Clemco Cool-Air Tube Cat User manual

COOL-AIR TUBE
MODEL CAT
O. M. 08956
© 2007 CLEMCO INDUSTRIES CORP.
One Cable Car Dr.
Washington, MO 63090
Phone [phone]
Fax [phone]
Email: [email protected]
www.clemcoindustries.com
®
MC FILE NUMBER: 577-0284
DATE OF ISSUE: 01-30-84
REVISION: G, 05-07
Do not proceed with
these instructions until
you have READ the
orange cover of this
MANUAL and YOU
UNDERSTAND its
contents. *
These WARNINGS are
included for the health
and safety of the
operator and those in
the immediate vicinity.
*If you are using a Clemco Distributor
Maintenance and Part Guide, refer to
the orange warnings insert preceding
the Index before continuing with the
enclosed instructions.
Electronic files include a Preface
containing the same important
information as the orange cover.
WARNING

PREFACE
•Read and follow ALL instructions before using
this equipment.
•Failure to comply with ALL instructions can result
in serious injury or death.
•In the event that the user, or any assistants of the
user of this equipment cannot read or cannot
completely understand the warnings and
information contained in these instructions, the
employer of the user and his assistants must
thoroughly educate and train them on the proper
operation and safety procedures of this
equipment.
NOTICE TO PURCHASERS AND USERS OF OUR
PRODUCTS AND THIS INFORMATIONAL MATERIAL
The products described in this material, and the information
relating to those products, is intended for knowledgeable,
experienced users of abrasive blasting equipment.
No representation is intended or made as to the suitability of
the products described herein for any particular purpose or
application. No representations are intended or made as to the
efficiency, production rate, or the useful life of the products
described herein. Any estimate regarding production rates or
production finishes are the responsibility of the user and must
be derived solely from the user’s experience and expertise,
and must not be based on information in this material.
The products described in this material may be combined by
the user in a variety of ways for purposes determined solely by
the user. No representations are intended or made as to the
suitability or engineering balance of the combination of
products determined by the user in his selection, nor as to the
compliance with regulations or standard practice of such
combinations of components or products.
Abrasive Blast Equipment is only a component of the range of
equipment used in an abrasive blasting job. Other products
may include an air compressor, abrasive, scaffolding, hydraulic
work platforms or booms, paint spray equipment,
dehumidification equipment, air filters and receivers, lights,
ventilation equipment, parts handling equipment, specialized
respirators, or equipment that while offered by Clemco may
have been supplied by others. Each manufacturer and supplier
of the other products used in the abrasive blasting job must be
contacted for information, training, instruction and warnings
with regard to the proper and safe use of their equipment in the
particular application for which the equipment is being used.
The information provided by Clemco is intended to provide
instruction only on Clemco products. All operators must be
trained in the proper, safe, use of this equipment. It is the
responsibility of the users to familiarize themselves with, and
comply with, all appropriate laws, regulations, and safe
practices that apply to the use of these products. Consult with
your employer about training programs and materials that are
available.
Our company is proud to provide a variety of products to the
abrasive blasting industry, and we have confidence that the
professionals in our industry will utilize their knowledge and
expertise in the safe efficient use of these products.
GENERAL INSTRUCTIONS
Described herein are some, BUT NOT ALL, of the major
requirements for safe and productive use of blast
machines, remote control systems, operator respirator
assemblies, and related accessories. Completely read ALL
instruction manuals prior to using equipment.
The user's work environment may include certain
HAZARDS related to the abrasive blasting operation.
Proper protection for the blaster, as well as anyone else
that may be EXPOSED to the hazards generated by the
blasting process, is the responsibility of the user and/or
the employer. Operators MUST consult with their employer
about what hazards may be present in the work
environment including, but not limited to, exposure to dust
that may contain TOXIC MATERIALS due to the presence
of silica, cyanide, arsenic or other toxins in the abrasive,
or materials present in the surface to be blasted such as
lead or heavy metals in coatings. The environment may
also include fumes that may be present from adjacent
coatings application, contaminated water, engine exhaust,
chemicals, and asbestos. The work area may include
PHYSICAL HAZARDS such as an uneven work surface,
poor visibility, excess noise, and electrical hazards. The
operator MUST consult with his employer on the
identification of potential hazards, and the appropriate
measures that MUST be taken to protect the blaster and
others that might be exposed to these hazards.
ALL machines, components and accessories MUST be
installed, tested, operated and maintained only by trained,
knowledgeable, experienced users.
DO NOT modify or substitute any Clemco parts with other
types or brands of equipment. Unauthorized modification
and parts substitution on supplied air respirators is a
violation of OSHA regulations and voids the NIOSH
approval.
