Clemco 1028 User manual

WARNING
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.
SINGLE CHAMBER BLAST MACHINE
MODELS 1028 AND 1042
O. M. 04124
DATE OF ISSUE: 01/15/77
REVISION: K, 07/13
© 2013 CLEMCO INDUSTRIES CORP.
One Cable Car Dr.
Washington, MO 63090
Phone [phone]
Fax [phone]
Email: [email protected]
www.clemcoindustries.com

MODELS 1028 & 1042 BLAST MACHINES Page 1
© 2013 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 04124, Rev. K
1.0 INTRODUCTION
1.1 Scope
1.1.1 These instructions include the set-up, operation,
maintenance, troubleshooting, and replacement parts for
Clemco Model 1028 (0.5 cu ft. capacity) and Model 1042
(1.0 cu ft. capacity) blast machines. The instructions
cover remote-controlled machines (when an operator
controls blasting from a pneumatically operated control
handle mounted at the nozzle), and manually-controlled
machines (a blast machine fitted with simple ball valves
at the inlet and outlet, that must be manually opened
and closed to start and stop the blast process). The
following separate manuals are included with a blast
machine when furnished with remote controls.
TLR-50 Remote Controls, Manual No. .......... 03358
RLX Control Handle, Manual No. ................... 10574
1.1.2 OSHA requires remote controls on all blast
machines when a blast operator commands the nozzle
Ref 29 CFR 1910.244(b). Manually-controlled blast
machines are allowed only where the nozzle is fixed to a
supporting fixture, and separated from the operator and
surrounding personnel. If this machine is intended for
use with a blast operator, and it is not equipped with
remotes controls, contact a Clemco distributor for a
TLR-50 remote control system (Stock No. 02518).
1.1.3 These instructions contain important safety
information. All operators and personnel involved with
the abrasive blast process must read and understand
the contents of these instructions, including the orange
cover. It is equally important that the operator is trained
and qualified to safely operate the blast machine and
remote controls, and all other equipment used with the
blast machine.
1.1.4 All personnel involved with the abrasive blasting
process must be made aware of the hazards associated
with abrasive blasting. The Clemco booklet Abrasive
Blasting Safety Practicesis included with every blast
machine, and contains important safety information
about abrasive blasting that may not be included in
equipment operation manuals. To order additional
copies, visit www.clemcoindustries.com or email
[email protected].
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 Description
1.3.1 The primary components of the blast machine
are shown in Figure 1.
1.3.2 Clemco blast machines (pressure vessels) are
manufactured to American Society of Mechanical
Engineers (ASME) standards, as described in Section
VII, Div. 1, and carry National Board certification. It is the
owner’s responsibility to maintain the integrity of the
vessel. In some states this may include regular
inspection and hydrostatic testing as described in
National Board Inspection Code and jurisdictional
regulations and /or laws.

MODELS 1028 & 1042 BLAST MACHINES Page 2
© 2013 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 04124, Rev. K
Figure 1
WARNING
Welding, grinding, or drilling on the blast
machine could weaken the vessel. Compressed
air pressure could cause a weakened blast
machine to rupture, resulting in death or
serious injury. Welding, grinding, or drilling on
the blast machine vessel, without a National
Board R stamp voids the ASME and National
Board certification.
1.3.3 All welding repairs done on the vessel must be
performed by certified welders, at shops holding a
National Board R Stamp. Welding performed by any
welder not properly qualified per the ASME Code voids
ASME and National Board certification of the vessel.
1.3.4 This blast machine is rated for a maximum
working pressure of 125 psi (pounds per square inch);
do not exceed the rated pressure.
WARNING
Excessive compressed air pressure could
cause a blast machine to rupture. To prevent
serious injury or death, do not exceed the rated
pressure of the blast machine.
1.3.5 OSHA does not require pressure relief valves on
blast machines when air compressors supplying air to
the blast machines are built to ASME(1) specifications
and comply with OSHA(2) regulations. ASME Manual
section VIII, Division 1, UG-125, paragraph A90 (g)
states that pressure relief valves or protective devices
"...need not be installed directly on a pressure
vessel when the source of pressure is external to
the vessel
Model 1028, 0.5 Cu Ft
Shown with remote controls
Model 1042, 1.0 Cu Ft.
