JCM Industrial Installation Instructions Manual.pdf

JCM Fittings and Fabrications for Industrial Service Product Installation Instructions Collection.

JCM Industries, Inc. Fittings and Fabrications for Industrial Service Product Installation Instruction Manual

Installation Instructions Models 101 and 102 Universal Clamp Couplings

Open clamp at open ear lug segment and place clamp on pipe so that gasket fl ap is on top is facing you. Bring back half of clamp around pipe. Feed tapered gasket end into place, mesh top lug fi ngers into “open ears” and engage bolts. Rotate clamp in direction of arrow to smooth tapered gasket fl aps. Finger tighten bolts to hold in place. Begin tightening bolts to proper torque values. Continue around pipe at each lug segment. Avoid tightening lugs to metal bound at any one segment - gaps between lugs should be approximately even on both sides. Continue bolting sequence to proper torque values below. 4. Tighten all bolts evenly to the following torque values:

5/8” Bolts to 70 Foot Pounds 3/4” Bolts to 90 Foot Pounds 5. Complete installation of fi tting, return after approximately 15 minutes and con fi rm minimum bolt torque levels have been maintained. Ensure proper torque level with a calibrated torque wrench. Thin wall, small diameter & fl exible types of pipe are subject to many variables which a ff ect torque values. Use discretion when tightening fi ttings on thin wall, small diameter & fl exible pipe in order to not crush or severely deform the pipe. This product does not prevent pipe movement or provide restraint. Take steps to prevent pipe pullout. *Ensure fi tting is suitable for application (con fi rm size, materials, pressure ratings, line content, meets local governing & association standards, etc.). Pipeline operation forces, including pressure fl uctuations, thermal expansion/contraction, movement/shifting, etc. will in fl uence the success of the application. Proper anchorage, restraint, harnessing, thrust blocks or other devices must be provided to prevent pipe movement (lateral, angular, axial) or pipe pullout from the bolt-on fi tting. Inspection of the pipe integrity is the responsibility of the end user. JCM recommends the use of calibrated torque wrench. Failure to follow installation instructions will result in voided product warranty.

For application review or questions contact JCM Industries at 1-800-527-8482, 903-832-2581 www.jcmindustries.com

INT101-0423

Tricks of the Trade for Installation Models 101 and 102 Universal Clamp Couplings

• Place a reference mark on the pipe back from the damaged area to help in centering clamp over break. Clamps provide maximum performance when centered over damage area.

• For installation on pipe under pressure: lubricate the clamp gasket with soap/water mixture, assemble clamp on the pipe beside the damaged area, lightly engage bolts and slid the clamp over the damaged area, ensure tapered gasket lays fl at without curl or fold, proceed with installation steps. • Breaks involving de fl ected pipe require a wider clamp. JCM lugs will articulate, permitting clamp to better conform to pipe. • Damage involving large holes or massive pitted areas - use stainless steel plate over large holes (under repair clamp) to provide the gasket a surface to seal against. • Drill holes in the ends of splits or cracks to relieve forces which could cause splits to continue. • Clamp performance drops when gap between pipe ends is larger than 1/2”. Use a stainless steel spacer to fi ll or to place over gap. • When repairing holes, gouges or centralized damage, position the bolting lug over the damaged area to provide additional gasket com- pression at the location. • Leave su ffi cient pressure on a broken line to prevent intrusion of foreign matter to prevent excessive line contamination.

• With pressure reduced, spraying water will cease as soon as water level rises above break. • Lubricating clamp bolts will ease clamp installation and assure proper torquing of bolts.

Making Larger Clamp From Smaller Clamps Longer than normal gasket tapers permit joining of Universal Clamp Couplings of like width and type to make a larger clamp. For instance, a nominal size 6” and 8” clamp can be joined to make a 14” clamp. This provides you with “on hand” capability to make repairs on larger pipe sizes. Contact JCM Industries for speci fi cs.

• Determine which clamps are available to make needed clamp, usually 2 or 3 clamps are su ffi cient. It is recommended that clamps to be joined be not more than one nominal size apart. Join clamps with ranges that when combined include O.D. of pipe to be repaired. For Example: Required clamp is 14” to fi t 16.44 O.D. Combining a 101-0905-12 (range 8.99 to 9.39) and a 101-0690-12 (range 6.84 to 7.25) will make a clamp with a range of 15.84 to 16.64. • Prior to joining clamps, reduce the curvature of the recessed bridge plate (as shown in photo) to slightly less than curvature of pipe to be repaired. This is done by laying bridge plate between two 2” x 4”’s and hitting with a small sledge hammer.