OPERATIONAL INSTRUCTIONS
OPERATOR SAFETY EQUIPMENT
•Blast operators and others working in the vicinity of
abrasive blasting must always wear properly-
maintained, NIOSH-approved, respiratory protection
appropriate for the job site hazards.
•DO NOT USE abrasives containing more than one
percent crystalline (free) silica. Ref. NIOSH Alert
#92-102
•Inhalation of toxic dust (crystalline silica, asbestos,
lead paint and other toxins) can lead to serious or
fatal disease (silicosis, asbestosis, lead or other
poisoning).
•ALWAYS wear NIOSH-approved supplied-air respirators
as required by OSHA, in the presence of any dust including,
but not limited to, handling or loading abrasive; blasting or
working in the vicinity of blast jobs; and cleanup of expended
abrasive. Prior to removing respirator, an air monitoring
WARNING
WARNING
I

PREFACE
instrument should be used to determine when surrounding
atmosphere is clear of dust and safe to breathe.
•NIOSH-approved, supplied-air respirators are to be worn
ONLY in atmospheres:
• NOT IMMEDIATELY dangerous to life or health and,
• from which a user can escape WITHOUT using the
respirator.
•Clemco supplied-air respirators DO NOT REMOVE OR
PROTECT AGAINST CARBON MONOXIDE (CO) OR ANY
OTHER TOXIC GAS. Carbon monoxide and toxic gas removal
and/or monitoring device must be used in conjunction with
respirator to insure safe breathing air.
•Air supplied to respirator MUST BE AT LEAST GRADE D
QUALITY as described in Compressed Gas Association
Commodity Specification G-7.1, and as specified by OSHA
Regulation 1910.139 (d).
•ALWAYS locate compressors to prevent contaminated air
(such as CO from engine exhaust) from entering the air intake
system. A suitable in-line air purifying sorbent bed and filter or
CO Monitor should be installed to assure breathing air quality.
•ALWAYS use a NIOSH-approved breathing air hose to
connect an appropriate air filter to the respirator. Use of a non-
approved air hose can subject the operator to illness caused
by the release of chemical agents used in the manufacture of
non-approved breathing air hose.
•ALWAYS check to make sure air filter and respirator
system hoses are NOT CONNECTED to in-plant lines that
contain nitrogen, acetylene or any other non-breathable gas.
NEVER use oxygen with air line respirators. NEVER modify air
line connections to accommodate air filter/respirator breathing
hose WITHOUT FIRST testing content of the air line. FAILURE
TO TEST THE AIR LINE MAY RESULT IN DEATH TO THE
RESPIRATOR USER.
•Respirator lenses are designed to protect against
rebounding abrasive. They do not protect against flying
objects, glare, liquids, radiation or high speed heavy materials.
Substitute lenses from sources other than the original
respirator manufacturer will void NIOSH-approval of this
respirator.
BLAST MACHINES AND REMOTE CONTROLS
•ALWAYS equip abrasive blast machines with
remote controls.
•Abrasive blast machine operators must wear NIOSH-
approved supplied-air respirators (ref: OSHA
regulations 1910.94, 1910.132, 1910.139 and
1910.244).
•NEVER modify OR substitute remote control parts. Parts
from different manufacturers are NOT compatible with Clemco
equipment. If controls are altered, involuntary activation, which
may cause serious injury, can occur.
•Inspect the air control orifice DAILY for cleanliness.
NEVER use welding hose in place of twinline control hose. The
internal diameter and rubber composition are UNSAFE for
remote control use.
•UNLESS OTHERWISE SPECIFIED, maximum working
pressure of blast machines and related components MUST
NOT exceed National Board approved 125 psig (8.5 BAR).
•NEVER weld on blast machine. Welding may affect
dimensional integrity of steel wall and WILL VOID National
Board approval.
•Point nozzle ONLY at structure being blasted. High
velocity abrasive particles WILL inflict serious injury. Keep
unprotected workers OUT of blast area.
•NEVER attempt to manually move blast machine when it
contains abrasive. EMPTY machines, up to 6 cu. ft.(270kg)
capacity, are designed to be moved:
• on flat, smooth surfaces by AT LEAST two people;
• with the Clemco "Mule"; or
• with other specially designed machine moving devices.
•Larger empty blast machines or ANY blast machine
containing abrasive MUST be transported by mechanical lifting
equipment.
AIR HOSE, BLAST HOSE, COUPLINGS, AND NOZZLE HOLDERS
•Air hose, air hose fittings and connectors at compressors
and blast machines MUST be FOUR times the size of the
nozzle orifice. Air hose lengths MUST be kept as short as
possible AND in a straight line. Inspect DAILY and repair
leakage IMMEDIATELY.
•Blast hose inside diameter MUST be THREE to FOUR
times the size of the nozzle orifice. AVOID sharp bends that
wear out hose rapidly. Use SHORTEST hose lengths possible
to reduce pressure loss. Check blast hose DAILY for soft
spots. Repair or replace IMMEDIATELY.
