Clemco APOLLO 20 User manual

APOLLO SUPPLIED-AIR RESPIRATOR
Helmet Model 20
Low Pressure 6 psi to 20 psi
O. M. 21991
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.
© 2011 CLEMCO INDUSTRIES CORP.
One Cable Car Dr.
Washington, MO 63090
Phone [phone]
Fax [phone]
Email: [email protected]
www.clemcoindustries.com
WARNING
NOTICE
This supplied air respirator conforms to all
NIOSH specifications and standards and carries
NIOSH approval. As manufactured, this
respirator complies only with those foreign
approvals that accept NIOSH certification.
Specifically, it has not been manufactured to
European standards and does not carry the
European mark.
MC FILE NUMBER: 1193-0196
DATE OF ISSUE: April, 1996
REVISION: H, 01/11

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

APOLLO LOW PRESSURE SUPPLIED-AIR RESPIRATOR Page 1
HELMET MODEL 20
© 2011 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 21991
1.0 INTRODUCTION
1.1 Scope of manual
1.1.1 This manual covers setup, operation,
maintenance, and replacement parts for Clemco Apollo
LP (low pressure) Series Supplied-Air Respirator:
Model 20 LP.
1.1.2 Read this entire manual and all accessory
manuals before setting-up and using the respirator.
Manuals for Clemco low pressure, ambient air pumps
that may be used with Apollo LP Respirators are
available on our web site, www.clemcoindustries.com,
Refer to Figure 1 for a typical set-up.
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 indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
1.3 NIOSH Approval Number 19C-339
1.3.1 The Clemco Apollo Supplied-Air Respirator is
approved by the National Institute of Occupational
Safety and Health (NIOSH).
1.3.2 The NIOSH label shown below lists the Apollo
respirator approval number. An X on the approval line
indicates which components are approved for the
specific respirator. Do not use any non-approved
components with this respirator.

APOLLO LOW PRESSURE SUPPLIED-AIR RESPIRATOR Page 2
HELMET MODEL 20
© 2011 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 21991
WARNING
NIOSH approval applies only when this
supplied-air respirator is 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 back
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.
1.4.3 It is essential that the user be properly
instructed in the use and maintenance of the respirator.
This manual 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 respirator 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 is properly used
and maintained.
1.5 Respiratory and Health Alerts
WARNING
TOXIC DUST POISONING
Research by the National Institute For
Occupational Safety and Health (NIOSH) has
discovered risks associated with dust produced
during abrasive blasting operations including but
not limited to Lead, Silica, Antimony, Arsenic,
Beryllium, Cadmium, Chromium, Cobalt, Nickel,
Tin, Nitrate and Nitrite, to unprotected abrasive
blasting operators and other personnel who may
be exposed to toxic dust in the abrasive blasting
vicinity. These risks include debilitating lung,
blood, liver, kidney, and skin injuries, and even
death. Toxic dust is produced primarily by the
breakdown of the abrasive being used and the
surface being treated, during abrasive blasting.
The breakdown of toxic coatings and hazardous
abrasive causes the contaminants to become
airborne. Breathing toxic dust generated by the
abrasive or surface being treated can cause health
and life-threatening toxic poisoning and can
damage vital organs. Breathing hazardous dust
produced from silica and other abrasives can
cause delayed life-threatening respiratory disease.
It is imperative that blasting contractors identify all
material being removed by blasting, and obtain
material safety data sheets (MSDS) for the blasting
abrasive prior to blasting. It is the responsibility of
the employer to identify all airborne contaminants
in the blast vicinity, and ensure they do not exceed
the permissible exposure limit (PEL) Ref. 29 CFR
1910.1000 and 29 CFR 1926.62. Thorough site
hazard examinations should be made by A
Certified Industrial Hygienist, Certified Safety
Professional or other qualified professional to
identify all contaminants generated by blasting
and in the blasting vicinity.
Exposure to dangerous levels of toxic or
hazardous dust is not restricted to blast operators.
There may be an equal or greater danger present
after the blasting process due to lingering airborne
dust particles, and especially from dust generated
during cleanup activity. Heavy metal paint,
asbestos, sand or other silica, and other toxic
material dusts will cause serious lung disease or
death if not prevented through the use of properly
designed, and maintained NIOSH-approved,
supplied-air respirators worn by blasting
operators and all personnel within the work area.
OSHA’s regulations found primarily in 29CFR1910,
Subpart Z provides the permissible exposure
limits for all toxic and hazardous substances. It is
the responsibility of the employer to determine the
inhalation hazards associated with the abrasive
blasting being performed. Do not begin any
operations including abrasive blasting without
being trained by the employer and fully
understanding the hazards associated with the
work performed.
The Apollo supplied-air respirator system is
approved by NIOSH as a Type-CE, continuous-
flow, abrasive blast, supplied-air respirator, in