• Install as a multi-band clamp, making sure to tighten bolts evenly keeping gaps between lugs approximately even.

For application review or questions contact JCM Industries at 1-800-527-8482, 903-832-2581 www.jcmindustries.com

Installation Instructions Models 103, 104, 133, 134, 173, 174 Tapped Outlet Universal Clamp Couplings

Read instructions before starting installation* Review of “Tricks of the Trade” on the reverse will assist with installation. For purposes other than water, contact JCM Industries for application and product assistance. *For Tapped Clamps: tapped outlet clamps are for use in the repair of damaged pipe, leaking service outlet areas and applications that involve previously drilled/tapped pipe. They are not intended to be used for tapping applications.

5/8” Bolts to 70 Foot Pounds 3/4” Bolts to 90 Foot Pounds 5. Complete installation of fitting, return after approximately 15 minutes and confirm minimum bolt torque levels have been maintained.

Ensure proper torque level with a field grade, calibrated torque wrench. Thin wall, small diameter & flexible types of pipe are subject to many variables which affect torque values. Use discretion when tightening fittings on thin wall, small diameter & flexible pipe in order to not crush or severely deform the pipe. This product does not prevent pipe movement or provide restraint. Take steps to prevent pipe pullout.

INTTapUCC-052022

*Ensure fitting is suitable for application (confirm size, materials, pressure ratings, line content, meets local governing & association standards, etc.). Pipeline operation forces, including pressure fluctuations, thermal expansion/contraction, movement/shifting, etc. will influence the success of the application. Proper anchorage, restraint, harnessing, thrust blocks or other devices must be provided to prevent pipe movement (lateral, angular, axial) or pipe pullout from the bolt-on fitting. Inspection of the pipe integrity is the responsibility of the end user. JCM recommends the use of calibrated torque wrench. Failure to follow installation instructions will result in voided product warranty. For application review or questions contact JCM Industries at 1-800-527-8482, 903-832-2581

Installation Instructions Models 131 and 132 All Stainless Steel Universal Clamp Couplings

Read instructions before starting installation* Review of “Tricks of the Trade” on the reverse will assist with installation. For purposes other than water, contact JCM Industries for application and product assistance. 1. Clean and scrape pipe. Remove any scale, pipe wrap, debris or dirt that may interfere with the complete sealing of the gasket. Inspect pipe for integrity, size, outside diameter and surface irregularities. Confirm the proper size and range of repair clamp. Inspect fitting to ensure all parts are included. Fittings furnished with stainless steel hardware; see reverse for fastener management. 2. Lubricate the pipe and the fitting gasket with soapy water. Do not use oil base pipe lubricant. Loosen nuts of bolts and back nuts to the end of the bolt (complete removal of bolts is not necessary). Release oval necked bolts from lug ears and open the clamp. 3 . For Model 131 - Place clamp on pipe and center over damaged area. Tuck tapered gasket in place; mesh finger lugs and rotate clamp in direction of arrow to smooth tapered gasket flap. Position bolting lug for easy access to continued bolt tightening. Engage bolts in receiver lugs and finger tighten to hold in place. Begin bolt tightening sequence. See step 4.

For 132 Multi Band Clamps - with multi lug segments. One section has “closed ears” (A) and “open ears” (B) for bolt engagement. Locate lug segment with open “ear” to loosen bolts. Loosen bolts of other lug segments. Do not remove bolts. Open clamp at open ear lug segment and place clamp on pipe so that gasket flap is on top is facing you. Bring back half of clamp around pipe. Feed tapered gasket end into place, mesh top lug fingers into “open ears” and engage bolts. Rotate clamp in

direction of arrow to smooth tapered gasket flaps. Finger tighten bolts to hold in place. Begin tightening bolts to proper torque values. Continue around pipe at each lug segment. Avoid tightening lugs to metal bound at any one segment - gaps between lugs should be approximately even on both sides. Continue bolting sequence to proper torque values below. 4. Tighten all bolts evenly to the following torque values, ensure torque values with calibrated field torque wrench: 5/8” Bolts to 70 Foot Pounds 3/4” Bolts to 90 Foot Pounds 5. Complete installation of fitting, return after approximately 15 minutes and confirm minimum bolt torque levels have been maintained. Ensure proper torque level with a field grade, calibrated torque wrench. Thin wall, small diameter & flexible types of pipe are subject to many variables which affect torque values. Use discretion when tightening fittings on thin wall, small diameter & flexible pipe in order to not crush or severely deform the pipe. This product does not prevent pipe movement or provide restraint. Take steps to prevent pipe pullout.