•ALWAYS cut loose hose ends square when installing hose
couplings and nozzle holders to allow uniform fit of hose to
coupling shoulder. NEVER install couplings or nozzle holders
that DO NOT provide a TIGHT fit on hose. ALWAYS use
manufacturers recommended coupling screws.
•Replace coupling gaskets FREQUENTLY to prevent
leakage. Abrasive leakage can result in dangerous coupling
failure. ALL gaskets MUST be checked SEVERAL times during
a working day for wear, distortion and softness.
•Install safety pins at EVERY coupling connection to
prevent accidental disengagement during hose movement.
•ALWAYS attach safety cables at ALL air hose AND blast
hose coupling connections. Cables relieve tension on hose and
control whipping action in the event of a coupling blow-out.
WARNING
II

PREFACE
MAINTENANCE
•ALWAYS shut off compressor and depressurize blast
machine BEFORE doing ANY maintenance.
•Always check and clean ALL filters, screens and alarm
systems when doing any maintenance.
•ALWAYS cage springs BEFORE disassembling valves IF
spring-loaded abrasive control valves are used.
•ALWAYS completely follow owner's manual instructions
and maintain equipment at RECOMMENDED intervals.
ADDITIONAL ASSISTANCE
•Training and Educational Programs.
Clemco Industries Corp. offers a booklet, Blast-Off 2,
developed to educate personnel on abrasive blast equipment
function and surface preparation techniques. Readers will learn
safe and productive use of machines, components and various
accessories, including selection of abrasive materials for
specific surface profiles and degrees of cleanliness.
•The Society for Protective Coatings (SSPC) offers a video
training series on protective coatings including one entitled
"Surface Preparation." For loan or purchase information,
contact SSPC at the address shown below.
TECHNICAL DATA AND RESEARCH COMMITTEES
•The following associations offer information, materials and
videos relating to abrasive blasting and safe operating
practices.
The Society for Protective Coatings (SSPC)
40 24th Street, Pittsburgh PA 15222-4643
Phone: [phone] • FAX [phone]
Email: [email protected] • Website: www.sspc.org
National Association of Corrosion Engineers (NACE)
1440 South Creek Drive, Houston TX 77084
Phone: [phone] • FAX [phone]
Email: [email protected] • Website: www.nace.org
American Society for Testing and Materials (ASTM)
100 Barr Harbor Dr., West Conshohocken, PA 19428
Phone [phone] • FAX [phone]
Email: [email protected] • Website: www.astm.org
NOTICE
This equipment is not intended to be used in an area that might
be considered a hazardous location as described in the
National Electric Code NFPA 70 1996, article 500.
WARRANTY
The following is in lieu of all warranties express, implied or
statutory and in no event shall seller or its agents, successors,
nominees or assignees, or either, be liable for special or
consequential damage arising out of a breach of warranty. This
warranty does not apply to any damage or defect resulting
from negligent or improper assembly or use of any item by the
buyer or its agent or from alteration or attempted repair by any
person other than an authorized agent of seller. All used,
repaired, modified or altered items are purchased “as is” and
with all faults. In no event shall seller be liable for
consequential or incidental damages. The sole and exclusive
remedy of buyer for breach of warranty by seller shall be repair
or replacement of defective parts or, at seller’s option, refund
of the purchase price, as set forth below:
1. Seller makes no warranty with respect to products used
other than in accordance hereunder.
2. On products seller manufactures, seller warrants that all
products are to be free from defects in workmanship and
materials for a period of one year from date of shipment to
buyer, but no warranty is made that the products are fit for a
particular purpose.
3. On products which seller buys and resells pursuant to this
order, seller warrants that the products shall carry the then
standard warranties of the manufacturers thereof, a copy of
which shall be made available to customer upon request.
4. The use of any sample or model in connection with this
order is for illustrative purposes only and is not to be construed
as a warranty that the product will conform to the sample or
model.
5. Seller makes no warranty that the products are delivered
free of the rightful claim of any third party by way of patent
infringement or the like.
6. This warranty is conditioned upon seller’s receipt within ten
(10) days after a buyer’s discovery of a defect, of a written
notice stating in what specific material respects the product
failed to meet this warranty. If such notice is timely given, seller
will, at its option, either modify the product or part to correct the
defect, replace the product or part with complying products or
parts, or refund the amount paid for the defective product, any
one of which will constitute the sole liability of seller and a full
settlement of all claims. No allowance will be made for
alterations or repairs made by other than those authorized by
seller without the prior written consent of seller. Buyer shall
afford seller prompt and reasonable opportunity to inspect the
products for which any claim is made as above stated.
Except as expressly set forth above, all warranties, express,
implied or statutory, including implied warranty of
merchantability, are hereby disclaimed.