APOLLO LOW PRESSURE SUPPLIED-AIR RESPIRATOR Page 3
HELMET MODEL 20
© 2011 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 21991
accordance with title 42 CFR Part 84. The NIOSH
recognized assigned protection factor (APF) for
any supplied-air respirator equipped with a loose-
fitting hood or helmet and operated in a
continuous flow mode is 25, based upon the
NIOSH Respirator Decision Logic (Pub. No. 87-
108). In other words, any Type-CE respirator
should be used only in atmospheres in which the
contaminant level does not exceed 25 times the
permissible exposure limit. However, OSHA
revised its existing Respiratory Protection
standard in 2006 to add APFs and Maximum Use
Concentration (MUC) provisions. APF means the
workplace level of respiratory protection that a
respirator or class of respirators is able to provide
to workers. OSHA placed a table reflecting the
appropriate APF for various respirators in 29CFR
1910.134(d)(3)(i)(A). OSHA also provides a free
publication titled “Assigned Protection Factors”
(reference number “OSHA 3352-02 2009”) to assist
the user and their employer in understanding the
selection of respirators based on APFs and MUCs.
This section of the OSHA regulations allow the
employer to assign an APF of 1000 to all Apollo
Series Respirators based on the simulated
workplace protection factor studies Clemco has
performed. These studies are available for
download from Clemco’s Website
www.clemcoindustries.com, under the “Safety
Info” tab
The employer must provide and maintain
appropriate approved respirators, in addition to
providing operator training and employing
required work site safety practices.
To avoid any potential danger of respiratory injury,
approved, supplied-air respirators must be worn at
all times in the presence of any type of dust. The
respirator must be maintained as described
herein. Improper use of any respirator may cause
life threatening respiratory disease, and immediate
poisoning from toxic dust. Respirators should be
removed only after the ambient air has been tested
with a dust monitor, and found to be safe to
breathe.
Toxic dust poisoning also may occur by eating,
drinking, or smoking in a contaminated area, or by
eating, drinking, or smoking in a non-hazardous
area before thorough washing of hands and face.
Do not eat, drink or smoke in the blast area.
Thoroughly wash hands and face to remove
contaminants before eating, drinking, or smoking
outside the blast area.
This manual does not contain all the health and
safety requirements regarding toxic and
hazardous dust exposure. Obtain copies of the
OSHA regulations and consult a safety
professional and/or industrial hygienist for
complete requirements.
Within this manual we refer to hazardous or
contaminated environments. These environments
can be any places around the blast area that could
contain toxic or hazardous dust.
If these warnings are not completely understood,
or if further information is required, contact a local
OSHA office. If any personnel in the abrasive
blasting vicinity cannot read or comprehend these
warnings and the entire content of this
instructional material, assign a qualified person to
instruct him/her.
Additional information on abrasive blasting
hazards titled “Preventing Silicosis and Death
From Sandblasting”, Publication No. 92-102, is
available from:
Publications Dissemination, DSDTT
National Institute for Occupational Safety and Health
4676 Columbia Parkway
Cincinnati, OH 45226 [phone]
1.6 Cautions and Limitations
A - Not for use in atmospheres containing less than
19.5 percent oxygen.
B - Not for use in atmospheres immediately dangerous
to life or health (IDLH).
C - Do not exceed maximum use concentrations
established by regulatory standards.
D - Air-line respirators can be used only when the
respirators are supplied with respirable air meeting the
requirements of CGA G-7.1 for Grade D or higher quality.
E - Use only the pressure ranges and hose lengths
specified in the user’s instructions.
J - Failure to properly use and maintain this product
could result in injury or death.
M - All approved respirators shall be selected, fitted,
used, and maintained in accordance with OSHA and
other applicable regulations.
N - Never substitute, modify, add, or omit parts. Use
only exact replacement parts in the configuration as
specified by the manufacturer.

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O - Refer to user’s instructions, and/or maintenance
manuals for information on use and maintenance of
these respirators.
S - Special or critical user’s instructions, and/or specific
use limitations apply. Refer to instruction manual before
donning.
1.7 S – Special or Critical User’s Instructions
1.7.1 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 the minimum and
maximum pressure as shown in the table in Section 4.2.
WARNING
Failure to maintain the minimum pressure at
the point of attachment may reduce air flow
below the minimum flow required by OSHA.
Reduced air flow may result in ingress of
hazardous toxic dust, subjecting the user to
immediate health and life threatening
poisoning and subsequent respiratory disease.
1.7.2 Couple no more than the maximum number of
sections and total maximum lengths of respirator hose
as noted in the table in Section 4.2.
1.7.3 The respirator is designed for specific use in
abrasive blasting applications. Do not use in other
operations such as painting or welding.
1.8 Protection
1.8.1 NIOSH recognized Assigned Protection Factor
(APF) for the Apollo type CE respirator is 25 times the
permissible exposure limit (PEL). In other words, NIOSH
recommends the Apollo type CE respirators should only
be used in atmospheres in which the contaminant level
does not exceed 25 times the PEL. However OSHA's
2006 revised Respirator Standard allows an exception for
type CE respirators which have validated third party
testing for use up to 1000 APF. In order not to be in
violation of OSHA 1000 APF the end-user must have a
copy of this validated testing. A copy of Clemco validated
testing may be downloaded from the "Safety Info" tab on
our website, www.clemcoindustries.com.
1.8.2 Head: The respirator protects the wearer’s
head and neck from impact and from abrasion caused
by rebounding abrasive. However, the respirator does
not the requirements for industrial head protection as
stated in ANSI Z89.1.
1.8.3 Face and Eye: The Apollo inner lens meets
impact and penetration requirements under ANSI
Z87.1-1989.
1.8.4 Hearing: Noise generated by the Apollo
respirator, and measured inside the helmet does not
exceed 80 decibels. (42 CFR part 84.140) When any
exterior noise causes the internal noise level to exceed
80 decibels, the user must wear additional hearing
protection. A variety of hearing protectors can be worn
with the respirator.
2.0 INSPECTION
NOTE: A Clemco respirator hose is part of the approval
assembly, and must be used with the respirator. Hoses
are not included with all respirators because blast
operators are often assigned personal respirators, while
using common respirator hoses. If a hose is not
available, it must be ordered from an authorized
distributor of Clemco products.
2.1 Component Checklist
2.1.1 Make sure that all the respirator components
are present. Each respirator box should contain the
following:
Helmet with chin strap, padded suspension and
cape attached
Breathing tube assembly
Alternate Web Suspension (not used with padded
suspension)
Constant-flow connector
NOTE: If the respirator does not include an approved
Clemco respirator hose, and if one is not at the work
site for use with the respirator, one or more alternate
hoses must be ordered separately.
2.1.2 When all of these components are present,
prepare the respirator for operation per Section 3.0.

