraulic tool pressure and attempt to
further tighten the pre-drilled nuts using a
tommy bar.
If the nuts cannot be turned then tensioning
is complete and the system may be de-
pressurised and the AquaJack removed.
10. Transfer the AquaJack to the remaining
50% of the bolts and repeat Steps 9 and 10
until the nuts cannot be rotated any further.
Should repeated cycling be necessary,
check that the correct grade of stud bolt/nut
is being used.
The above tensioning procedure is typical only.
Should the operator wish to adopt their own
‘tried and tested’ subsea tensioning procedures
with the AquaJack equipment then Enerpac will
be pleased to advise accordingly.
7.3 De-tensioning Instructions
IMPORTANT: Read precautions and instructions
at beginning of Section 7.0 before beginning the
following steps. Also refer to safety information
contained in Section 2.1.
NOTICE
A hydraulic tool pressure for de-tensioning
is not normally provided as it is not always
possible to predict the pressure at which the
nut will break free. However, it is beneficial to
be aware of the original ‘make-up’ tensioning
pressure before the de-tensioning procedure
is carried out as generally, the de-tensioning
pressure is marginally higher than the original
make-up pressure.
A general subsea de-tensioning procedure is
described below.
1. Pre-set the pump unit to deliver the maximum
system working pressure of 21750 psi (1500
bar).
2. Before lowering the AquaJack underwater,
advance the piston of each AquaJack
approximately 10 mm.
3. Assemble the AquaJack and hydraulic
circuit as per Section 6.4. Obtain final
confirmation from the diver at the work site
that he is satisfied with the set-up and ready
for pressurisation to begin.
4. With the AquaJack assembled and the
hydraulic circuit connected, apply a nominal
hydraulic tool pressure of 1000 psi.
Check the AquaJack tensioners for
squareness and centralisation. Ensure the
reaction nuts are firmly engaged.
5. Apply hydraulic pressure to the system until
the pre-drilled hexagonal nuts within the
AquaJack bridges can be released. (This
pressure is normally slightly higher than the
make-up tensioning pressure).
6. Turn back each pre-drilled nut two complete
turns i.e. 12 flats.
7. De-pressurise the system and remove the
AquaJack.
7.4 AquaJack Retraction
The AquaJack tensioner piston must be
retracted if:
1. The maximum piston stroke indicator
becomes visible (The stroke indicator is in
the form of a yellow band marked around
the periphery of the piston).
2. The operator is unsure of the maximum
piston stroke.
© 2022 Enerpac, All Rights Reserved. 17

Over-stroking the piston can be dangerous
and injury may occur by the high pressure oil
released from the tensioner as the piston is
ejected from the cylinder.
The AquaJack tensioner possesses two safety
features to counteract this dangerous situation.
However, it must be stressed that piston over-
stroke will not be encountered if the piston
stroke is continually monitored, the moment
that the maximum stroke indicator band
becomes visible, the pump stopped and the
pistons retracted.
Primary Over-stoke Elimination (No Oil Spill)
This is the main over-stroke elimination
feature which utilises the standard pre-drilled
hexagonal nut for operation. As the AquaJack
operates, the pre-drilled nut lifts from the flange
surface at a proportional rate to the piston
stroke. As the piston approaches it’s maximum
stroke, the top surface of the pre-drilled nut will
contact the underside of the tensioner body,
preventing further movement of the piston.
At this point the maximum stroke indicator
will be clearly visible and the pistons must be
retracted, as described in fig. 19 illustrates the
system.
The above primary over-stroke
eliminator will only operate if the following
parameters are met.
1. The pre-drilled hexagonal nuts must be
of standard heavy series form, i.e. nut
height equal to one bolt diameter. Nut
heights less than one bolt diameter may
still be tensioned but primary over-stroke
elimination will not be operative.
2. The pre-drilled nuts must not be turned
down until the pre-determined hydraulic
pressure has been reached. Neither should
they be turned down whilst the system is
building up pressure, nor at intermediate
pressures such as half pressure, three
quarters pressure, etc.
