Clemco TLR 100 Series User manual

TLR 100/300 SERIES
PNEUMATIC REMOTE CONTROLS
O. M. 22428
MC FILE NUMBER: 2068-1298
DATE OF ISSUE: 12/98
REVISION: B, 10/09
© 2009 CLEMCO INDUSTRIES CORP.
ONE CABLE CAR DR.
WASHINGTON, MO 63090
Phone [phone]
Fax [phone]
Email: [email protected]
www.clemcoindustries.com
Do not proceed with
these instructions until
you have READ the
orange cover of this
MANUAL and YOU
UNDERSTAND its
contents. *
These WARNINGS are
included for the health
and safety of the
operator and those in
the immediate vicinity.
*If you are using a Clemco Distributor
Maintenance and Part Guide, refer to
the orange warnings insert preceding
the Index before continuing with the
enclosed instructions.
Electronic files include a Preface
containing the same important
information as the orange cover.
WARNING

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

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

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

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

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 1
© 2009 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 22428
1.0 INTRODUCTION
1.1 Scope
1.1.1 This manual covers installation, operation,
maintenance, troubleshooting, and replacement parts for
the following Clemco Remote Control Systems.
TLR-100, 1" w/Piston outlet .................................01935
TLR-300, 11/4" (11/2" inlet) w/Piston outlet ............ 01936
TLR-100D, 1" w/Diaphragm outlet........................03449
TLR-300D, 11/4" (11/2" inlet) w/Diaphragm outlet.. 03448
Note: The following remote control systems include an
Abrasive Cut-off (ACS). The optional system uses a
pneumatically operated abrasive metering valve.
Operation instructions and replacement parts for the
metering valve are supplied with the valve.
TLR-100-C, 1" w/Piston outlet .............................. 07632
TLR-300-C, 11/4" (11/2" inlet) w/Piston outlet ........ 07633
TLR-100D-C, 1" w/Diaphragm outlet.................... 07634
TLR-300D-C, 11/4" (11/2" inlet) w/Diaphragm out.. 07635
1.1.2 All blast operator(s) and machine (pot) tenders
must be trained in the safe operation of the remote
control system and all blasting accessories. The
operators and all personnel involved with the abrasive
blasting process must know about the hazards
associated with abrasive blasting. Before using the
machine, all personnel involved with the blast machine
operation must read this entire manual, including the
orange cover, and all accessory manuals. Some
accessory manuals that may be used with the remote
controls are shown below. Manuals are available on our
web site at www.clemcoindustries.com.
Classic Blast Machine with Remote Controls ......22501
RLX Control Handle ............................................ 10574
Muffler Service .....................................................22322
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 General Description
1.3.1 A remote control system is an OSHA-required
safety device. The control handle, located near the blast
nozzle, is the activator for the remote control system.
When the operator intentionally or unintentionally
removes hand-held pressure from the remote control
handle, the machine deactivates, stopping air and
abrasive flow through the nozzle. The remote control
system “fails to safe”, which means any interruption in
the control-air circuit for reasons such as a break in the
line, the compressor stops running, or the operator drops
the blast hose, the remote controls deactivate the blast
machine.
WARNING
Never modify or substitute remote control parts.
Parts from different manufacturers are not
compatible with Clemco equipment. If ANY part
of the remote control system is altered,
involuntary activation, which may cause serious
injury, can occur.