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Figure 1
3.0 PREPARATION
3.1 When using the alternate web suspension with
sweatband, adjust it per Section 6.1. There is no
adjustment with the padded suspension.
3.2 Prepare Lens System
WARNING
Never use the respirator without a complete
lens system in place. A complete lens system
includes the fixed inner lens, middle lens,
perforated cover lenses, and lens gasket. The
fixed, inner lens provides support for the
window gasket. If the gasket is not adequately
supported, leaks can occur which could permit
entry of toxic and hazardous dust or abrasive
into the helmet.
3.2.1 The lens system is an important part of the
respirator assembly. The helmet is supplied with an
inner lens that is secured by the window gasket. To
protect the inner lens, a middle lens and up to three
perforated cover lenses are securely held in position by
the lens gasket and frame.
3.2.2 Make sure the inner lens is in place per Section
9.2.
3.2.3 When the perforated cover lenses are correctly
installed, as one lens becomes frosted during blasting, it
can be torn off to expose the next lens. To protect the
inner lens, make sure the perforated cover lenses and
middle lens are in place per Section 9.1.
Apollo Helmet Assembly
Model 20
Breathin
g
Tube Assembl
y
Point of Attachment
Constant Flow Connector
Res
p
irator Hose
Ambient Air Pump
NOTE: The air pump must be located to
ensure the intake draws Grade D or higher
quality respirable air. If air quality at the
pump’s intake cannot be assured use an
intake hose extension to draw air from an
area where clean, respirable air is certain.
Some items are positioned for clarity.
The air pump must be protected from the blasting environment.

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3.3 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.
3.3.1 The breathing tube has a clamped-on end and a
molded-on end. 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.
3.3.2 Attach the molded-on swivel connector to the
constant-flow connector.
Figure 2
CAUTION
Use the handle to carry or hang the respirator.
Never hold, carry or hang the respirator by the
breathing tube. Mishandling the respirator in
this manner may damage the tube or helmet
inlet. Any leaks or breaks in the breathing tube
will alter the air flow through the respirator and
affect user’s safety and comfort.
3.4 Respirator Hose
WARNING
OSHA regulations 29 CFR 1910 and 29 CFR
1926 require that respirator air line couplers be
incompatible with air lines for non-respirable
use. This incompatibility prevents inadvertent
supply of respirators with potentially
hazardous, non-respirable gases or oxygen. It
is the employer's or facility owner's
responsibility to comply with the regulation.
3.4.1 Respirator hose must be NIOSH-approved
Clemco 1/2"ID respirator hose.
3.4.2 If longer hose is required, it must be a NIOSH-
approved Clemco 1/2"respirator hose extension. Use
50-foot or 100-foot Clemco respirator hoses in any
combination as noted in the table in Section 4.2, not to
exceed 300 ft. or three individual hose lengths.
3.4.3 Attach the female disconnect end of the
respirator hose to the constant-flow connector. The male
end attaches to the ambient air pump.
3.5 CMS-3 CO Monitor Option, Respirator Mounted
The Clemco supplied air respirator model Apollo 20 LP is
NIOSH approved with the accessory CMS-3 personal
carbon monoxide alarm, but NIOSH has not evaluated the
function of the CMS-3 personal carbon monoxide alarm.
3.5.1 Open the lens frame and remove the lenses per
Section 9.2.
3.5.2 Don the helmet and place monitor on one of the
side walls of the window extension, positioning it to make
sure the alarm light is visible from inside the helmet.
3.5.3 Mark the location and remove the monitor and
helmet.
3.5.4 Remove backing from the Velcro®hook tape and
adhere it at the marked location (the loop tape adheres to
the monitor). Attach the monitor and make sure the
monitor’s alarm lights are visible from inside the helmet.
3.5.5 Remove the monitor and prepare it for operation
per instructions supplied with the monitor.
3.5.6 Replace the lenses and lens frame assembly.
3.5.7 After the initial setup is done, remove and
reattach the monitor from inside the helmet. Remove the
monitor to do any service or calibration, including turning
Connect the molded-on
swivel to the constant-flow
connecto
r
Breathin
g
Tube Assembl
y
Connect the clamped-on
swivel to the helmet’s
inlet fitting.
Handle
Constant-Flow Connector