DAILY SET-UP CHECK LIST
•ALL piping, fittings and hoses MUST be checked
DAILY for tightness and leakage.
•ALL equipment and components MUST be thoroughly
checked for wear.
•ALL worn or suspicious parts MUST be replaced.
•ALL blast operators MUST be properly trained to
operate equipment.
•ALL blast operators MUST be properly outfitted with
abrasive resistant clothing, safety shoes, leather gloves
and ear protection.
•BEFORE blasting ALWAYS use the following check list.
□1. PROPERLY MAINTAINED AIR COMPRESSOR sized
to provide sufficient volume (cfm) for nozzle and other tools
PLUS a 50% reserve to allow for nozzle wear. Use large
compressor outlet and large air hose (4 times the nozzle orifice
size). FOLLOW MANUFACTURERS MAINTENANCE
INSTRUCTIONS.
□2. BREATHING AIR COMPRESSOR (oil-less air pump)
capable of providing Grade D Quality air located in a dust free,
contaminant free area. If oil-lubricated air compressor is used
to supply respirator, it should have high temperature monitor
and CO monitor or both. If CO monitor is not used, air MUST
be tested FREQUENTLY to ensure proper air quality.
WARNING
III

PREFACE
□3. Clean, properly maintained NIOSH-APPROVED
SUPPLIED-AIR RESPIRATOR. ALL components should
ALWAYS be present. NEVER operate without inner lens in
place. Thoroughly inspect ALL components DAILY for
cleanliness and wear. ANY substitution of parts voids NIOSH
approval i.e. cape, lenses, breathing hose, breathing air supply
hose, air control valve, cool air or climate control devices.
□4. OSHA required BREATHING AIR FILTER for removal
of moisture and particulate matter from breathing air supply.
THIS DEVICE DOES NOT REMOVE OR DETECT CARBON
MONOXIDE (CO). ALWAYS USE CO MONITOR ALARM.
□5. ASME CODED BLAST MACHINE sized to hold 1/2
hour abrasive supply. ALWAYS ground machine to eliminate
static electricity hazard. Examine pop up valve for alignment.
Blast machine MUST be fitted with a screen to keep out foreign
objects and a cover to prevent entry of moisture overnight.
□6. AIR LINE FILTER installed AS CLOSE AS POSSIBLE
to machine inlet. Sized to match inlet piping or larger air supply
line. Clean filter DAILY. Drain OFTEN.
□7. REMOTE CONTROLS MUST be in PERFECT
operating condition. ONLY use APPROVED spare parts,
including twin- line hose. DAILY: test system operation and
check button bumper and spring action of lever and lever lock.
DO NOT USE WELDING HOSE.
□8. BLAST HOSE with ID 3 to 4 times the nozzle orifice.
Lines MUST be run AS STRAIGHT AS POSSIBLE from
machine to work area with NO sharp bends. Check DAILY for
internal wear and external damage.
□9. HOSE COUPLINGS, NOZZLE HOLDERS fitted
SNUGLY to hose end and installed using PROPER coupling
screws. Coupling lugs MUST be snapped FIRMLY into locking
position. Gasket MUST form positive seal with safety pins
inserted through pin holes. Check gaskets and replace if ANY
sign of wear, softness or distortion. ALWAYS install safety
cables at every connection to prevent disengagement. Check
nozzle holder for worn threads. NEVER MIX DIFFERENT
BRANDS OF COMPONENTS. Check each of these
components DAILY.
□10. Inspect NOZZLE and GASKET DAILY for wear.
Replace nozzle when 1/16" larger than original size or if liner
appears cracked. Check nozzle threads for wear.
□11. Use abrasive that is properly sized and free of harmful
substances; such as, free silica, cyanide, arsenic or lead.
Check material data sheet for presence of toxic or harmful
substances.
□12. Test surface to be blasted for toxic substances. Take
appropriate, and NIOSH required, protective measures for
operator and bystanders which pertain to substances found on
the surface to be blasted.
3. NIOSH
Approved
Supplied-Air
Respirator
11. Silica-free Abrasive 5. ASME Coded
Blast Machine
8. Blast Hose
10. Appropriately
Sized Nozzle
2. Breathing Air Compressor
4. CPF Air-Filter
6. Air Line
Filter
9. Hose Couplings and
Safety Cables
1 Air Compressor
(or)
2. Ambient Air Pump
for low pressure
respirator
7. Remote
Controls
IV

CAT COOL-AIR TUBE Page 1
© 2007 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 08956
1.0 INTRODUCTION
1.1 Scope
1.1.1 This manual covers the preparation, operation,
maintenance, troubleshooting, and replacement parts for
Clemco’s CAT Cool-Air Tube. The cool-air tube is used to
cool compressed respirable air supplying an Apollo
supplied-air respirator or Comfort Vest. Read this manual
and the appropriate Apollo HP (high pressure) respirator
manual and/or Comfort Vest manual before using the cool-
air tube.