Shown with manual valves
Manual Outlet Valve
Manual Inlet Va
lve
Choke Valve
Outlet Valve
Inlet Valve Compressed Air Supply
Hose Connection Point
Blast-Hose Connection
A
brasive
Metering valve
Inspection Doo
r
Pop-up Valve
Optional Screen Compressed Air Suppl
y
Hose Connection Point

MODELS 1028 & 1042 BLAST MACHINES Page 3
© 2013 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 04124, Rev. K
Compressed Air and Abrasives Consumption
Consumption rates are based on abrasives that weigh 100 pounds per cubic foot
Pressure at the Nozzle (psi) Air, Power
Nozzle and Abrasive
Orifice Size (inch) 50 60 70 80 90 100 Requirements
11 13 15 17 19 20 Air (cfm)
No. 2 (1/8 inch) 67 77 88 101 112 123 Abrasive lbs/hr)
2.5 3 3.5 4 4.5 5 Compressor (hp)
26 30 33 38 41 45 Air (cfm)
No. 3 (3/16 inch) 150 171 196 216 238 264 Abrasive (lbs/hr)
6 7 8 9 10 10 Compressor (hp)
47 54 61 68 74 81 Air (cfm)
No. 4 (1/4 inch) 268 312 354 408 448 494 Abrasive (lbs/hr)
11 12 14 16 17 18 Compressor (hp)
Air requirements were measured by a flow meter under actual blasting conditions, and are therefore lower than figures
for air alone, with no abrasive.
Horsepower requirements are based on 4.5 cfm per horsepower.
Figures are for reference only, and may vary for different working conditions. Several variables, including metering valve
adjustments, can affect abrasive flow.
Figures show approximate compressed air and abrasive consumption when nozzles are new. Consumption will increase
as the nozzle wears.
Figure 2
and is under such positive control that the pressure
in the vessel cannot exceed the maximum allowable
working pressure at the operating temperature...".
OSHA regulation 1910.169 refers to the above ASME
code when describing the necessity of pressure relief
valves on compressed air equipment. DO NOT operate
blast machines with air compressors that are not
equipped with properly functioning pressure relief
valves.
(1) American Society of Mechanical Engineers, Boiler and Pressure
Vessel Code, 1989
(2) Occupational Safety and Health Administration, 29 CFR 1910,
Subpart M - Compressed Gas and Compressed Air Equipment.
1.3.6 Compressed-air Requirements
1.3.6.1 The size of the compressor required depends on
the orifice size of the nozzle and blasting pressure.
Unless otherwise specified, blast machine packages are
supplied with a 1/4" orifice nozzle. Nozzles larger than
1/4" are not recommended because they will rapidly
wear the 1/2" blast hose used with these machines.
1.3.6.2 Refer to the table in Figure 2 to determine cfm
requirements. The table shows air consumption of
nozzles when new. It does not show the recommended
compressor size. As nozzles wear, they will consume
70% to 80% more air. Consult with a compressor
supplier for suggested compressor size based on the air
consumption of the next larger orifice size.
1.3.7 Remote Controls
1.3.7.1 Separate manuals are provided for the
operation, maintenance, and replacement parts for the
TLR-50 remote controls (Manual Stock No. 03358) and
RLX control handle (Manuals Stock No. 10574). Refer to
those manuals for set-up and operation of the remote
control system.
1.3.8 Air Filter, Optional
1.3.8.1 The optional air filter at the blast machine inlet
removes water condensed in the compressed air line. Its
use is especially important in areas of high humidity, or
when fine-mesh abrasive is used. Moisture causes
media to clot and inhibits free flow through the metering
valve. See Section 7.1 for accessories. If moisture
problems persist, an air dryer may be required.

MODELS 1028 & 1042 BLAST MACHINES Page 4
© 2013 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 04124, Rev. K
1.4 Abrasive
WARNING
Obtain a material safety data sheet (MSDS) for
the blast abrasive. Abrasive blasting with sands
containing crystalline (free) silica can lead to
serious or fatal respiratory disease. As OSHA
recommends, do not use abrasives containing
more than trace amounts (more than one
percent) free silica.
1.4.1 Selection of blasting abrasive can play a
significant part in the health risk, productivity, and
maintenance of the blast machine. DO NOT USE
abrasives containing more than one percent crystalline
(free) silica. Obtain material safety data sheets (MSDS)
for the blasting abrasive prior to blasting, paying
particular attention the health risks and presence of any
hazardous/toxic substances. Use only abrasives
specifically manufactured for blast cleaning, and that
are compatible with the surface being blasted. Abrasive
produced for other applications may be inconsistent in
size and shape, and contain particles that could jam the
abrasive metering valve, or cause irregular wear.
1.4.2 Abrasive Size: The choice of abrasive size
depends on the desired profile, cleaning rate, nozzle size
and availability of clean dry air. Generally, larger and
denser abrasive provide a deeper profile, while smaller
abrasives clean faster. Most abrasive blasting is done
with abrasive between 20 and 80 mesh. Larger sizes may
be used if the nozzle orifice is large enough to prevent
particles to pass without jamming. Finer abrasive is
especially sensitive to moisture and requires very dry air
to prevent bridging in the metering valve.