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the monitor on and off. Do this to make sure the monitor
is fully functional before placing it inside the helmet.
4.0 AIR SUPPLY
WARNING
Air supplied to this respirator system is critical
to the safety of the user. Read this section
carefully. Poor quality air or low air volume will
cause serious respiratory injury or death to the
user. See Toxic Dust Poisoning Warning in
Section 1.5.
WARNING
This respirator is intended for use with (low
pressure) ambient air pumps. Do not use
compressors or high pressure cylinders
(bottles) as an air source for this respirator. Air
supplied from compressors poses hazards,
especially from carbon monoxide that are not
covered in these instructions. High pressure
cylinders require special knowledge for their
use and compliance, details of which are not
covered in these instructions.
4.1 Air Quality
4.1.1 The quality of air supplied to the respirator is
extremely critical to the safety of the user. Special care
must also be taken to avoid accidental connection to any
other gas lines; such as, oxygen, acetylene, or nitrogen.
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.
4.1.2 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)).
4.1.3 Limiting characteristics of Grade D air, at the
time of publication of this manual are 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.
4.1.4 Prior to using the respirator, read the owner’s
manual and all instructions, labels, and warnings relating
to the ambient air pump.
WARNING
The air pump must be located where Grade D or
higher quality respirable air is ensured. If air
quality at the pump’s intake cannot be assured,
use an intake hose extension to draw air from
an area where clean, respirable air is certain.
Any toxic air entering the pump will enter the
respirator and will cause severe illness or death
to the user.
4.1.5 Take precautions to prevent contaminants from
entering through the air pump's inlet filter. Locate the air
pump's inlet filter away from all sources of contaminants
including carbon monoxide, which is found in engine
exhaust, and in any form of combustion. Place the pump
in an area away from vehicle traffic. Do not locate the
pump's inlet filter near any exhaust system outlet,
ventilation flue, or source of fumes or particles of any
kind. If the ambient air pump cannot be placed in an
area where respirable air can be guaranteed, use an air
inlet extension hose as specified by the pump
manufacturer to bring air from an area where clean
respirable air is ensured.
S – Special or Critical User’s Instructions
4.2 Air Volume and Pressure
4.2.1 LP respirators are for use with ambient pumps,
which provide 6 to 20 cfm of Grade D air at pressures
shown in table in Section 4.2.2. Maintaining the correct
operating pressure at the point of attachment ensures
the correct air flow to the respirator.
4.2.2 Use the following table to determine the
minimum and maximum pressure settings and maximum

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respirator hose length. 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 instructed will provide a
minimum of 7 cfm to the respirator.
Total Hose
Length
Maximum Number
of Hose Sections
Pressure (psi)
Min. Max.
50 feet 1 6 to 10
100 feet 2 8 to 14
200 feet 2 11 to 20
300 feet 3 15 to 20
NOTE: Use any combination of hose shown to provide a
maximum of 300 ft., but not to exceed three individual
hose lengths.
4.2.3 Pressure Conversion Kit
4.2.3.1 This optional accessory kit contains parts and
instructions to convert an Apollo 20 respirator from low
pressure (for use with an ambient air pump) to high
pressure (Grade “D” Compressed Air). The kit is listed in
Section 10.1.
5.0 OPERATION
WARNING
Except for emergency evacuation when the use
of the respirator hinders escape, keep the
respirator on and leave the respirator-use area
immediately if any of the following occur:
Any part of the respirator system
becomes damaged
Any air monitoring alarm is activated
Air flow into the respirator is reduced or
stops
Breathing becomes difficult
At the first sign of dizziness, nausea,
fever, illness or injury
Any contamination is noted by taste,
smell or vision inside the respirator
Vision becomes impaired
Any irritation is noted
5.1 Prior to use, thoroughly inspect and clean the
helmet, breathing tube, respirator hose, air entry ports,
and fittings of all dust and debris. Inspect the helmet
suspension and if necessary replace it per Section 9.6.
5.2 Begin the operation of the ambient air pump per
the manufacturer’s instructions.
5.3 Check air pressure at the point of attachment.
Set the pressure within the minimum and maximum
pressures assigned in Section 4.2. Pressure must be set
with the respirator connected.
5.4 Inspect all safety and breathing equipment used
in conjunction with the respirator as recommended by
the manufacturer.
5.5 Inspect respirator hoses and connections for
tightness and leaks.
5.6 Don the respirator in a clean non-hazardous
environment, free of contaminants, where the air is safe
to breathe.
5.7 When donning and removing the respirator,
keep it upright to prevent dust and abrasive from falling
inside. Holding the chin strap while donning the helmet
will make it easier to position it once the helmet is on.
5.8 Position the chin strap so it fits comfortably
under the chin.
5.9 Position the knit cuff on the inner collar so that it
fits snugly around the neck in turtleneck fashion, and
without any interference from clothing or long hair. When
correctly positioned, the smaller elastic end of the collar
must face up.
WARNING
Correct placement of the inner collar is critical
for providing the protection for which the
respirator is designed. The collar must be
positioned and maintained without any
interference from items such as hair, facial hair,
or shirt collars, between the inner collar and
user’s neck.
5.10 Pull the cape down to fully extend it and connect
the four elastic straps (two on each side) under the
arms, and tighten using the slides provided.
5.11 Put on the belt and constant-flow connector over
the cape. Buckle the belt around the waist, and tighten it
by pulling the belt end through the buckle insert.