INT131-052022

Tricks of the Trade for Installation Models 131 and 132 All Stainless Steel Universal Clamp Couplings

This JCM Quality Fitting is equipped with 18-8 stainless steel bolts and nuts for superior corrosion resistance. When not properly handled it is the nature of stainless steel fasteners to gall and freeze (seize up). This is due to the inherent properties of the stainless material. Galling and freezing is often triggered by the presence of metal chips, burrs and grains of sand on the threads of the bolts and nuts. Extra

care has been taken by JCM prior to assembly and packing of this fitting to assure a trouble-free installation. 1. The nuts and bolts are made from material of different hardness so that they have different strengths.

2. Standard 5/8” and 3/4” nuts are coated with a special blue or green (antiseize) coating. Additional lubricant may be needed. Uncoated stainless steel hardware is provided without lubrication to prevent a build up of dirt, sand or grit during shipment. A Molybdenum-Base lubricant is recommended.

3. Each nut is assembled by hand to be sure that it went on the bolt freely. 4. The bolts and nuts are handled carefully to avoid damage to the threads.

5. The bolts and nuts are made to exacting specifications to assure that the correct material is used and that the thread form is correct. Stainless hardware is especially susceptible to galling. JCM supplies specially coated nuts to eliminate the galling caused by overtorquing, but the bolt threads must be kept clean, free from nicks and not pitched or thrown into the tool bucket during the installation process. Use of pneumatic wrench for installation could cause hardware to seize and is not recommended. Tricks of the Trade Years of field experience, special applications and product testing have revealed many subtleties regarding application and installation of repair clamps. For maximum performance under adverse conditions take advantage of the JCM “Tricks of the Trade.” • Always clean and lubricate pipe with water or soapy water. This helps overcome friction when rotating the clamp to smooth the gasket. Do not use oil base pipe lubricant; the oil does not disperse, leaves residue and prevents the gasket from sealing/adhering to the pipe wall. Use water solvent lubricant. Use of a mirror will assist inspection of backside of pipe or pipe in cramped, limited space. • Place a reference mark on the pipe back from the damaged area to help in centering clamp over break. Clamps provide maximum performance when centered over damage area.

• Breaks involving deflected pipe require a wider clamp. JCM lugs will articulate, permitting clamp to better conform to pipe. • Damage involving large holes or massive pitted areas - use stainless steel plate over large holes (under repair clamp) to provide the gasket a surface to seal against. • Drill holes in the ends of splits or cracks to relieve forces which could cause splits to continue. • Clamp performance drops when gap between pipe ends is larger than 1/2”. Use a stainless steel spacer to fill or to place over gap. • When repairing holes, gouges or centralized damage, position the bolting lug over the damaged area to provide additional gasket compression at the location. • Leave sufficient pressure on a broken line to prevent intrusion of foreign matter to prevent excessive line contamination.

• With pressure reduced, spraying water will cease as soon as water level rises above break. • Lubricating clamp bolts will ease clamp installation and assure proper torquing of bolts.

Installation Instructions Models 105 & 135 Collar Leak Clamps

Read instructions before starting installation* For purposes other than water, contact JCM Industries for application and product assistance. Review of “Tricks of the Trade” on the reverse will assist with installation. Pipe and coupling joints with a wall thickness greater than 5/32” and less than 5/16” are best repaired with a JCM Collar Leak Clamp utilizing an extra thickness of gasket on one end.

+During bolt tightening sequence, the installer should take care to prevent overtightening bolts causing the pipe to deform or misshapen.

*Ensure fi tting is suitable for application (con fi rm size, materials, pressure ratings, line content, meets local governing & association standards, etc.). Pipeline operation forces, including pressure fl uctuations, thermal expansion/contraction, movement/shifting, etc. will in fl uence the success of the application. Proper anchorage, restraint, harnessing, thrust blocks or other devices must be provided to prevent pipe movement (lateral, angular, axial) or pipe pullout from the bolt-on fi tting. Inspection of the pipe integrity is the responsibility of the end user. JCM recommends the use of calibrated torque wrench. Failure to follow installation instructions will result in voided product warranty. INT105135-0423 For application review or questions contact JCM Industries at 1-800-527-8482, 903-832-2581 www.jcmindustries.com