1.1.2 The National Institute for Occupational Safety
and Health (NIOSH) approval and Occupational Safety &
Health Administration (OSHA) regulations cited within
this manual apply when the cool-air tube is used to
provide air to a supplied-air respirator. The regulations
do not apply if the cool-air tube is used with a Comfort
Vest alone. When a vest is used with a respirator having
a cape that extends over the vest, air from the vest could
be ingested by the user. For that reason, Grade D air or
higher quality, as defined in Section 2.1 of this manual,
must be provided to both the respirator and vest.
1.2 Safety Alerts
1.2.1 Clemco uses safety alert signal words, based on
ANSI Z535.4-1998, to alert the user of a potentially
hazardous situation that may be encountered while
operating this equipment. ANSI's definitions of the signal
words are as follows:
This is the safety alert symbol. It is
used to alert the user of this equipment
of potential personal injury hazards.
Obey all safety messages that follow this symbol to
avoid possible injury or death.
CAUTION
Caution used without the safety alert symbol
indicates a potentially hazardous situation
which, if not avoided, may result in property
damage.
CAUTION
Caution indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
WARNING
Warning indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
DANGER
Danger indicatesanimminently hazardous
situation which, if not avoided, will result in
death or serious injury.
1.3 NIOSH Approval
1.3.1 The CAT Cool-Air Tube is approved by NIOSH
to use with Clemco Apollo respirators.
1.3.2 The NIOSH label shown below lists the Apollo
respirator approval numbers. An X on the approval line
indicates which components are approved for the
specific respirator. Do not use any non-approved
components with the respirator.

CAT COOL-AIR TUBE Page 2
© 2007 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 08956
WARNING
NIOSH approval applies to items shown on the
label when used as a complete system. Do not
make any non-approved modification, deletion,
or substitution. Non-approved components void
the NIOSH approval and may permit ingress of
toxic and hazardous dust, resulting in toxic
poisoning and respiratory disease.
1.4 OSHA Regulations
1.4.1 OSHA Regulation 29 CFR 1910.134 for
respiratory protection in General Industry is referenced
throughout this document. Respiratory protection
standards for Construction 29 CFR 1926.103 and for
Maritime 29 CFR-1915.154, 1917, and 1918 refer to
1910.134. The complete regulation is available through
the U.S. Dept. of Labor web site at www.osha.gov.
1.4.2 OSHA Regulations 29 CFR 1910.134(a) and (c)
require the employer to establish and maintain a
comprehensive, written, respiratory protection program
administered by a suitably-trained program
administrator. The program must include, but is not
limited to the following:
1. Procedures for selecting NIOSH-certified respirators.
2. Medical evaluations of employees required to use
respirators.
3. Fit testing procedures.
4. Procedures for proper use of respirator in routine
and foreseeable emergency situations.
5. Procedures and schedules for cleaning, disinfecting,
storing, inspecting, repairing, discarding and
otherwise maintaining respirators.
6. Procedures to ensure adequate air quality, quantity
and flow of breathing air for atmosphere-supplying
respirators.
7. Training of employees in the respiratory hazards to
which they are potentially exposed during routine
and emergency situations.
8. Training of employees in the proper use of the
respirators, including putting on and removing them,
any limitations on their use, and their maintenance.
9. Procedures for regularly evaluating the effectiveness
of the program.
1.4.3 It is essential that the user be properly instructed
in the use and maintenance of the respirator. The
respirator manual and this manual for the cool-air tube
must be made available to all users of the respirator, and
the users must demonstrate their understanding of its
subject matter. Read the entire manual before installing
or operating the equipment.
1.4.4 The cool-air tube must be supplied with
respirable air meeting requirements described herein. It
is the responsibility of the employer to provide quality
breathing-air to the respirator, and to establish a
program to ensure that the respirator and accessories
are properly used and maintained.
1.5 Description
1.5.1 The CAT Cool-Air Tube is an approved alternate
air control valve, which provides the user with a source of
cool air when used in conjunction with a Clemco supplied-
air respirator or Comfort Vest. The illustration in Figure 1
shows components and controls for the cool-air tube.
Figure 1
2.0 AIR SUPPLY
2.1 Air Quality
DANGER
Never connect a breathing air line to an air
source that has not been tested for gas and
particulate contamination. The presence of
unacceptable levels of carbon monoxide (CO)
or other gases, or oxygen deficiency in
breathing air will cause death to the user.
2.1.1 The employer is responsible for ensuring that
breathing air shall meet the requirements for Grade D or
higher quality, as described in Compressed Gas
Association Commodity Specification pamphlet G-7.1.,
titled Commodity Specification For Air, published by
Compressed Gas Association Inc., Chantilly, VA.