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5.12 When finished blasting, and after cleanup is
completed, remove the respirator outside the respirator-
use area and where the air is safe to breathe.
WARNING
Do not don the respirator, or store it in a blast
contaminated environment. Do not remove the
respirator in a contaminated environment
except for emergency evacuation when the use
of the respirator hinders escape.
NOTE: The quick disconnect coupling on the end of the
respirator hose is not equipped with a shut-off.
Therefore, if the hose is disconnected from the respirator
while the pump is in operation, air will continue to flow
freely from the hose. After removing the respirator in a
clean environment, the air pump should be shut off.
6.0 ADJUSTMENTS
6.1 Alternate Web Suspension with Sweatband
WARNING
The suspension maintains a fixed distance
between the head and the helmet. It is critical
that the suspension is properly installed, and
adjusted as described, to provide maximum
head protection and comfort.
6.1.1 Remove cape from the helmet per Section 9.5.
6.1.2 Unfasten the vinyl sweatband from the two
lower, outside buttons, ref. Figure 3. It is not necessary
to remove the suspension to make adjustments.
6.1.3 The suspension fits head sizes 6.5 to 8. Head
sizes are marked on the headband slots. Slide the
headband tongue in or out of the guide to attain the
desired head size. It is important that the adjustment be
made evenly on both sides. Press the selected slots
firmly onto the fastening lugs on the front band.
6.1.4 Refasten the vinyl sweatband onto the
suspension buttons.
6.1.5 Try on the helmet for fit and readjust if
necessary.
6.1.6 Reattach the cape to the helmet by following the
instructions in Section 9.5.
Figure 3
7.0 MAINTENANCE PROGRAM
7.1 Basic Service
7.1.1 A program for maintenance and care of the
respirator must be established based on application,
working conditions, and hazards involved, and include
the following basic service.
• Inspection for defects (including a leak check)
• Cleaning and disinfecting
• Repair (service maintenance)
• Storage
Equipment must be properly maintained to retain its
original effectiveness. Reference OSHA Regulation 29
CFR 1910.134 (h).
7.2 Inspection
Inspection must be done in compliance with OSHA
Regulation 29 CFR 1910.134 (h)(3).
7.2.1 Inspect respirator before and after each use,
and during cleaning. Inspection shall include a check for
tightness of connections and the condition of the lenses,
suspension, cape and elastic parts, breathing tube,
respirator hoses and connectors, and constant-flow
connector.
7.2.2 Inspect the respirator hoses, breathing tube, air
entry ports, and fittings for dust contamination; make
sure they are clean before making connections.
Sweatband
Lower Outside Buttons
(one on each side of sweatband)
Sizing Slots
Guide
Suspension Strap
With yellow tabs
Headband Tongue
White Tabs
Suspension