3. Prior to tensioning, pistons must be fully
retracted and the reaction nuts firmly seated.
NOTICE
3. The operator would like to ensure that
maximum stroke is available.
Under normal circumstances piston retraction
will only be carried out during post-use
maintenance, as the piston stroke available
is more than adequate for most subsea
tensioning operations. However, occasionally
the AquaJacks may be required to be retracted
during subsea tensioning, particularly where
long strokes are used to close joints or if the
two pass tensioning procedure is adopted
(50% tensioner coverage).
Piston Retraction During Subsea Use
1. Prior to opening the pump hydraulic oil
return valve, turn down the pre-drilled nuts
within the AquaJack bridge window. This
will prevent the joint from re-opening as the
pressure is released.
When attempting to turn down the
pre-drilled nuts, should one or two of the nuts
be locked onto the underside of the tensioner
(due to over-stroking, see Section 11), do not
attempt to release the locked nuts but simply
turn down the remaining ‘free’ nuts. The locked
nuts will become free when the system pressure
is released and can then be turned down.
Should all, or the majority, of the pre-drilled
nuts be locked onto the underside of the
tensioner, then momentarily open, then shut
the pump hydraulic oil return valve until the nuts
become free and can then be turned down.
2. De-pressurise the system and ensure the
pump hydraulic oil return valve is FULLY
open.
3. Screw down the reaction nuts, using a
tommy bar if necessary, until all pistons are
fully retracted.
Piston Retraction Topside
1. Refer to Section 9 Maintenance.
7.4 AquaJack Retraction
The AquaJack tensioner has been purposely
designed with a long piston stroke to ensure
that the majority of tensioning operations can
be completed without the fear of the piston
over-stroking.
NOTICE
18 © 2022 Enerpac, All Rights Reserved.

Secondary Over-stroke Elimination
Should the above parameters not be met, i.e.,
nut heights less than one bolt diameter or nuts
required to be intermediately turned down, then
the secondary over-stroke elimination device
will operate, should the piston exceed it’s
maximum stroke.
If the maximum stroke is exceeded, the piston
will become free of the cylinder and the high
pressure oil will be safely released integrally.
This feature is only included as a fail-safe
safety measure and is not intended to be
used continually, as hydraulic seal damage will
occur when the high pressure oil is released,
rendering the AquaJack inoperative. Although
the suspect AquaJack will require removal and
replacement, this in comparison to a potentially
injured operator is insignificant.
FIGURE 19, PRIMARY OVER-STROKE
ELIMINATION
© 2022 Enerpac, All Rights Reserved. 19
Should this feature operate, the
piston will become free from the cylinder,
therefore, before the AquaJack is removed it
is advisable to partially retract the piston by
screwing down the reaction nut.
8.0 EMERGENCY MEASURES
Standard Hexagonal Nuts Used as Reaction
Nuts
A standard hexagonal nut
CANNOT be used as a direct replacement
for a reaction nut. Damage will occur to the
AquaJack piston (and possibly the cylinder) if
a hexagonal nut is used and any warranty or
guarantee will be invalidated.
In instances where a reaction nut is lost or
misplaced, then spare solid reaction nuts are
included with the standard accessory kit and
these should be used.
In cases of extreme emergency a standard
hexagonal nut can be used PROVIDED that a
thick washer, large enough in diameter to cover
the entire piston surface, is fitted underneath
the standard hexagonal ‘reaction’ nut.
Hose Connection In Space Restricted
Applications
Should difficulty be experienced in routing
interconnecting hoses due to space restrictions
such as overhead pipes, etc. then included in
the standard accessory kit are elbow couplings
which can quickly be assembled onto the hose
allowing the hose to be directed axially rather
than radially outward.