1.4.3 Sand: Sand should never be used because of the
respiratory hazards associated with abrasive containing
free silica.
1.4.4 Slags: Slag abrasives are compatible with the
blast machine and accessories. Obtain a material safety
data sheets (MSDS).
1.4.5 Steel: The abrasive metering valve used with the
0.5 cu. ft. and 1.0 cu ft blast machines are generally not
suitable for use with steel or iron abrasive. Steel may
wedge between the narrow gap between the pop-up valve
and pop-up guide and cause the pop-up valve to stick.
1.4.6 Silicon Carbide, Aluminum Oxide, and
Garnet: These are the most aggressive, high-volume
abrasives in the blasting industry. Aggressive abrasive
such as these may be used, but the service life will be
reduced on any equipment components which come in
contact with the abrasive. Use a nozzle lined with boron
carbide with these abrasives.
1.4.7 Glass Bead: Most beads are treated to ensure
free-flow operation even under moderately high-humidity.
Glass beads subjected to excessive moisture may be
reused after thorough drying and breaking up any lumps.
Clean dry air is a necessity. Minor surging will be noted at
startup when using glass bead.
1.4.8 Lightweight Abrasive: Plastic media and most
agricultural media may be occasionally used in a standard
blast machine. Exclusive use of plastic, and some
lightweight media, requires a blast machine with a 60o
conical bottom to maintain continuous media flow.
2.0 INITIAL SET-UP
2.1 Blast Machine Set-Up
2.1.2 Install an air supply hose fitting to the inlet valve
(or filter), that is compatible with the compressed-air
supply hose. See Section 3.2.2.
2.2 Remote Control Set-Up
2.2.1 Refer to the remote control manual for set-up
and operation of the control system.
3.0 OPERATION
3.1 Transporting and moving
3.1.1 Transporting a blast machine
WARNING
Always empty the blast machine before
lifting or hoisting.
Never hoist the machine by the handle or
piping, or with a sling through the handle or
piping.
When transporting a machine on a pallet,
always securely attach the machine to a sturdy
pallet.
Always securely anchor the machine to the
transport vehicle.
Failure to observe these warnings could
result in serious injury or death.
3.1.1.1 Always empty the machine before transporting.
Transporting a machine containing abrasive may
increase the weight to an unsafe handling limit, and
could cause abrasive to settle in the piping.

MODELS 1028 & 1042 BLAST MACHINES Page 5
© 2013 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 04124, Rev. K
3.1.2 Moving a blast machine
WARNING
Never manually move a blast machine when it
contains abrasive. Empty (model 1028 and
1042) machines may be moved when the
following criteria are met.
3.1.2.1 An empty machine may be moved manually on
level flat surfaces.
3.1.2.2 Move the machine by pushing it in a forward
direction. Do not back-up while moving the machine, as
potential tripping hazards cannot be seen.
3.2 Set-up
3.2.1 Locate the compressor upwind and/or away
from the blasting operation to prevent contaminated air
from entering the compressor intake.
3.2.2 Connect a 3/4" ID or larger air line from the
compressor to the air supply hose connector previously
installed on the blast machine inlet.
NOTE: If the air line supplies air to other pneumatic
tools, install isolation valves to enable depressurization
of each line for service.
WARNING
If twist-on type air hose couplings are used,
they must be secured by safety lock pins or
wires to prevent accidental disconnection while
under pressure. Hose disconnection while
under pressure could cause serious injury.
3.2.3 Make sure the coupling gaskets are in place and
in good condition before connecting the blast hose to the
quick coupling on the blast machine. To prevent
accidental separation during blasting, use safety lock-
pins or safety wire to lock the couplings together.
3.2.4 Make sure that all hose connections are secure.
Install safety lock pins on all quick couplings. Use lock
pins and safety cables at all quick coupling connections
to help prevent accidental separation of hoses. Lock
pins and safety cables are listed in Section 7.3.
WARNING
Hose disconnection while under pressure could
cause serious injury or death. Use safety lock-
pins and safety cables on all coupling
connections to help prevent hose couplings
from accidental disconnection.
3.2.5 Make sure the choke valve is open (handle in-
line with the piping).
3.2.6 Close the abrasive metering valve. The closed
position is when the handle is pointing toward the pipe
nipples in the metering valve.
3.2.7 Close the air valve on the compressor. Start the
compressor, and bring it up to operating temperature
and pressure. The pressure must not exceed 125 psi.