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7.2.3 The helmet suspension is very important for
maintaining maximum head and respiratory protection. It
must be inspected for fit and wear on a daily basis, and
replaced immediately at the first sign of wear. . Refer to
Section 9.6 for suspension replacement.
NOTE: Refer to Section 6.1 for adjustment of the
alternate web suspension with sweatband.
7.2.4 The inner collar is very important for controlling
air escape from the helmet and preventing ingress of
dust. The elastic collar should fit snugly around the
user’s neck. Replace the cape when the collar no longer
fits snugly around the neck.
7.2.5 The outer cape provides protection from
rebounding abrasive and from abrasive ingress into the
helmet. Inspect the outer cape frequently for wear.
Replace the cape before holes appear, or any wear
occurs that prevents the cape from providing the
protection for which it is intended.
7.3 Cleaning and Disinfecting
Cleaning and disinfecting must be done in compliance
with OSHA Regulation 29 CFR 1910.134 (h)(1).
Refer to Section 8.0 for cleaning instructions.
7.3.1 A respirator issued for the exclusive use of an
employee shall be cleaned and disinfected as often as
necessary to be maintained in a sanitary condition.
7.3.2 Shared respirators must be cleaned and
disinfected before being worn by different individuals.
7.4 Repairs (Service Maintenance)
Repairs must be done in compliance with OSHA
Regulation 29 CFR 1910.134 (h)(4).
7.4.1 The employer shall ensure that respirators that
fail an inspection or are otherwise found to be defective
are removed from service, adjusted, repaired or
discarded in accordance with the following procedures:
7.4.2 Adjustments and repairs must be made only by
appropriately-trained persons, and only with genuine
Clemco NIOSH-approved parts designed for the
respirator. No attempt shall be made to substitute
components or to make adjustment or repairs beyond
the manufacturer’s recommendations. Refer to Section.
9.0 for service instructions.
7.5 Storage
Storage of the respirator must be done in compliance
with OSHA Regulation 29 CFR 1910.134 (h)(2).
7.5.1 Daily Storage
7.5.1.1 When the respirator is not in use, it must be
stored in a clean, dry area. Hang the respirator by the
handle. Do not tuck the cape inside the helmet. Let the
cape hang loose to allow air to circulate, and
condensation on the cape and inside the helmet to dry.
7.5.2 Long-term Storage
7.5.2.1 After inspection, cleaning, and thorough drying,
and after necessary repairs are made, the cape should
be tucked inside the helmet. The respirator shall be
placed in a plastic bag and the bag sealed to keep out
dust and moisture. Place the bag in a clearly-marked
carton and store it in a clean, dry place.
8.0 CLEANING AND DISINFECTING
NOTE: Unless otherwise stated all cleaning and
disinfecting should be done in accordance to OSHA
Regulation 29 CFR-134 App. B-2.
CAUTION
Follow washing instructions as described in
this section. Do not use any caustic chemicals
or solvents that may be irritating or harmful to
the user, or which change the properties of the
materials used in any part of the respirator.
8.1 Outer Cape
8.1.1 Refer to Section 9.5 for removal and installation
instructions.
8.1.2 Machine wash in warm water with mild
detergent. Dry in a clothes dryer at the lowest
temperature setting. Do not dry clean.
8.2 Suspensions and Chin Strap
8.2.1 Standard Padded Suspension
8.2.1.1 Refer to Section 9.6.1 for removing and
replacing padded suspension.

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8.2.1.2 Wash the suspension pads, suspension web,
and chin strap with warm water and mild detergent, and
rinse with clean, warm water.
8.2.1.3 Squeeze pads to remove excess water. Wrap
pads in a towel and squeeze to remove additional water.
All items may be air-dried or tumble-dried at the lowest
possible setting.
8.2.2 Web Suspension with Sweatband (alternate)
8.2.2.1 Refer to Section 9.6.2 to remove and replace the
suspension. Wash the sweatband, suspension, and chin
strap, using warm water and mild detergent, and rinse
with clean water. Remove excess water with a towel and
allow to air-dry.
8.3 Helmet Assembly
8.3.1 The helmet assembly should be wiped clean
with a cloth dampened with water and mild detergent. If
the helmet must be immersed in water, remove the
breathing tube, cape, suspension and all other
removable items before immersing. While this will not
permanently damage the helmet, it will require an
extended drying period.
8.3.2 Care must be taken to prevent abrasive entry
when donning and removing the respirator and when
changing lenses. Vacuum the inside of the helmet to
remove any abrasive.
8.4 Disinfecting
8.4.1 Washing the respirator as instructed also
disinfects it. Additional disinfecting may be done before
and/or after use by wiping the surfaces with a
commercial disinfecting wipe or spray.
9.0 SERVICE MAINTENANCE
CAUTION
To prevent recontamination of the respirator,
clean the respirator of dust and abrasive before
maintenance. All maintenance must be done in
a clean environment away from dust and
abrasive, and outside the respirator use area.
9.1 Replacing Outer and Middle Lenses
Preparing lenses in the following manner will permit the
cover lenses to be torn off while blasting to expose a
fresh lens as needed, while preserving the innermost
perforated lens to protect the middle lens.
9.1.1 Unlatch and open the lens frame, and remove
remnants of old lenses. The middle lens may be reused
if it is in good condition.
9.1.2 Inspect the lens frame gasket; replace if worn or
damaged.
9.1.3 Inspect the window gasket and inner lens. If
necessary replace per Section 9.2.
9.1.4 Up to three cover lenses may be installed at one
time. For maximum visibility, install only enough lenses
to last during a work period.
9.1.5 Preparing lenses in the following manner will
permit lenses to be pulled off easily by a user wearing
heavy gloves.
9.1.6 Place the middle lens on a clean flat surface.
Place up to three cover lenses on top of it.
9.1.7 Fold the pull-tab of the bottom lens down as
shown in Figure 4.
9.1.8 Fold the pull-tab of the center, and top lens up.
Figure 4
Fold the pull-tab of the
top and center lens "up"
Fold the pull-tab of the
bottom lens "down"
Middle Lens
Perforated cover lens