Tricks of the Trade for Installation Models 105 & 135 Collar Leak Clamps

JCM Quality Fitting Equipped With 18-8 Stainless Steel Bolts and Nuts

When not properly handled it is the nature of stainless steel fasteners to gall and freeze (seize up). This is due to the inherent properties of the stainless material. Galling and freezing is often triggered by the presence of metal chips, burrs and grains of sand on the threads of the bolts and nuts. Extra care has been taken by JCM prior to assembly and packing of this fi tting to assure a trouble-free installation. 1. The nuts and bolts are made from material of di ff erent hardness so that they have di ff erent strengths. 2. Standard 5/8” and 3/4” nuts are coated with a special blue or green (antiseize) coating. Additional lubricant may be needed. Each nut is assembled by hand to be sure that it went on the bolt freely. Uncoated stainless steel hardware is provided without lubrication to prevent a build-up of dirt, sand or grit during shipment. A Molybdenum-Base lubricant is recommended. 3. The bolts and nuts are handled carefully to avoid damage to the threads. 4. The bolts and nuts are made to exacting speci fi cations to assure that the correct material is used and that the thread form is correct. Stainless hardware is especially susceptible to galling. JCM supplies specially coated nuts to eliminate the galling caused by over-torquing, but the bolt threads must be kept clean, free from nicks and not pitched or thrown into the tool bucket during the installation process. Use of a Torque Wrench with Deep Socket is highly recommended. Use of pneumatic wrench for installation could cause hardware to seize and is not recommended.

Tricks of the Trade

• Always clean and lubricate pipe with water or soapy water. This helps overcome friction when rotating the clamp to smooth the gasket. Do not use oil base pipe lubricant; the oil does not disperse, leaves residue and prevents the gasket from sealing/adhering to the pipe wall. Use water soluble lubricant. Use of a mirror will assist inspection of backside of pipe or pipe in cramped, limited space.

• Place a reference mark on the pipe back from the damaged area to help in centering clamp over break. Clamps provide maximum performance when centered over damage area.

• Breaks involving de fl ected pipe require a wider clamp. JCM lugs will articulate, permitting clamp to better conform to pipe.

• Damage involving large holes or massive pitted areas - use stainless steel plate over large holes (under repair clamp) to provide the gasket a surface to seal against. • Drill holes in the ends of splits or cracks to relieve forces which could cause splits to continue. • Leave su ffi cient pressure on a broken line to prevent intrusion of foreign matter to prevent excessive line contamination.

• With pressure reduced, spraying water will cease as soon as water level rises above break.

• Lubricating clamp bolts will ease clamp installation and assure proper torquing of bolts.

For additional guidance, contact JCM Industries Technical Services at 1-800-527-8482.

Installation Instructions Model 106 Leak Clamp For IPS PVC Bell Joints/Steel Threaded Couplings

Read instructions before starting installation* For purposes other than water, contact JCM Industries for application and product assistance. 1. Clean and scrape pipe. Remove any scale, pipe wrap, debris or dirt that may interfere with the complete sealing of the gasket. Inspect pipe for integrity, size, outside diameter and surface irregularities. Confirm the proper size and range of repair clamp. Inspect fitting to ensure all parts are included. For fittings furnished with stainless steel hardware, see reverse for fastener management. 2. Lubricate the pipe and the fitting gasket with soapy water. Do not use oil base pipe lubricant. 3 . Install a gasket (key-locked for installation) on the spigot side of the joint, flat side of gasket toward the face of the bell (the tapered side will fit into the iron pusher ring). Install the other gasket in the same manner on the bell side of the joint where the bell tapers down to the straight run of pipe. This gasket protects the PVC pipe wall from the iron pusher ring at the bell. 4. Interlock the ductile iron clamp ring segments on the spigot side of the joint. Ensure that the ductile iron clamp ring joint is rotated 90 o (1/4 turn) from the gasket joint. Install a track head bolt into the bolt holes to hold the segments together. On the bell side of the joint install the other set of clamp ring segments in the same manner, behind the protective gasket. To ensure proper gasket compression, rotate the bell side ductile iron clamp ring one bolt hole turn from the spigot ductile iron ring ( i.e. do not align clamp ring joints or gasket joints ). Interlock the segments. Starting from the bell side to the spigot side, install track head bolts through the segments and over the joint into the corresponding bolt holes of the opposite clamp rings. Loosely assemble nuts on the ends of the bolts. 5. Tighten the nuts evenly (ensure gasket compresses against bell face on complete circumference of the pipe) until the spigot gasket compresses against the joint and the leak stops. Tighten nuts to approximately 20 - 30 ft. lbs. of torque. To ensure integrity of installation, wait 15 minutes, inspect for leaking, and confirm bolt torque. If necessary, retighten bolts evenly as required to stop the leak. Installation for IPS PVC or Threaded Steel Collar Joint JCM 106 Bell Joint Leak Clamp repairs (and prevents) leaks on both sides of the collar joint. 1. Follow steps above. During step 2, place the first and second gaskets in the same manner with the flat side meeting up against the lip of the collar. 2. Continue with installation of ductile iron clamp ring segments and position against gasket (taper facing out) and install bolts as described in step 4 above.