3.2.8 Load abrasive into the machine by following the
instructions in Section 3.6.
3.2.9 If the machine is equipped with manual valves,
make sure the inlet valve is closed (handle
perpendicular to the valve).
3.2.10 If the machine is equipped with remote controls,
make sure the control handle is in the "up" (no blast)
position.
3.2.11 Slowly open the compressor air valve to
pressurize the air supply line. Listen for noise that
indicates any open lines or leaks.
3.2.12 Do not allow anyone around the blast machine
except machine tenders, who are appropriately fitted
with approved personal protective equipment.
WARNING
Everyone except for the blast operator or blast
machine tender must stay clear of the blast
machine. The machine tender or blast operator
may pressurize or depressurize the machine at
any time, which could cause abrasive to vent
under pressure, causing dust and toxins to
become airborne. Noise is produced by the
sudden release of compressed air when the
machine is pressurized or depressurized. These
conditions could cause injury. Both the
operator and machine tender must wear
suitable personal protective equipment
including an approved respirator, plus
approved eye, face, and hearing protection.

MODELS 1028 & 1042 BLAST MACHINES Page 6
© 2013 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 04124, Rev. K
3.3 Manual Blasting. Refer to Section 3.4 for
blasting with remote controls.
3.3.1 Make sure the ventilation system is running.
3.3.2 Make sure the nozzle fixture is secure and that
the nozzle is directed only toward objects intended to be
blast cleaned.
WARNING
OSHA requires remote controls on all blast
machines when an operator controls the nozzle.
Ignoring this warning places the operator at
risk of severe injury or death from accidents
that could occur from an uncontrolled blast
nozzle.
3.3.3 Make sure the blasting area is contained.
WARNING
Abrasive blasting produces harmful dust.
Everyone exposed to blasting dust must wear a
properly-fitted and properly-maintained NIOSH-
approved, respiratory protection appropriate for
the job site hazards. Loud noise generated by
the use of compressed air could cause hearing
damage. Everyone exposed to the noise must
wear approved hearing protection.
3.3.4 The machine tender closes the outlet valve, and
while standing back and facing away from the concave
filling head, opens the inlet valve. This action causes the
pop-up valve to seal off the filling port and pressurizes
the blast machine.
3.3.5 If the abrasive metering valve is closed as
instructed in Section 3.2.6, only air will exit the nozzle.
Adjust the metering valve per Section 3.5.
WARNING
Never leave a pressurized machine unattended.
If an emergency occurs, such as a burst blast
hose, shut-down the machine immediately.
3.3.6 To stop blasting, the machine tender closes the
inlet valve, and while standing back and facing away
from the concave head and outlet valve, quickly opens
the outlet valve. The pop-up valve drops when air is
expelled from the machine and pressure equalizes.
3.4 Blasting with Remote Controls. Refer to
Section 3.3 for manually-controlled blasting.
3.4.1 Refer to the remote control manual to ensure
the machine is correctly set-up and ready for blasting.
3.4.2 Blasting Attire
3.4.2.1 Operators and anyone else that may be
exposed to the hazards generated by the blasting
process must wear appropriate protective gear,
including abrasive-resistant clothing, leather gloves, eye
and hearing protection, and a NIOSH-approved Type CE
Supplied-Air Respirator.
WARNING
Before blasting, test the coating and substrate
for toxic materials (such as lead or other heavy
metals, or asbestos). These hazards require
special measures to protect the operators and
the environment.
No dust is safe to breathe. Abrasive blasting
produces harmful dust. Failure to wear
approved respirators could result in serious
lung disease or death. Blast operators must
wear properly-fitted and maintained NIOSH-
approved, type-CE supplied-air respirators
approved for abrasive blasting.
During abrasive blasting, abrasive particles and
dust in the area around the blast machine and
blast nozzle become airborne. Everyone
working in the vicinity of abrasive blasting must
wear properly-maintained, NIOSH-approved,
respiratory protection and eye protection
appropriate for the job site hazards.
Loud noise generated by the use of
compressed air could cause hearing damage.
Everyone in the blasting area must wear
approved hearing protection.
3.4.3 Close the safety petcock located on the inlet
valve. Air should now be heard escaping from the orifice
under the control handle lever, but from no other place.
3.4.4 Pull back the safety lever lock under the control
handle lever.
3.4.5 Point the nozzle only toward objects intended to
be blast cleaned.
3.4.6 While holding the lever lock down, press the
control handle lever. Be prepared; blasting will begin as
soon as the machine pressurizes.

MODELS 1028 & 1042 BLAST MACHINES Page 7
© 2013 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 04124, Rev. K
WARNING
OSHA requires remote controls on all blast
machines when an operator controls the nozzle.
