JCM Industries 201, 203, 204 Installation Manual

Installation Instructions

Bolted Steel Couplings

Models 201, 203, 204

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.
NOTE: Maximum 90 PSI working pressure on gas service applications.
For higher pressure ratings, contact JCM Industries Engineered and Technical Sales.

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 coupling. 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.

3. Measure back on each pipe end one-half of the middle ring length plus two inches and place a reference
mark. These marks will be a visual reference point for centering the middle ring over the joint.

3. Install follower rings, then gasket onto the pipe ends. NOTE: Flat side of the gasket face meets the follower
ring, the tapered side inserts into the middle ring.

4. Install middle ring on one pipe end. Insert other pipe end into middle ring and center the middle ring over the
joint, between the reference marks. Lift the middle ring to insure that the gaskets are evenly centered
in the ends. Center follower rings on the pipe to ensure even gasket compression into the middle ring.

5. Torque coupling bolts on opposite sides, using a star rotation pattern,
drawing up the followers evenly until all bolts have been tightened to a
minimum of 75 foot pounds of torque.

NOTES: On joints that do not permit centering of the coupling, the pipe
ends must be inserted past the end of the gasket a minimum of one and
one-half (1-1/2”) inch.

For applications with deflection or offset pipe ends, the pipe end must be
inserted a minimum of one and one-half (1-1/2”) inch past the end of the
gasket after the deflection/offset has occurred. Do not exceed a
recommended 4° of pipe deflection with the coupling without inspecting the
centering and sealing of the gasket in the middle ring and follower ring.
Excessive deflection will cause the gasket to improperly seal.

IMPORTANT: Standard couplings do not provide for axial pipe movement.
In applications in which lateral pipe pullout may occur, pipe restraint must be
provided. See fitting manufacturer recommendations for applications on
High Density Polyethylene Pipe.

INT2010304-0115

*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

Tricks of the Trade for Installation

Bolted Steel Couplings

Models 201, 203, 204

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 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.

Tricks of the Trade

Years of field experience, special applications and product testing have revealed many subtleties
regarding application and installation of bolted fittings. 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 installing 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. Alcohol may be added to water in freezing
weather.

Difficult to reach or cramped areas on the backside or underside of the pipe can be visually checked by using a
mirror.

Couplings perform at optimal effectiveness when centered over joint area.
Use of short shims will assist in keeping the follower centered on the pipe and can be removed as bolts are

tightened.
Lubricating coupling bolts will ease installation and assure proper torquing of bolts.
Tightening bolts a star rotation pattern will compress the gasket evenly into the coupling ring and prevent leak or

blowout due to misaligned gasket.