Website: www.cganet.com, (29 CFR 1910.134 (i)).
Disconnect Control Knob
Heat Shield
(Regulates air
tem
p
erature
)
Outlet Connecto
r
(Connection for
res
p
irator or vest
)
(Connection
for respirator
supply hose)

CAT COOL-AIR TUBE Page 3
© 2007 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 08956
2.1.2 Limiting characteristics of Grade D air, as of the
publication of this manual is as follows:
Carbon Dioxide ............. maximum of 1000 ppm
Carbon Monoxide .............. maximum of 10 ppm
Odor ................................. *No pronounced odor
Oil (hydrocarbons) .............maximum of 5 mg/m3
Oxygen .............................between 19.5 - 23.5%
* Specific measurement of odor in gaseous air is
impractical. Air may have a slight odor but the presence
of a pronounced odor renders the air unsatisfactory.
2.1.3 Special care must be taken to avoid accidental
connection to any lines other than compressed air; such
as, oxygen, acetylene, or nitrogen.
2.1.4 When the cool-air tube is used for breathing air,
the quality of air supplied to the cool-air tube is extremely
critical to the safety of the user.
2.1.5 Any air ingested from the cool-air tube must
meet the requirement for respirable air as stated herein.
If the cool-air tube supplies air to a vest that is used with
a hooded respirator, air supplied to the vest must also be
respirable air meeting the requirements for Grade D or
better.
2.1.6 Prior to using the respirator, read the owner’s
manual and all instructions, labels, and warnings relating
to the compressed air source. Take special care to abide
by all warnings from the compressor manufacturer
regarding compressor use, and from the cylinder and air
supplier, for breathing air cylinders and their use.
2.1.7 A Clemco CPF filter may be installed and
regularly maintained to remove objectionable odors, oil
mist, water, pipe scale, and other particulate matter.
2.2 Breathing-Air from Cylinders
DANGER
Operators must never use or operate breathing
air cylinders, without proper pressure reducing
devices, and training on their use. Breathing
cylinders are under extremely high air pressure.
Improper use could cause cylinders or
accessories to rupture, resulting in severe
injury or death.
2.2.1 Using cylinders (high-pressure air bottles)
requires special knowledge of their use and compliance
with OSHA Regulations. Refer to 29 CFR 1910.134(h)
and (i) and 49 CFR part 173, and part 178.
2.2.2 The employer shall ensure that cylinders used
to supply breathing air to respirators meet all
requirements which may include, but are not limited to,
their testing and maintenance, a certificate of analysis
for air quality and moisture.
2.2.3 Cylinders must be equipped with a properly
maintained pressure-reducing valve that reduces
pressure to the approved pressure range as shown in
Section 2.4.3.
2.3 Breathing-Air from Compressors
2.3.1 The employer shall ensure that air from
compressors used to supply breathing air to respirators
meets the requirements in 29 CFR 1910.134.(i)(5).
2.3.2 Precautions must be taken to prevent
contaminants from entering through the compressor
intake: Ref. 29 CFR 1910.134.(i)(5)(i). The compressor
inlet must be located away from all sources of toxic
contaminants including carbon monoxide, which is found
in engine exhaust (including the exhaust from the
compressor’s engine), and in any form of combustion.
No vehicles should be allowed near the compressor
intake. Contaminants can enter respiratory equipment
through the compressor air inlet. This inlet must not be
located near any exhaust system outlet, ventilation flue,
or source of fumes or particles of any kind.
2.3.3 The compressed-air supply system must be
equipped with suitable in-line air-purifying sorbent beds
and filters, and be maintained to further ensure
breathing air quality: 29 CFR 1910.134 (iii).
2.3.4 If the breathing-air supply is from a non-oil-
lubricated compressor, the employer shall ensure that
the carbon monoxide levels in the breathing air do not
exceed 10 ppm: 29 CFR 1910.134 (i)(6).
2.3.5 If an oil-lubricated compressor is used, the
employer shall use a high-temperature alarm or carbon
monoxide (CO) alarm, or both, to monitor carbon
monoxide levels. If only high-temperature alarms are
used, the air supply shall be monitored at intervals
sufficient to prevent carbon monoxide in the breathing
air from exceeding 10 ppm: 29 CFR 1910.134 (i)(7).

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© 2007 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 08956
2.4 Operating Pressure
2.4.1 Air pressure at the point of attachment (the point
of attachment is where the respirator supply hose is
connected to the respirable air source) must be
maintained at pressures between 90 to 100 psi (pounds
per square inch), as shown in the table in Section 2.4.3.
Maintaining the correct operating pressure at the point of
attachment ensures the correct air flow to the respirator.
2.4.2 The Clemco CPF Inline Particulate Filter with
regulator meets this requirement for a regulator and
gauge, provided inlet pressure does not exceed 150 psi.