Do not tie down the control handle or attempt to
bypass any part of the remote control system.
Doing so will defeat the purpose of the fail-to-
safe feature of the remote control. Severe injury
or death can result from uncontrolled blasting.
3.4.7 If the abrasive metering valve is closed as
instructed, in Section 3.2.6, only air will exit the nozzle.
Adjust the metering valve per Section 3.5.
3.4.8 To stop blasting, release the control handle
lever. The safety lever lock automatically pops up to
prevent accidental activation of the blast machine.
3.4.9 Open the safety petcock. Always open the
safety petcock during work breaks to prevent
unintentional blasting.
3.5 Adjust Abrasive Metering Valve
3.5.1 Abrasive flow is adjusted with the metering
handle. Begin adjustments with the metering valve
closed. Closed is when the handle is turned fully
clockwise when viewed from the top.
3.5.2 Increase abrasive flow by moving the handle
counterclockwise, at 1/8" or increments or less, allowing
time for the flow to stabilize before readjusting.
3.5.3 Optimum abrasive flow depends on the type and
size of abrasive and blast pressure, and can best be
determined by experience. Use as little abrasive as
possible while maintaining the maximum cleaning rate.
The air/abrasive mixture should be mainly air. The
abrasive exiting the nozzle should barely discolor the air
when seen against a contrasting background.
3.6 Loading Abrasive into the Blast Machine
3.6.1 Depressurize the machine using procedures for
manual blasting per Section 3.3, or blasting with remote
controls per Section 3.4.
3.6.2 Load abrasive into the machine by pouring it into
the concave head. Using an optional screen, placed
over the head, prevents large objects from falling inside.
A screen is recommended to keep objects such as
pieces of abrasive bags and rocks from falling into the
machine. Foreign objects will jam the machine. Abrasive
flows through the filling port into the machine. Keep the
abrasive level below the pop-up valve to prevent
abrasive on the pop-up valve from being forced up and
out of the top of the machine when the machine is
pressurized.
3.6.3 After the machine is filled, use procedures for
manual blasting per Section 3.3, or blasting with remote
controls per Section 3.4, to begin blasting.
3.7 Emptying the Machine of Abrasive
3.7.1 When working in environments subject to
extreme temperature changes, or very humid conditions,
condensation may develop inside the machine.
Condensation wets abrasive and causes flow problems.
To prevent this, empty the machine of all abrasive when
shutting down for the day. This will eliminate trouble from
moist abrasive when starting a new day's blasting. One
way to avoid having to empty the machine is to load only
as much abrasive as will be used during the work period.
If the machine must be purged of abrasive, do the
following:
3.7.2 With the blast machine off, turn the blast
pressure to approximately 40-50 psi, close the choke
valve, and set the abrasive metering valve at full open.
3.7.3 Purging the machine without a nozzle, will
eventually erode the thread area of the nozzle holder,
which could cause a hazardous condition. To prevent
wear of the nozzle holder threads, the nozzle should be
firmly attached to the nozzle holder. Removal of the
nozzle is not recommended. If circumstances require the
nozzle to be removed, also remove the nozzle washer.
WARNING
The threads on the nozzle and nozzle holder
must be inspected each time the nozzle is
secured to the holder. A loose fitting nozzle
may eject under pressure and could cause
severe injury. Check the threads for wear, and
make sure the nozzle holder securely holds the
nozzle. The nozzle washer must also be
inspected for wear. When nozzle washers are
worn, abrasive could erode nozzle threads.
3.7.4 Point the nozzle (or hose end) into a drum or
suitable container, or in the direction of the abrasive
disposal location.
3.7.5 Ensure that the hose is secure, and pressurize
the machine.
3.7.6 Depressurize the machine when empty, and
open the choke valve.

MODELS 1028 & 1042 BLAST MACHINES Page 8
© 2013 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 04124, Rev. K
3.7.7 If the nozzle was removed, thoroughly inspect
the nozzle holder threads for wear before installing the
nozzle washer and attaching the nozzle.
3.8 Shutdown
3.8.1 When finished blasting, and after cleanup is
completed, remove the respirator outside the respirator-
use area and where the air is safe to breathe.
3.8.2 Depressurize the blast machine.
3.8.3 Close the compressed-air supply valve at the
compressor.
3.8.4 Drain receiver tank, filters, and water collecting
devices, and bleed the compressed-air supply hose.
3.8.5 Shutdown the compressor.
3.8.6 Cover the machine when not in use. Refer to
Section 7.1 for optional covers.