9.0 MAINTENANCE
It is recommended that repairs and servicing
be carried out by Enerpac at intervals agreed
by Enerpac and customer. All parts will be
thoroughly inspected and replaced where
necessary, certain components (e.g. seals)
will be replaced automatically. Tensioners will
be re-assembled, pressure tested and a test
certificate issued.
Note: All parts will have been manufactured,
inspected and tested in accordance with
Enerpac’s stringent requirements. Any parts
failing in use that are found upon Enerpac’s
inspection not to be Enerpac’s genuine spare
parts will invalidate any operative warranty or
guarantee.
NOTICE
WARNING

20 © 2022 Enerpac, All Rights Reserved.
The tool is of rugged construction and utilises
reliable seals. The only maintenance that may
be occasionally required is the replacement of
seals or repair of a hydraulic fitting.
Note: It is strongly recommended that in the
event of seal failure the tensioners are returned
to Enerpac for seal replacement, however if this
is not possible then the enclosed procedure
should be followed.
9.1 Pre-Use Maintenance
Assemble the tensioner onto a suitable bolt
(see Section 6.0), check that the bolt material
is capable of taking the applied load i.e. do not
pressurise to max working pressure if the bolt is
not strong enough to withstand the full load of
the tool. Piston stroke should be minimised to
prevent the over-stroke eliminator valve being
activated.
Pressurise for approximately one minute, a
pressure drop of 50 bar is acceptable during
this time.
If the tensioner passes this test, then the piston
should be reset and the tensioner is ready for
use.
If any leakage is noticed within the head
assembly, then a full strip down will be
necessary to change the seals, as described
in Section 9.4.
9.2 Post-Use Maintenance
In order to keep the equipment in good working
condition it is important that at the end of each
period of use, prior to being replaced into dry
storage, a post-use maintenance is carried out.
1. AquaJack Tensioner
Thoroughly rinse each AquaJack under running
fresh water (not sea water).
Retract the pistons by attaching open ended
female quick-disconnects (supplied in the
standard accessory kit) to the AquaJack male
inlets. With the AquaJack standing on the
ground and a suitable container positioned
below the open ended couplings to catch the
hydraulic fluid, push the piston back to its fully
retracted position. The hydraulic fluid which has
been bled from the tool during retraction must
be discarded as it will be contaminated with
sea water. It must NOT be returned into the
pump unit hydraulic fluid reservoir.
Coat each AquaJack in a water repellent spray
such as WD40 or similar. Alternatively rinse in
light oil.
If any leakage is noticed within the head
assembly, then a full strip down will be
necessary to change the seals, as described
in Section 9.4.
If tensioners are subject to a lot of use it is
advisable to fully strip them and clean and
inspect all components, at least once a year.
Refer to Section 9.3.
2. Quick-Fastening Reaction Nuts
Thoroughly rinse each Quick-Fastening reaction
nut under running fresh water (not seawater)
continuously operating the locking mechanisms
to clear any debris which may have become
lodged.
Coat each Quick-Fastening reaction nut in a
water repellent spray such as WD40 or similar.
Alternatively, rinse in light oil.
3. Hoses and Ancillaries
Vent each interconnecting hose, feed hose,
down line and manifold by connecting an
open ended male quick-disconnect coupling
(supplied in the standard accessory kit) into
each female coupling. The couplings may be
required to be forced together should internal
pressure exist within the hoses resulting from
being used at depth.
Any hydraulic fluid which has vented
from the hoses must be discarded as it will
be contaminated with seawater. It must NOT
be returned into the pump unit hydraulic fluid
reservoir.
Coat each quick disconnect coupling in a
water repellent spray such as WD40 or similar,
retracting and releasing the collars several
times. Ensure that the collars do not seize in the
retracted position.
9.3 AquaJack Tensioner Full Maintenance/
Servicing
It is recommended that repairs and servicing
be carried out by Enerpac at intervals
agreed by Enerpac and customer. All parts
will be thoroughly inspected, specified parts
will be non-destructively tested using MPI
techniques and replaced where necessary,
certain components (e.g. seals) will be replaced
automatically.
NOTICE