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9.1.9 Place the stack of prepared lenses into the lens
frame so the pull-tab of the top lens sticks through the
front of the lens opening. When placed correctly, the
perforated lenses will be against the frame, and the
middle lens will be behind them offering additional
support.
9.1.10 Installing the lenses in this manner will prevent
unintentional removal of the last perforated lens and
prolong the life of the middle and inner lenses. It will be
easier to remove the cover lens while wearing heavy
gloves, if the tab is bent outward slightly.
9.2 Removing and Replacing the Inner Lens and
Window Gasket
9.2.1 Open the lens frame and remove the middle
lens and cover lenses.
9.2.2 Pull the lens gasket and inner lens off the
window opening flange. The gasket is held in place by
tabs on the flange that fit into slots on the gaskets as
shown in Figure 5.
9.2.3 Remove old lens from the gasket lens channel.
9.2.4 Clean or replace the gasket as needed.
9.2.5 Place a new lens into the channel. The lens
must be in place before affixing the gasket to the window
flange.
Figure 5
9.2.6 Slide one end of the gasket (with lens) onto the
window opening flange, so the holding tab on the
opening is inserted into the gasket retaining slot.
9.2.7 Push the gasket against the flange. Working
from inside the helmet, push the gasket toward the tab,
until the tab is fully inserted into the retaining slot.
9.2.8 Repeat the process on the opposite side. The
gasket must be pushed beyond the holding tab in order
to insert it into the slot.
9.2.9 Repeat the process on the top and bottom to
lock the gasket in place.
9.2.10 Place perforated cover lenses and one middle
lens in the lens frame per Section 9.1 before closing the
frame.
9.2.11 To maximize the wear life of the inner and
middle lenses, do not remove the last perforated cover
lens (See Section 9.1). The respirator must never be
used without the inner and middle lenses in place.
9.3 Removing and Replacing the Lens Frame
9.3.1 The lens frame must be replaced at the first sign
of wear, or of cracking around the hinge.
9.3.2 Open the lens frame, and remove the perforated
cover lenses and middle lens.
9.3.3 Remove the two hinge screws, and replace the
frame.
9.3.4 Install a new frame gasket before installing new
lenses.
9.4 Rubber Window Frame Latch
9.4.1 Pull the old latch off of the three buttons.
9.4.2 Place the flat side of the latch against the frame
and align the holes in the new latch over the buttons.
9.4.3 Push the latch over each button, making sure
the rubber is fastened under the button.
9.5 Removing and Replacing the Cape
9.5.1 When the cape becomes soiled or requires
replacement, it can easily be removed as follows.
9.5.2 Separate the Velcro®tabs on the back of the
cape. Refer to Figure 6.
Retaining Slot
(one on each side)
Holding Tab
(one on each side of
the window flange)
Lens Gasket
with Inner Lens

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HELMET MODEL 20
© 2011 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 21991
Figure 6
9.5.3 Slide the ends of the cape to the notch.
Continue sliding one end of the cape out of the groove
until the entire cape is detached from the helmet.
9.5.4 To install the cape, separate the Velcro®tabs on
the cape and slide one end into the groove on the
bottom edge of the cape attachment strap at the point
where the groove is notched. Continue sliding the cape
around the bottom of the helmet until the entire cape is
completely into the groove. NOTE: Spraying a small
amount of food grade silicone into the groove will reduce
friction and ease assembly.
9.5.5 Join the Velcro®tabs at the notch.
9.6 Removing and Replacing Suspensions
9.6.1 Standard Padded Suspension
9.6.1.1 All pads are held in place with strips of adhesive
backed, hook and loop fastener material (the green side
of the pad is Velcro®receptive, the black side is not).
Remove the side and middle pads by pulling them free
of the hook-fastener strip.
9.6.1.2 Remove the suspension web, by extracting the
plastic tabs from the mounting slots in the helmet shell.
While holding the top pad in place, pull the webbing to
separate it from the top pad.
9.6.1.3 To remove the top pad, hold the air baffle
partition (Figure 7, item 10) in place, and pull the pad to
separate it from the partition.
9.6.1.4 Inspect the chin strap, and if necessary replace
it before installing the suspension.
9.6.1.5 Make sure the air baffle partition is correctly
located, before installing the top pad. Align the pad while
pressing it into place against the fastener strip.
9.6.1.6 Place the suspension web under the chin strap
and then secure the suspension by inserting the plastic
tabs into their respective mounts; the yellow tabs go on
the side mounts.
9.6.1.7 Align the middle pad so the elastic cord is
toward the back and the center of the pad is centered to
the suspension web. Press the pad to engage the
fastener strip, minor repositioning may be needed to fully
seat the pad.
9.6.1.8 Place the Velcro®receptive green side of the
side pad against the helmet shell, Attach it by pressing it
onto the fastener strips. The black side faces the
operator’s head.
9.6.1.9 Reattach the cape to the helmet by following the
instructions in Section 9.5.
9.6.2 Web Suspension with Sweatband, Alternate
9.6.2.1 Remove cape from the helmet per Section 9.5.
9.6.2.2 Remove and discard the old suspension and
suspension strap by extracting the plastic tabs from the
wedge-shaped clefts in the shell.
9.6.2.3 Unfasten the vinyl sweatband from the two
lower, outside buttons, ref. Figure 3.
9.6.2.4 The suspension fits head sizes 6.5 to 8. Head
sizes are marked on the headband slots. Slide the
headband tongue in or out of the guide, to attain the
desired head size. It is important that the adjustment be
made evenly on both sides. Press the selected slots
firmly onto the fastening lugs on the front band.
9.6.2.5 Refasten the vinyl sweatband onto the
suspension buttons.
9.6.2.6 Install the suspension strap before installing the
suspension. Insert the yellow end tabs into the clefts on the
helmet shell. When correctly installed, the strap is between
the suspension and helmet shell and above the ears.
9.6.2.7 Install the suspension by inserting the four white
plastic tabs into the clefts on the shell. The tabs must
fully seat in their respective clefts.
9.6.2.8 Try on the helmet for fit and readjust if
necessary. It is not necessary to remove the suspension
to make adjustments.
Notch
Velcro
®
Tab