4.0 PREVENTIVE MAINTENANCE
NOTE: These preventive maintenance instructions
pertain to the blast machine. Read the owners manuals
for all blast accessories, for their inspection and
maintenance schedules.
4.1 Daily Inspection
4.1.1 With the air off, before blasting, inspect the
following:
Make sure that couplings are secure and lock pins
and safety cables are in place.
For machines with manual controls, make sure the
nozzle supporting fixture is secure.
4.1.2 During blasting, inspect the following:
Inspect all couplings and coupling gaskets for leaks.
Check the blast machine for leaks. If leaks are found
around the pop-up valve, inspection door, or pipe
fittings at the bottom of the cone, stop blasting
immediately and repair or replace worn parts.
CAUTION
If leaks are allowed to continue, abrasive
erosion could cause extensive or irreparable
damage to the blast machine.
Check all external piping, control hoses, and valves
for leaks. If leaks are found, stop blasting and repair.
Inspect blast hose, couplings, and nozzle holders for
leaks. At the first sign of a leak, stop blasting and
inspect all items for wear. Replace worn parts.
WARNING
Leaks around couplings and nozzle holders
indicate worn or loose-fitting parts. Nozzle
holders and couplings that do not fit tightly on
hose, and nozzles that do not fit tightly in
nozzle holders could disconnect while under
pressure. Impact from nozzles, couplings,
hoses, or abrasive, and parts disconnected while
under pressure could cause severe injury.
4.2 Weekly Inspection
4.2.1 With the air off, before blasting, inspect the
following:
Inspect the blast hose for wear; squeeze the hose
every three to four feet, look for soft spots. Soft
spots mean the hose is worn. Replace the blast
hose before the tube wears as far as the fabric plies.
WARNING
Worn blast hose could suddenly burst.
Couplings and nozzle holders may not
adequately grip worn hose, causing them to
blow off under pressure. Compressed air and
abrasive escaping from a burst hose, or
disconnected coupling or nozzle holder, could
cause severe injury.
Remove the nozzle for inspection. Replace if the
diameter is worn 1/16or more, or if the liner is
cracked.
Make sure the nozzle washer is in place and not
worn.
WARNING
The threads on the nozzle and nozzle holder
must be inspected each time the nozzle is
secured to the holder. A loose fitting nozzle
may eject under pressure and could cause
severe injury. Check the threads for wear, and
make sure the nozzle holder securely holds the
nozzle. The nozzle washer must also be
inspected for wear. When nozzle washers are
worn, abrasive could erode nozzle threads.
When an optional air filter is used, inspect the filter
element, and clean the bowl.

MODELS 1028 & 1042 BLAST MACHINES Page 9
© 2013 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 04124, Rev. K
4.3 Monthly Inspection
4.3.1 With the air off, before blasting, inspect the
following:
Check the pop-up valve’s urethane coating for
cracks and grooves. Replace the pop-up valve at
the first sign of wear. See Section 5.3.
Inspect the rubber pop-up seal, and replace at the
first sign of wear, drying, or cracking. See Section 5.4.
5.0 SERVICE MAINTENANCE
WARNING
Failure to observe the following before
performing any maintenance could cause
serious injury or death from the sudden release
of compressed air.
Depressurize the blast machine.
Lockout and tagout the compressed air
supply.
Bleed the air supply line to the blast
machine.
5.1 Removing damp abrasive from the blast
machine.
5.1.1 To clear a minor blockage caused from damp
abrasive, during operation, rapidly open and close the
choke valve several times.
5.1.2 For more difficult blockages, proceed as follows:
See Section 5.2 to check for obstructions in the metering
valve.
5.1.3 With the blast machine depressurized,
disconnect the blast hose and remove the gasket from
the quick coupling on the machine.
5.1.4 Place the machine so that the outlet is pointed
away from any objects or persons.
WARNING
Place the machine so that the outlet is pointed
away from any objects or persons. Stand clear
of the path of exiting abrasive. It may come out
at high velocity. Impact from exiting abrasive
could cause severe injury.
5.1.5 Close the choke valve and fully open the
abrasive metering valve. Pressurize the machine to
force out any damp abrasive.
5.1.6 When the obstruction has been cleared,
depressurize the machine. Remove the nozzle and
nozzle washer, and reconnect the hose. Open the choke
valve and close the abrasive metering valve. Pressurize
the machine to clear the hose. When the hose is
cleared, depressurize the machine so the nozzle and
nozzle washer can be attached.
WARNING
The threads on the nozzle and nozzle holder
must be inspected each time the nozzle is
secured to the holder. A loose fitting nozzle
may eject under pressure and could cause
severe injury. Check the threads for wear, and
make sure the nozzle holder securely holds the
nozzle. The nozzle washer must also be
inspected for wear. When nozzle washers are
worn, abrasive could erode nozzle threads.