INT106-0115

Stainless Steel Fastener Management Model 106 Leak Clamp For IPS PVC Bell Joints/Steel Threaded Couplings

JCM Quality Fittings Equipped With 18-8 Stainless Steel Bolts and Nuts When not properly handled it is the nature of stainless steel fasteners to gall and freeze (seize up). This is due to the inherent properties of the stainless material. Galling and freezing is often triggered by the presence of metal chips, burrs and grains of sand on the threads of the bolts and nuts. Extra care has been taken by JCM prior to assembly and packing of this fitting to assure a trouble-free installation. 1. The nuts and bolts are made from material of different hardness so that they have different strengths. 2. Standard 5/8” and 3/4” nuts are coated with a special blue or green (antiseize) coating. Additional lubricant may be needed. Uncoated stainless steel hardware is provided without lubrication to prevent a build up of dirt, sand or grit during shipment. A Molybdenum-Base lubricant is recommended. 3. Each nut is assembled by hand to be sure that it went on the bolt freely. 4. The bolts and nuts are handled carefully to avoid damage to the threads. 5. The bolts and nuts are made to exacting specifications to assure that the correct material is used and that the thread form is correct. Stainless hardware is especially susceptible to galling. JCM supplies specially coated nuts to eliminate the galling caused by overtorquing, but the bolt threads must be kept clean, free from nicks and not pitched or thrown into the tool bucket during the installation process. Use of the J CM 901 Master Wrench or JCM 905 Torque Wrench with Deep Socket is highly recommended. Use of pneumatic wrench for installation could cause hardware to seize and is not recommended.

Installation Instructions Model 110 Patch Clamps

For fittings furnished with stainless steel hardware, see reverse for fastener management.

2. Lubricate the pipe and the fitting gasket with soapy water. Do not use oil base pipe lubricant. Loosen nuts of bolts and back nuts to the end of the bolt (complete removal of bolts is not necessary). Release square necked bolts from lug ears and open the clamp. 3 . Place clamp on pipe and center gasket pad over damaged area. Engage bolt(s) in slotted receiver lugs and finger tighten to hold in place. Begin bolt tightening. 4. Tighten bolt(s) evenly to the following torque values, ensure torque values with calibrated field torque wrench: Nominal sizes 1/2” - 1-1/4” with 3/8” Bolts 25 Foot Pounds Nominal sizes 1-1/2” - 12” with 7/16” Bolts 35 Foot Pounds 5. Complete installation of fitting, return after approximately 15 minutes and confirm minimum bolt torque levels have been maintained.

Recommended for the following service ratings:

Water Service Gas Service

150 PSI 100 PSI

INT110-0115

Tricks of the Trade for Installation Model 110 Patch Clamps

• Place a reference mark on the pipe back from the damaged area to help in centering clamp over break. Clamps provide maximum performance when centered over damage area. • For installation on pipe under pressure: lubricate the clamp gasket with soap/water mixture, assemble clamp on the pipe beside the damaged area, lightly engage bolts and slid the clamp over the damaged area, proceed with installation steps. • Damage involving large holes or massive pitted areas - use stainless steel plate over large holes (under repair clamp) to provide the gasket a surface to seal against.

• Drill holes in the ends of splits or cracks to relieve forces which could cause splits to continue.

• Leave sufficient pressure on a broken line to prevent intrusion of foreign matter to prevent excessive line contamination.

• With pressure reduced, spraying water will cease as soon as water level rises above break.

• Lubricating clamp bolts will ease clamp installation and assure proper torquing of bolts.

3. Each nut is assembled by hand to be sure that it went on the bolt freely. 4. The bolts and nuts are handled carefully to avoid damage to the threads.