DANGER
Do not connect the cool-air tube, CPF Filter, or
any other regulator or filter, to bottled air that
does not have a pressure reducing valve that
reduces pressure to the maximum operating
pressure of the respirator of filter it services.
Failure to comply with this warning will cause
devices rated at lower pressures to rupture
under the high pressure of bottled air, which
could cause severe injury or death.
2.4.3 Use the following table to determine the
minimum pressure setting and maximum respirator hose
length that may be used with the cool-air tube. Adjust the
pressure with the respirator hose and respirator
attached. If the regulator is adjusted with static pressure
(no air flow), pressure may drop below the required
pressure when the respirator is connected, and may
result in low air flow. Setting the pressure as shown
provides a minimum of 7 cfm (cubic feet per minute) to
the respirator. The maximum allowable pressure for use
with the cool-air tube is 100 psi.
Minimum Overall hose length measured in feet
Pressure 25 50 75 100 125 150 175 200
90 psi x x x
95 psi x x x x x
The maximum overall hose length used with the cool-air
tube is 200 feet when providing air to a respirator.
2.5 Air Volume
2.5.1 The cool-air tube must be supplied with 20 cfm
of Grade D breathing air at 90 to 100 psi.
WARNING
The compressor must provide adequate output
and the plumbing between the compressor and
the point of attaching the respirator hose must
have sufficient capacity to supply the volume
of air at the pressure required. Restricted air
flow will cause discomfort to the user, and may
result in ingress of hazardous and toxic dust,
subjecting the user to health and life
threatening toxic poisoning and long term
respiratory disease and death.
3.0 SET-UP and ADJUSTMENTS
3.1 Attach Breathing Tube Assembly
CAUTION
Note the directional flow arrows on the labels at
both ends of the breathing tube. The flow
arrows indicate the direction of air flow to the
helmet. Flow arrows must point toward the
helmet. Failure to properly attach the breathing
tube may damage the tube's acoustical foam,
which will block air flow, or it may increase
noise levels beyond OSHA limits.
3.1.1 The breathing tube has a clamped-on end and a
molded-on end. Attach the molded-on swivel connector
to the cool-air tube’s outlet as shown in Figure 2.
Figure 2
Attach clamped end of
breathing tube to the respirator
Attach the molded end
of the breathing tube to
the cool-air tube

CAT COOL-AIR TUBE Page 5
© 2007 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 08956
3.1.2 Attach the clamped-on end to the threaded air
inlet fitting at the back of the helmet as shown in Figure
2. Do not over-tighten; hand-tight is sufficient.
3.1.3 Attach an approved Clemco respirator hose to
the quick-disconnect nipple.
3.2 Air Supply and Pressure
3.2.1 Initiate the air supply and regulate air pressure
between 90 and 100 psi, as shown in Section 2.4.3.
3.3 After donning the respirator, securely attach the
belt and cool-air tube around the waist. Adjust the belt size
as required.
3.4 Adjust Air Temperature
3.4.1 To adjust air temperature, rotate the temperature
control knob (shown in Figure 3) located on the bottom of
the cool-air tube, toward the broader, darker end of the
arrow for ambient temperature or toward narrower, lighter
end for maximum cooling. The knob may be positioned
anyplace in between to attain the most comfortable
temperature setting.
O
O
CLER
O
O
CLER
Figure 3
4.0 PREVENTIVE MAINTENANCE
4.1 Air Filter Screen
4.1.1 Inspect and clean the air filter screen monthly. If
inadequate air flow is experienced, stop using the cool-
air tube and inspect the screen for blockage.
CAUTION
Debris or abrasion on the screen is one
indication of dirty air. Dirty air will cause rapid
erosion of critical parts of the cool-air tube,
which will decrease efficiency and life of the air
tube.
4.1.2 To clean the air filter screen, unscrew the quick
disconnect nipple from the inlet elbow. Turn the elbow
upside down and tap it on a solid surface to remove
loose debris. The screen can be removed by tapping the
elbow described above. If the screen is wedged in place
it may be necessary to destroy it in order to remove.
Replace the screen before reassembly.
5.0 SERVICE MAINTENANCE
5.1 O-Rings Replacement
5.1.1 Replace o-rings when air leaks are detected.
5.1.2 Replace the o-ring in the cool-end venturi by
following instructions in Section 5.2 (cool-end venturi).
5.1.3 Replace o-rings on the valve stem assembly by
following instructions in Section 5.3 (vortex tube assembly).
5.2 Cool-End Venturi, Figure 4
5.2.1 Clean and inspect the cool-end venturi every 4-6
weeks. Clean all parts with soap and water only, and
thoroughly rinse.
5.2.2 Unscrew the outlet connector from the top of the
cool-air tube. Grasp the stem of the cool-end venturi and
pull to remove the assembly (cool-end venturi, o-ring,
spring washers and back-up washer).