5.1.7 With the hose cleared, start the machine using
procedures for manual blasting per Section 3.3, or
blasting with remote controls per Section 3.4.
5.2 Clearing obstructions in the abrasive
metering valve and blast machine.
5.2.1 If the nature of the obstruction permits emptying
the machine of abrasive, follow the instructions per
Section 3.7.
5.2.2 Turn off the compressed air supply. Lockout and
tagout the air supply, and bleed the air supply line to the
blast machine.
5.2.3 Remove the inspection plate and check the
inside of the machine for obstructions from foreign
objects.
5.2.4 Check the inside of the machine for signs of
moisture. If moisture is present, condensation is in the
compressed air, and must be eliminated.
5.2.5 Make sure the inspection door gasket is in good
condition and that it is correctly in place before bolting
the door onto the machine.
5.2.6 Check to make sure all inspection door and
hoses are secure before starting the compressed air
supply.
5.3. Replacing the Pop-Up Valve, Figure 3
5.3.1 All service on the pop-up valve must be done
with the compressed air off and the air supply locked-out
and tagged-out.

MODELS 1028 & 1042 BLAST MACHINES Page 10
© 2013 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 04124, Rev. K
5.3.2 To gain access to the pop-up valve, remove the
inspection door assembly.
5.3.3 Using a small pipe wrench, unscrew the pop-up
valve guide by turning it counterclockwise. Remove the
pop-up valve and guide from the machine.
5.3.4 While the pop-up valve is out, check alignment.
A misaligned pop-up valve could result in early valve
failure, or abrasive leakage when the machine is
pressurized or depressurized.
Figure 3
5.3.5 Slide the new pop-up valve into the guide, and
then screw the valve guide (with the pop-up valve in it)
into position inside the machine. Tighten the guide until
wrench-snug, but not wrench-tight. Over-tightening the
guide will make it difficult to remove the next time the
pop-up valve needs replacement.
5.3.6 Put a new gasket on the inspection door
assembly before bolting the door onto the machine.
5.4 Replacing the Pop-Up Seal
5.4.1 All service on the blast machine must be done
with the compressed air off and the air supply locked-out
and tagged-out.
5.4.2 If unable to change the seal using the following
methods, or if the seal falls inside the machine, remove
the inspection door and work from inside the machine.
5.4.3 Remove the old seal using fingers, screwdriver,
or similar object, to work the seal out of the retaining
groove.
5.4.4 Push the new seal all the way through the port
and then fit it into the retaining groove. For the last few
inches, pull up on the seal and allow it to pop into position.
6.0 TROUBLESHOOTING
NOTE: This section only identifies conditions and
problems in the blast machine. Always refer to the
appropriate section of this manual, or manuals for
the remote controls or other accessory equipment,
before servicing the equipment.
WARNING
To avoid serious injury when troubleshooting
the machine, turn off the compressed air, and
lockout and tagout the air supply.
6.1 Neither abrasive nor air comes out of the
nozzle while the machine is under pressure
6.1.1 Depressurize the blast machine. After the pop-
up valve has dropped, remove the nozzle, and check for
obstruction.
6.1.2 Make sure that both the abrasive metering valve
and choke valve are open.
6.2 Air only (no abrasive) comes out the nozzle
6.2.1 Abrasive metering valve may be closed or
needs adjustment. Adjust the metering valve per Section
3.5.
6.2.2 Blast machine may be empty.
6.2.3 Abrasive may be damp. Refer to Section 5.1 to
clear damp abrasive.
6.2.4 There may be an obstruction in the machine.
Check for obstructions per Section 5.2.
6.3 Heavy abrasive flow
6.3.1 Make sure the choke valve is open. The valve is
open when the handle is in-line with the piping.
6.3.2 Abrasive metering valve may be open too far.
See Section 3.5.
Loosen Tighten
Pop-up Guide
Pop-up Valve

MODELS 1028 & 1042 BLAST MACHINES Page 11
© 2013 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 04124, Rev. K
6.4 Abrasive surging
6.4.1 A certain amount of abrasive surge is normal at
start-up. Should the flow of abrasive continue to surge,
reduce the amount of abrasive in the air stream by
adjusting the metering valve. See Section 3.5.
6.4.2 Rapidly depressurize the machine. Slow
depressurization will load the blast hose with abrasive,
and cause surging at start-up.