Installation Instructions Models 111 Full Repair Clamps

4. Tighten bolt(s) evenly to the following torque values, ensure torque values with calibrated field torque wrench: Nominal sizes 1/2” - 1-1/4” with 3/8” Bolts 25 Foot Pounds Nominal sizes 1-1/2” - 2” with 7/16” Bolts 35 Foot Pounds

5. Complete installation of fitting, return after approximately 15 minutes and confirm minimum bolt torque levels have been maintained. Recommended for the following service ratings: Water Service 150 PSI Gas Service 100 PSI

+During bolt tightening sequence, the installer should take care to prevent overtightening bolts causing the pipe to deform or misshapen. *Ensure fitting is suitable for application (confirm size, materials, pressure ratings, line content, meets local governing & association standards, etc.). Pipeline operation forces, including pressure fluctuations, thermal expansion/contraction, movement/shifting, etc. will influence the success of the application. Proper anchorage, restraint, harnessing, thrust blocks or other devices must be provided to prevent pipe movement (lateral, angular, axial) or pipe pullout from the bolt-on fitting. Inspection of the pipe integrity is the responsibility of the end user. JCM recommends the use of calibrated torque wrench. Failure to follow installation instructions will result in voided product warranty. INT111-022022 For application review or questions contact JCM Industries at 1-800-527-8482, 903-832-2581

Tricks of the Trade for Installation Model 111 Full Repair Clamps

JCM Quality Fitting Equipped With 18-8 Stainless Steel Bolts and Nuts When not properly handled it is the nature of stainless steel fasteners to gall and freeze (seize up). This is due to the inherent properties of the stainless material. Galling and freezing is often triggered by the presence of metal chips, burrs and grains of sand on the threads of the bolts and nuts. Extra care has been taken by JCM prior to assembly and packing of this fitting to assure a trouble-free installation. 1. The nuts and bolts are made from material of different hardness so that they have different strengths. 2. Standard 5/8” and 3/4” nuts are coated with a special blue or green (antiseize) coating. Additional lubricant may be needed. Uncoated stainless steel hardware is provided without lubrication to prevent a build-up of dirt, sand or grit during shipment. A Molybdenum-Base lubricant is recommended. 3. Each nut is assembled by hand to be sure that it went on the bolt freely. 4. The bolts and nuts are handled carefully to avoid damage to the threads. 5. The bolts and nuts are made to exacting specifications to assure that the correct material is used and that the thread form is correct. Stainless hardware is especially susceptible to galling. JCM supplies specially coated nuts to eliminate the galling caused by over- torquing, but the bolt threads must be kept clean, free from nicks and not pitched or thrown into the tool bucket during the installation process. Use of the JCM 901 Master Wrench or Torque Wrench with Deep Socket is highly recommended. Use of pneumatic wrench for installation could cause hardware to seize and is not recommended.

Tricks of the Trade

• Place a reference mark on the pipe back from the damaged area to help in centering clamp over break. Clamps provide maximum performance when centered over damage area.

• Breaks involving deflected pipe require a wider clamp. JCM lugs will articulate, permitting clamp to better conform to pipe.

• Damage involving large holes or massive pitted areas - use stainless steel plate over large holes (under repair clamp) to provide the gasket a surface to seal against.

• Drill holes in the ends of splits or cracks to relieve forces which could cause splits to continue.

• Leave sufficient pressure on a broken line to prevent intrusion of foreign matter to prevent excessive line contamination.

• With pressure reduced, spraying water will cease as soon as water level rises above break.

• Lubricating clamp bolts will ease clamp installation and assure proper torquing of bolts.

For additional guidance, contact JCM Industries Technical Services at 1-800-527-8482.

Installation Instructions Models 112 and 113 Heavy Duty Patch Clamps

Read instructions before starting installation* Review of “Tricks of the Trade” on the reverse will assist with installation. For purposes other than water, contact JCM Industries for application and product assistance. 1. Clean and scrape pipe. Remove any scale, pipe wrap, debris or dirt that may interfere with the complete sealing of the gasket. Inspect pipe for integrity, size, outside diameter and surface irregularities. Con fi rm the proper size and range of repair clamp. Inspect fi tting to ensure all parts are included. For fi ttings furnished with stainless steel hardware, see reverse for fastener management. 2. Lubricate the pipe and the fi tting gasket with soapy water. Do not use oil base pipe lubricant. Loosen nuts of bolts and back nuts to the end of the bolt (complete removal of bolts is not necessary). Release oval necked bolts from lug ears and open the clamp. 3. Single Band Clamps - Place clamp on pipe and center gasket pad over damaged area. Engage bolts in slotted fi nger lugs. Finger tighten to hold in place. Begin bolt tightening.

