JCM INDUSTRIES 131 (01) PDF Document

Before beginning the installation, please follow these preparatory steps:

1. Read the installation instructions thoroughly and review the “Tricks of the Trade” section for additional assistance.

2. Clean and scrape the pipe. Remove any scale, pipe wrap, debris, or dirt that may interfere with the complete sealing of the gasket.

3. Inspect the pipe for integrity, size, outside diameter, and surface irregularities.

4. Confirm the proper size and range of the repair clamp for your application.

5. Inspect the JCM INDUSTRIES 131 fitting to ensure all parts are included.

Lubricate the pipe and the fitting gasket with soapy water. Do not use an oil-based pipe lubricant. Loosen the nuts of the bolts and back the nuts to the end of the bolt; complete removal of the bolts is not necessary. Release the oval-necked bolts from the lug ears and open the clamp.

1. Place the clamp on the pipe and center it over the damaged area.

2. Tuck the tapered gasket in place.

3. Mesh the finger lugs and rotate the clamp in the direction of the arrow to smooth the tapered gasket flap.

4. Position the bolting lug for easy access to continue bolt tightening.

5. Engage the bolts in the receiver lugs and finger-tighten them to hold the clamp in place.

6. Begin the bolt tightening sequence according to the specified torque values.

These clamps have multi-lug segments, with one section having “closed ears” (A) and another having “open ears” (B) for bolt engagement.

1. Locate the lug segment with the open “ear” to loosen bolts. Loosen the bolts of other lug segments. Do not remove the bolts.

2. Open the clamp at the open ear lug segment and place it on the pipe so that the gasket flap is on top, facing you.

3. Bring the back half of the clamp around the pipe.

4. Feed the tapered gasket end into place, mesh the top lug fingers into the “open ears,” and engage the bolts.

5. Rotate the clamp in the direction of the arrow to smooth the tapered gasket flaps.

6. Finger-tighten the bolts to hold the clamp in place.

7. Begin tightening bolts to the proper torque values. Continue around the pipe at each lug segment.

8. Avoid tightening lugs to the point of being metal-bound at any one segment; gaps between lugs should be approximately even on both sides.

9. Continue the bolting sequence until the proper torque values are reached.

Tighten all bolts evenly to the following torque values, using a calibrated field torque wrench:

After completing the initial installation, return after approximately 15 minutes and confirm that the minimum bolt torque levels have been maintained. For JCM 133 and 134 Tapped Clamps, you may now proceed with the tapping process.

The JCM INDUSTRIES 131 is 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). To ensure a trouble-free installation, please note the following:

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. A Molybdenum-Base lubricant is recommended for uncoated hardware.

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.

To prevent galling, the bolt threads must be kept clean, free from nicks, and not pitched or thrown into the tool bucket during the installation process. The use of a pneumatic wrench for installation is not recommended as it could cause the hardware to seize.

For maximum performance under adverse conditions, take advantage of the following “Tricks of the Trade”:

• Always clean and lubricate the pipe with water or soapy water. This helps overcome friction when rotating the clamp to smooth the gasket. Do not use oil-based pipe lubricant. Use of a mirror will assist inspection of the backside of a pipe or a pipe in a cramped, limited space.

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

• For installation on a pipe under pressure: lubricate the clamp gasket with a soap/water mixture, assemble the clamp on the pipe beside the damaged area, lightly engage the bolts and slide the clamp over the damaged area, ensure the tapered gasket lays flat without curl or fold, then proceed with installation steps.

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

• For damage involving large holes or massive pitted areas, use a stainless steel plate over the large holes (under the 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 the splits to continue.

• Clamp performance drops when the gap between pipe ends is larger than 1/2″. Use a stainless steel spacer to fill or to place over the gap.

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

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

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