6.5 Intermittent abrasive flow
6.5.1 Moisture in the blast machine or in the air
supply. Drain moisture from the compressor's receiver
tank, and if so equipped, the blast machine's air filter. If
moisture continues to be a problem, a dryer or
aftercooler may be required in the air supply line.
6.5.2 Abrasive may be worn from recycling. Replace
abrasive.
6.6 Blast machine will not pressurize
6.6.1 Make sure the compressor is "on" and all air
supply valves to the machine are open.
6.6.2 Insufficient-size air supply hose or reduced-size
fittings between the compressor and blast machine. See
Section 3.2.2.
6.6.3 Dirty filter element in air filter. Check filter
element.
6.6.4 Pop-up valve stuck, or internal piping worn or
out of alignment. Inspect internal piping.
7.0 REPLACEMENT PARTS
7.1 Accessories, not shown
Description Stock No.
Remote control system, TLR-50 ............................02518
Filter, 1/2" NPT with manual drain .........................01308
Regulator, 1/2" pressure ........................................01902
Cover, blast machine, poly .................................... 15097
Cover, 10" diameter, steel......................................03107
Screen, 10" diameter ............................................. 03362
Blast hose, 1/2" ID x 25 ft. 2-braid
without couplings ............................................. 23750
coupled with 00577 and 00599 ....................... 01268
Holder, nozzle, CHE-1/2 ........................................ 00577
Coupling, CQA-1/2 quick .......................................00599
Gaskets, CQG, for 00559, pack of 10 ................... 00850
Nozzle, tungsten lined, 3/4" NPT x 1-3/4" long
CT-2, 1/8" orifice ............................................. 01351
CT-3, 3/16" orifice ...........................................01352
CT-4, 1/4" orifice ............................................. 01353
Nozzle, boron lined, 3/4" NPT x 1-3/4" long
CTB-2, 1/8" orifice ...........................................21090
CTB-3, 3/16" orifice .........................................21091
CTB-4, 1/4" orifice ...........................................21092
Washers, NW-1 for CT & CTB nozzle, pack of 10 21580
7.2 Abrasive Metering Valve, 1/2-In. NPT
Figure 4
Item Description Stock No.
(-) Metering valve assembly, Model MSV ..... 01247
1. Upper valve body ......................................01258
2. Gasket, valve body ...................................01260
3. Metering plate and stem ...........................01261
4. O-ring, .......................................................00794
5. Pin, handle ................................................01263
6. Washer, nylon ...........................................01266
7. Lower valve body ......................................01259
8. Spring .......................................................02178
9. Handle, metering ......................................01262
10. Cap screw, 5/16-NC x 1-3/4" ....Purchase locally
11. Nut, 5/16-NC hex ......................Purchase locally
Figure 4
4
3
6
2
11
7
9
5
8
1
10

MODELS 1028 & 1042 BLAST MACHINES Page 12
© 2013 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 04124, Rev. K
7.3 Blast Machines, Replacement Parts
and Accessories, Figure 5
Item Description Stock No.
(-) Model 1028, 0.5 cu. ft. capacity blast Machine
without
remote controls ..........................21050
with TLR-50 remote controls ..................21051
(-) Model 1042, 1.0 cu. ft. capacity blast Machine
without
remote controls ..........................21052
with TLR-50 remote controls ..................21053
1. Seal, pop-up, rubber .................................01245
2. Pop-up valve and shaft .............................
01242
3. Handle, 1/2" ball valve ...............................01252
4. Valve, 1/2" NPT ball w/ handle ..................01241
5. Wheel, 6" diameter, rubber tire ................. 02326
6. Metering valve, abrasive ...........................
01247
7. Coupling, CFA-1/2, 1/2" NPT alum. ..........
00558
8. Gasket, inspection door, 3" x 4" ................
01249
9. Inspection door assembly, 3" x 4" .............
01267
10. Gaskets, CQG, for 00558, pack of 10 .......
00850
11.* Pusher line assembly, flexible
11" nominal for model 1028....................24621
19" nominal for model 1042 ...................24622
12.* Adaptor, 1/2" NPT x 3/4 JIC ......................25084
13. Axle ........................................................... 02404
14. Washer, 3/4" thrust ....................................03804
15. Retaining ring ............................................03805
16. Screen, 10" dia. .........................................03362
17. Cover, 10" dia. ...........................................03107
18. Lock pin, coupling, package of 25 ............. 11203
19. Safety cable, 1/2" to 1-1/4" OD hose ........
15012
*Flexible pusher lines are supplied on factory
machines as of October 1, 2011. Hard, formed-
pipe pusher lines are no longer available.
Figure 5
2
1
8
9
4
4
3, 4
3
3
12
10 7
6
13
14
16
17
15
5
19
18
11