Multi Band Clamps - with multi lug segments. One section has “closed ears” (A) and “open ears” (B) for bolt engagement. Locate lug segment with open “ear” to loosen bolts. Loosen bolts of other lug segments. Do not remove bolts.

Open clamp at open ear lug segment and place clamp on pipe. Bring back half of clamp around pipe. Mesh top lug fi ngers into “open ears” and engage bolts. Finger tighten bolts to hold in place. Begin tightening bolts to proper torque values. Continue around pipe at each lug segment. Avoid tightening lugs to metal bound at any one segment - gaps between lugs should be approximately even on both sides. Continue bolting sequence to proper torque values below. 4. Tighten all bolts evenly to the following torque values, ensure torque values with calibrated fi eld torque wrench: 5/8” Bolts to 70 Foot Pounds 3/4” Bolts to 90 Foot Pounds 5. Complete installation of fi tting, return after approximately 15 minutes and con fi rm minimum bolt torque levels have been maintained.

*Ensure fi tting is suitable for application (con fi rm size, materials, pressure ratings, line content, meets local governing & association standards, etc.). Pipe- line operation forces, including pressure fl uctuations, thermal expansion/contraction, movement/shifting, etc. will in fl uence the success of the application. Proper anchorage, restraint, harnessing, thrust blocks or other devices must be provided to prevent pipe movement (lateral, angular, axial) or pipe pullout from the bolt-on fi tting. Inspection of the pipe integrity is the responsibility of the end user. JCM recommends the use of calibrated torque wrench. Failure to follow installation instructions will result in voided product warranty. For application review or questions contact JCM Industries at 1-800-527-8482, 903-832-2581

INT112-0423

Tricks of the Trade for Installation Models 112 and 113 Heavy Duty Patch Clamps

Years of fi eld experience, special applications and product testing have revealed many subtleties regarding application and installation of repair clamps. For maximum performance under adverse conditions take advantage of the JCM “Tricks of the Trade.” • Always clean and lubricate pipe with water or soapy water. This helps overcome friction when positioning the clamp. Do not use oil base pipe lubricant; the oil does not disperse, leaves residue and prevents the gasket from sealing/adhering to the pipe wall. Use water solvent lubricant. Use of a mirror will assist inspection of backside of pipe or pipe in cramped, limited space. • Place a reference mark on the pipe back from the damaged area to help in centering clamp over break. Clamps provide maximum performance when centered over damage area. • For installation on pipe under pressure: lubricate the clamp gasket with soap/water mixture, assemble clamp on the pipe beside the damaged area, lightly engage bolts and slid the clamp over the damaged area; proceed with installation steps. • Damage involving large holes or massive pitted areas - use stainless steel plate over large holes (under repair clamp) to provide the gasket a surface to seal against. • Leave su ffi cient pressure on a broken line to prevent intrusion of foreign matter to prevent excessive line contamination. • Lubricating clamp bolts will ease clamp installation and assure proper torquing of bolts. JCM Quality Fitting Equipped With 18-8 Stainless Steel Bolts and Nuts When not properly handled it is the nature of stainless steel fasteners to gall and freeze (seize up). This is due to the inherent properties of the stainless material. Galling and freezing is often triggered by the presence of metal chips, burrs and grains of sand on the threads of the bolts and nuts. Extra care has been taken by JCM prior to assembly and packing of this fi tting to assure a trouble-free installation. 1. The nuts and bolts are made from material of di ff erent hardness so that they have di ff erent strengths. 2. Standard 5/8” and 3/4” nuts are coated with a special blue or green (antiseize) coating. Additional lubricant may be needed. Uncoated stainless steel hardware is provided without lubrication to prevent a build up of dirt, sand or grit during shipment. A Molybdenum-Base lubricant is recommended.

3. Each nut is assembled by hand to be sure that it went on the bolt freely. 4. The bolts and nuts are handled carefully to avoid damage to the threads.

Installation Instructions Model 114 Mechanical Joint Bell/Split Repair Sleeve Failure to follow installation instructions will result in voided product warranty.

Read instructions before starting installation* Review of Drawings on the reverse before starting will assist with installation. For purposes other than water, contact JCM Industries for application and product assistance.

