Romac Industries DJ405 Installation Manual

INSTALLATION INSTRUCTIONS

ROMAC
INDUSTRIES,
INC.

6

Read installation instructions rst before installing. Check parts to ensure that no damage has occurred during transit and that no
parts are missing. Also check the diameter of the pipe and the range marked on the coupling to ensure you have the proper size.

Style DJ405 Dismantling Joint

Step 1 • Check the DJ405 parts to ensure no damage oc-

curred during transit and that no parts are missing.

Step 2 • Check the

mating anges to insure
that they match the drilling
of DJ405 anges. Mating
anges must be aligned, and
angular deection must be
within the limits stated in the
chart below. Also, check the
length between the ange
faces and make sure the
DJ405 face to face length
matches.

Nom. Maximum Angular

Size Deection (degrees)

3 2.0
4 - 6 3.5
8 3.3
10 - 12 3.0
14 - 16 2.0
18 - 24 1.5

Step 3 • If needed, loosen the T-bolts to allow the spool

piece to move freely within the Restrained Flange Coupling
Adapter (RFCA) body.

When stainless steel fasteners are requested, Romac provides
all-thread-rod and two nuts. The underside of the lug on the RFCA
body is designed to capture hex nuts as well as
"T" head bolts.

Step 4 • Move

the DJ405 into position
between the mating
anges. Insert a ange
gasket between the
ange faces on ange
spool side. The RFCA
side has an o-ring ange
gasket. No additional
gasket is required.Using
ange bolts, fasten the
RFCA end of the dismantling joint
to one of the mating anges.

Step 5 • Attach the

anged spool to the opposite mat­ing ange, and fasten together
with ange bolts. Make sure the
spool piece is inserted at least 1
inch past the gasket inside the
RFCA body. Snug up all of the
ange bolts.

Document #20-9-0033 09/18/2014

Note: The spool piece should be
within the deection tolerance of
the RFCA after bolting the anges.
If this is not the case, the mating

anges must be realigned.

21919 20th Avenue SE • Suite 100 • Bothell, WA 98021 • Phone [phone] • 1-800-426-9341 • Fax [phone]

Step 6 • If the RFCA

was completely disassembled,
make sure the beveled edge of
the gasket matches the gasket
pocket of the RFCA. Slide the
RomaGrip into position and
install the T-bolts, tightening
them nger tight.

Step 7 • Tighten ange

bolts evenly, alternating to diametrically opposite positions at ap­proximately 20 ft-lb increments, to the recommended torque for
your size.

Nom. Flange Bolt Recommended
Size Size Min. Torque (ft-lbs)
3 - 4

6 -8
10 - 12
14 - 16 1 245
18 - 20 11/8 355
24 11/4 500

5

/8 60

3

/4 100

7

/8 160

Step 8 • Tighten T-bolts on RomaGrip evenly, alternating to

diametrically opposite positions at approximately 20 ft-lb incre­ments, to the recommended torque for your size.

Note: 90 ft-lbs torque = 12 inch wrench with 90 pounds force.

For best results, wait 10 minutes and retighten all bolts to the
proper torque.

Nom. T-Bolt Recommended
Size Size Min. Torque (ft-lbs)

3 5/8 45 - 65

4 - 24 3/4 75 - 90

Installation Instructions continued on back

ROMAC
INDUSTRIES,
INC.

INSTALLATION INSTRUCTIONS

Style DJ405 Dismantling Joint

(continued from front)

Step 9 • Hand tighten the restrainer bolts until the restraining

pads touch the surface of the pipe. The bolts should then be tightened
in a uniform crisscross pattern, until the heads break off above the
notch.

Note: Do not turn a bolt more than one turn before alternating to the
next bolt.

Step 10 • Pressure test for leaks before backlling.

PRECAUTIONS

1. Check anges to make sure you are using the correct size DJ405; also check the length of DJ405 to make sure it will t in the space
allocated.

2. Make sure a ange gasket on spool side is used between mating anges.

3. Make sure no foreign materials lodge between gasket and spool.

4. Avoid loose tting wrenches, or wrenches too short to achieve proper torque.

5. Keep threads free of foreign material to allow proper tightening.

6. Make sure angular deection is within limits

7. Take extra care to follow proper bolt tightening procedures and torque recommendations. Bolts are often not tightened enough when a torque
wrench is not used.

8. Pressure test for leaks before backlling.

9. Backll and compact carefully around pipe and ttings.

10. When reinstalling parts with stainless steel hardware, there may be a loss in pressure holding ability due to worn or damaged threads during
the original installation.

11. Some initial axial movement may occur in lug style restraints as the lugs seat. Movement is directly related to the size of the piping system
and the system pressure. In general terms movement of approximately 0.25" can be expected in restraints under 16”. For larger sizes,
movement of approximately 0.4” may be seen. If this is critical to your application please contact Romac Engineering for additional
information.

COMMON INSTALLATION PROBLEMS

1. Flange gasket not installed on ange spool side.

2. Bolts are not tightened to the proper torque.

3. Rocks or debris between spool and gasket.

4. Dirt or debris between pipe and restraining pad.

5. Dirt on threads of bolts or nuts.

6. Restraining bolt heads not snapped off.

7. Not enough pipe insertion.

8. Incorrect mating ange.

IF DJ405 MUST BE REMOVED

1. Make sure pipe is not pressurized. Removing the restrainer could cause the pipe joint to separate.

2. To remove the DJ405, use a 5/8" hex wrench or socket.

3. To reassemble, follow installation procedures. Tighten the restraining bolts using a 5/8" hex wrench to 75-ft-lbs minimum.

21919 20th Avenue SE • Suite 100 • Bothell, WA 98021 • Phone [phone] • 1-800-426-9341 • Fax [phone]