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HELMET MODEL 20
© 2011 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 21991
9.6.2.9 Make sure the chin strap is in place, then
reattach the cape to the helmet by following the
instructions in Section 9.5.
9.7 Chin Strap
9.7.1 Replace the chin strap when worn or when it
loses its elasticity.
9.8 Removing and Replacing the Air Channel
Partition
9.8.1 Remove the cape and suspension per Sections
9.5 and 9.6.
9.8.2 Pull the partition from the front to unsnap it from
the retainers. Remove the back end of the partition from
the tabs.
9.8.3 Place a new partition into the hood; insert the
slots on the back end of the partition behind the tabs.
9.8.4 While applying pressure on the front of the
partition, work from the back toward the front and snap it
into place.
9.8.5 Replace the suspension and cape.
10.0 REPLACEMENT PARTS
WARNING
Use of any non-Clemco replacements parts may
permit ingress of hazardous contaminants, and
may cause injury, disease, or death to the user.
OSHA Regulation 29 CFR 1910.134(H)(4)(i)
requires the use of the respirator
manufacturer’s NIOSH-approved parts
designated for the respirator. Using any parts
listed in this section made by any manufacturer
other than Clemco voids the NIOSH approval,
and voids Clemco’s warranty.
10.1 Supplied-Air Respirator Systems and
Alternate Accessories
Respirator Systems
Description Stock No.
Apollo 20 LP Supplied-Air Respirator with Standard
DLX Padded Suspension
less respirator hose...........................................25292
with 50-foot respirator hose..............................25293
Accessories
Description Stock No.
Constant-flow connector, LP with belt ....................21777
Pressure conversion kit, LP to HP
Converts Apollo 20 LP, low pressure
(ambient air) respirator to high pressure
(Grade “D” Compressed Air) respirator................22690
DLX padded suspension kit
Includes everything needed to replace padded
suspension, or to convert from web suspension
to DLX padded suspension ...............................25215
Hearing protection muffs,
Low profile noise reduction muffs
for use with web suspension w/sweatband only.
May not work with all head sizes .......................23886
Do-rag, washable head scarf .................................23814
CMS-3 CO monitor package...................................24612

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HELMET MODEL 20
© 2011 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 21991
10.2 Respirator Replacement Parts, Figure 7
Item Description Stock No.
1. Gasket, molded window ........................... 99996
2. Inner lens, 4-5/8" x 6-5/8" nom., .125"
package of 5 .......................................... 21409
3. Middle lens, 5" x 7" nom., .094"
package of 5 .......................................... 21410
4. Cover lens, perforated, .0075"
package of 25 ........................................ 21411
5. Gasket, lens frame .................................. 21041
6. Lens frame ................................................ 20976
7. Latch, lens frame, rubber .......................... 21298
8. Button, latch .............................................. 21040
9. Respirator hose,
1/2" x 50 ft. (alternate) ........................... 22510
1/2" x 100 ft. (alternate) ......................... 21413
10. Partition, air baffle...................................... 21118
11. Cape attachment strap ............................. 10534
12. Cape with inner collar ............................... 21301
13. O-Ring, 7/8" OD, 2 required ..................... 22815
14. Breathing tube assembly
includes two of item 13 .......................... 22811
15. Constant-flow connector, LP w/o belt ....... 21429
16. Belt, 2" web with buckle............................. 04430
17. Nut, lens frame, 2 required .......................90041
18. Screw, lens frame, 2 required ................... 90295
19. Screw, 8-32 x 1/2" for latch, 2 required .... 21402
20. Screw, 8-32 x 1" for latch, 2 required........21403
21. Chin Strap .................................................04460
22. Chin strap holder, 2 required ....................21696
23. Screw, 8-32 x 1/2” Ph Hd, 2 required ....... 21119
24. DLX padded suspension kit
includes items 25 thru 29 ....................... 25215
25. Pad, top .................................................... 25216
26. Suspension web ....................................... 25219
27. Pad, middle ............................................... 25182
28. Pad, side ..................................................25218
29. Hook-fastener tape, adhesive backed,
1-inch x 2-feet long................................. 24655
30. Web suspension w/sweatband (alternate) 10532
Some items are rotated for clarity
Figure 7
4
2
3
18 6
11
16
9
10
30
14
15
22
5
12
8
,
19
,
20
23
1
13
13
21
17
7
25
26
27
28
29
DLX Padded
Suspension
24