1. Clean and scrape pipe. Remove any scale, pipe wrap, debris or dirt that may interfere with the complete sealing of the gasket. Inspect pipe for integrity, size, outside diameter and surface irregularities. Confirm the proper size and range of repair sleeve. Inspect fitting to ensure all parts are included. For fittings furnished with stainless steel hardware, see reverse for fastener management. Lubricate the pipe and the fitting gasket with soapy water. Do not use oil base pipe lubricant. 2. Check to be sure that the square side gaskets are properly seated in side bar grooves. Side gaskets will protrude from side bar ends about 1 inch (1”). Do not cut the gaskets at this point . 3. (Drawing - A) See reverse side for drawings. Install sleeve in proper position on pipe and match color marks on body. Install longest “corner” bolts loosely to align sleeve halves. Install side bar bolts. For sleeve sizes provided with two bolt lengths, longer bolts are to be installed on the MJ ends. For underwater applications be familiar with and rehearse proper procedures. 4. Tighten side bar bolts first, starting in the center and working toward the ends. Next, tighten the end bolts so that the sleeve halves are butted together evenly and squarely. Note: The square side gaskets should protrude into the area where the end gasket will seat. Cut the gasket such that it protrudes 1/8” to 3/16” into the area where the end gasket will seat, as show in Drawing D. Do NOT pull on the gasket when cutting, simply hold the gasket without tension. If the gasket is pulled/stressed when cut, it will contract back (like a rubber band) into the groove cavity - and be too short to contact the end gasket. All bolts should be @ 80 Ft/Lbs. torque minimum (Stainless Steel hardware may require molybdenum-base antiseize lubricant.) 5. Block under sleeve to center it on pipe . (Drawing - B) Install end gaskets, placing lap 45 o (1/8 turn) from side bars. Side bar gaskets will protrude approximately 1/8” to 3/16” length from the side bar joint. NOTE 1: Sleeves are furnished with long end gaskets. To cut them to length, place the gaskets around the pipe and cut one end on the bias so that the gasket fits snugly around the pipe and the bias cut ends match. (Drawing B) NOTE 2: If necessary, lubricate end gaskets for easier installation. Apply a standard gasket soap lubricant as used in rubber joint pipe installations or soapy water. Do not use oil base lubricant. Do use water soluble lubricant. NOTE 3: JCM provides the gasket thickness calculated for the fitting/application. JCM can provide different thicknesses of MJ end gaskets should the gaskets provided not complete the water tight installation. For gasket information, contact JCM Technical Sales. NOTE 4: If two sets of MJ end gasket have been included with your fitting , notice they are different thicknesses. During the product ordering process it was determined that unknown pipe irregularities may require a different thickness of gasket to provide the best fit. For gasket information, contact JCM Technical Sales. 6. (Drawing - C) Pusher glands have color match marks indicating the proper end and location of each segment of the pusher gland. Install glands so that the color match marks are to the outside. On the pusher gland, install the longer lip of the ring towards the MJ gasket. Install pusher gland so that joints are 90 o (1/4 turn) from side bars. Install pusher gland so color match marks line up. Tighten bolts evenly to approximately 80 ft. lbs. (more if required). For sleeve sizes 30" and larger, pushers are provided in multi segments and include doubler kits, match colored dots accordingly. NOTE: Pusher glands must be positioned and matched to the markings provided for proper installation. For proper gasket and pusher gland positioning, see drawing on reverse. No “joints” (gasket, body, pusher gland) should be in line with each other. 7. Test sleeve. A test plug is provided on the sleeve for this purpose should testing be required. When assured that all seals are tight and test is completed, re-check bolt torques after 15 minutes. JCM endorses the ANSI/AWWA C105/A21.5 and ASTM A674 for polyethylene encasement for corrosion protection. For water applications: if applicable, test assembly seals with water (per ANSI/AWWA C223). When testing the assembly against the pipe to pressures greater than the internal pressure of the host pipe, application should be treated with caution to prevent imploding or damaging the pipe wall due to thin wall, flexible or brittle conditions. For inquiries, contact JCM Industries, Inc. *Ensure fitting is suitable for application (confirm size, materials, pressure ratings, line content, meets local governing & association standards, etc.). Pipeline operation forces, including pressure fluctuations, thermal expansion/contraction, movement/shifting, etc. will influence the success of the application. Proper anchorage, restraint, harnessing, thrust blocks or other devices must be provided to prevent pipe movement (lateral, angular, axial) or pipe pullout from the bolt-on fitting. Inspection of the pipe integrity is the responsibility of the end user. JCM recommends the use of calibrated torque wrench. Failure to follow installation instructions will result in voided product warranty. For application review or questions contact JCM Industries at 1-800-527-8482, 903-832-2581 INT114-1019

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