5.2.3 Gently clean the slots on the venturi with a brush
or small screwdriver. If the slots are worn, replace the
assembly. Look into the cool-air tube body to inspect the
top surface of the spacer for wear. If dirty or worn,
continue to Paragraph 5.3 before replacing the cool-end
venturi assembly. Otherwise, replace the venturi assembly
making sure the cone side of the spring washers face
each other. Apply thread sealant to the body end of the
outlet connector and secure it tightly with a wrench. A
loose connection will reduce performance.
Control Knob
Turn the control knob to adjust
from ambient temperature (no
cooling) to maximum cooling

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© 2007 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 08956
Figure 4
5.3 Vortex Tube Assembly, Figure 5
5.3.1 Remove the cool-end venturi per Section 5.2.
Remove the inlet elbow, and temperature control knob.
Using a pencil or similar object, gently push the valve stem
from the bottom of the body. Continue to push the entire
vortex tube assembly through the top of the body. Inspect
the inside of the tube body to make sure the 11/16" o-ring
is removed.
Figure 5
5.3.2 Unscrew the valve stem from the valve insert and
remove the two o-rings.
5.3.3 Clean all parts with soap and water only and
thoroughly rinse.
5.3.4 Lubricate the valve stem threads with silicone
grease and screw it fully, finger-tight, into the valve insert.
Lubricate new o-rings. Slide the 9/16" and 1/2" o-rings
onto the stem, with the larger of the two toward the insert.
Put a new o-ring on the insert and reassemble the vortex
tube assembly and cool-air tube as shown in Figures 4
and 5. NOTE: One end of the vortex tube has a metal
"vortex breaker" in it. Inspect the breaker for wear or
damage. Reassemble, making sure the valve insert
and stem are installed on the breaker end of the tube.
To ease assembly of the vortex tube assembly, assemble
it as shown in Figure 5, turn the body upside down and
insert the assembly into the body
5.4 Belt Bracket Screws
5.4.1 If for any reason the belt bracket screws are
removed, reinstall them using thread sealant to prevent air
leaks.
6.0 TROUBLESHOOTING
6.1 Inadequate Air Flow
6.1.1 Check filter screen for debris.
6.1.2 Make sure supply air pressure is between 90 to
100 psi. A pressure regulator and gauge must be installed
at the point of attachment (where the respirator hose is
connected to the respirable air source).
6.2 Poor Cooling Performance
6.2.1 Inadequate air flow affects cooling performance.
Refer to Paragraph 6.1.
6.2.2 The temperature of the compressed air has an
effect on the cool-air tube’s discharge temperature. Make
sure that none of the lines that supply compressed air to
the cool-air tube is routed near any source of heat, such
as a steam radiator, furnace, etc. When possible, avoid
exposure to direct sunlight.
6.2.3 Erosion of internal parts: Compressed air moving
through the air tube will eventually wear critical
components. Dirty air accelerates wear of internal parts.
6.2.4 Vortex breaker may be loose, worn, or damaged.
Inspect the breaker per Section 5.3.1.
Outlet Connector
Spring Washers (2)
Back-up Washer
15/16" O-Ring
Cool-end Venturi
Cool-air Tube Body
Spacer
11/16" O-Ring
9/16" O-Ring
1/2" O-Ring
Valve Stem
Control Knob
Spacer 1, Thin
Inlet Elbow
Spacer 2, Thick
Valve Insert
Vortex Tube
Assemble breaker end
of tube onto valve insert
Venturi
Body

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© 2007 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 08956
7.0 REPLACEMENT PARTS, Figure 6
Item Description Stock No.
(-) CAT Cool-air tube assembly w/ belt .............04410
1. Belt .................................................................04430
2. Disconnect nipple ..........................................08449
3. Elbow, 1/4" male ............................................08869
4.* Seal kit (o-rings) ............................................08870
5.* Venturi kit, cool-end .......................................08871
6. Stem, valve ....................................................08962
7. Insert, valve ...................................................08963
8. Vortex tube with breaker ...............................23030
9. Spacer 1, thin ................................................08966
10. Venturi tube ...................................................08967
11. Spacer 2, thick ...............................................08968
12. Connector, outlet ...........................................08971
13. Screen ............................................................08983
14. Heat shield .....................................................08981
15. Knob w/set screws ........................................08985
16. Body ...............................................................08961
17. Screw, machine 10-24 x 1/4", r/h (each).......08980
18. Bracket, belt ...................................................08974
* Items 4 and 5 include the cool-end o-ring. If both items
are ordered together, you will receive an extra o-ring.
Figure 6
15
1
Some items are rotated for clarity
2
13
3
18 17
4
4
12
5
11
9
10
8
14
16
7
6