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 2
© 2009 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 22428
Figure 1
1.3.2 The components of a standard system are
shown in Figure 1. They include the inlet valve, piston or
diaphragm outlet valve (the piston valve is used in most
applications, the diaphragm valve is recommended for
use with fine mesh, or aggressive abrasive), RLX
Control Handle, 55-ft. and 5-ft. long twinline control
hoses, 2 control hose unions, and an 18-in. long
interconnecting hose.
1.3.3 Additional parts used with optional ACS cut-off
systems are shown in Figure 2. ACS systems include a
50 ft. single line hose, and additional 18-in. long inter
connecting hose, an RLX Control handle with ACS air
switch assembly, and a pneumatically operated
metering valve. The metering valve supplied with the
system may differ from that shown. NOTE: Instructions
and replacement parts are in the manual supplied with
the metering valve.
1.3.4 TLR-100 and TLR-300 Remote Controls are
pressure-release style systems which control the
pressurization and depressurization of the blast
machine. Pressurization occurs when the control handle
is pressed and depressurization occurs when the handle
is released.
1.4 Operating Principles
1.4.1 Clemco TLR Remote Controls operate
pneumatically on return air (See Figure 1). If the control
handle lever (the main activator of the system) is in the
up (no blast) position, one stream of air travels down the
outbound side of the twinline and escapes through an
opening located under the lever. The normally-closed
inlet valve remains closed, and the normally-open outlet
valve remains open. When the control handle lever is
pressed, the opening is sealed, and air in the outbound
line returns through the inbound line to open the inlet
valve and close the outlet valve. This action pressurizes
the blast machine and begins the blasting process.
Releasing the handle exhausts the control air, which
closes the inlet valve, and opens the outlet valve to
depressurize the blast machine and stop the blasting.
1.4.2 Abrasive Cut-Off (ACS)
The abrasive cut-off switch is mounted on the control
handle. The ACS closes the metering valve independently
of the blasting, so air without abrasive exits the nozzle. The
operator uses this feature for blow-down.
When using a regulator to reduce
blast pressure, relocate the orifice
upstream of the regulator, and plug
the orifice port in the inlet valve.
Refer to the note in Paragraph 2.4.7. Piston Type Outlet Valve
Diaphragm Outlet Valve
Abrasive Trap
Inlet Valve
5-Ft. Twinline Hose
RLX Control Handle
50-Ft. Twinline Hose
Muffler
(accessory)
Orifice Fitting
18-Inch Hose
Safety Petcock
Elbow Adaptor
Pressure Regulator
Orifice Fitting
Twinline Hose Unions (2)

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 3
© 2009 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 22428
1.5 Electric Control Option
1.5.1 Electric remote controls (electro-pneumatic) are
recommended when the nozzle and remote control handle
are farther than 100 feet from the blast machine. Pressure
loss of pneumatic systems over longer distances increases
actuation time, which prevents fast, safe operation.
2.0 INSTALLATION
2.1 Factory installation: If the remote control has
been factory installed, skip to Paragraph 2.4. If the
remote system is equipped with the optional ACS
feature skip to Section 2.3.
2.2 Field Installation: Refer to Figure 1.
WARNING
Failure to observe the following procedure
could cause serious injury or death from the
sudden release of compressed air.
•Empty the blast machine of abrasive.
•Depressurize the blast machine.
•Lockout and tagout the compressed air
supply.
•Bleed the air supply line to the blast
machine.
2.2.1 Remove the existing inlet valve and replace it
with the TLR Inlet Valve. The directional arrow on the
valve points toward the blast machine, indicating the
direction of air flow.
2.2.2 Remove the existing outlet valve.
2.2.3 Install the abrasive trap on the blast machine as
shown in Figure 1. The air flow directional arrow points
away from the machine, and with the screen end up and
clean-out down.
2.2.4 Install the piston or diaphragm outlet valve as
follows:
2.2.4.1 Piston outlet valves must have the directional
arrow pointing away from the abrasive trap. Attach an
elbow and optional muffler. The muffler must face up as
shown in Figure 1. -OR-
2.2.4.2 Diaphragm outlet valves should be installed as
shown, with the optional muffler facing up.
WARNING
Clemco supplies an exhaust muffler with all
blast machines of 2 cu. ft. capacity and larger.
The muffler reduces exhaust noise and
prevents abrasive from exhausting upward or
sideways into the air. When the blast machine
is depressurized, the muffler body will pop up
to diffuse the air and abrasive. When the
machine is fully depressurized, the muffler
body will drop, permitting trapped abrasive to
empty. For the muffler to work properly, it must
be installed with the body facing up, as shown
in Figure 1.
If a muffler is not used, the exhaust piping must
be plumbed to direct exhausting air in a
direction that ensures no persons will be
exposed to possible injury from high velocity
air and media which escapes when the blast
machine is depressurized.
2.2.5 Connect a 3/16" x 18" air hose between the
outlet valve and one of the elbow fittings near the top of
the inlet valve as shown.
2.3 Optional ACS set up Ref. Figure 2. If the
remote control does not have the ACS feature skip to
Section 2.4.
Figure 2
Metering Valve
Valve may differ
from that shown.
ACS Switch
Assembly
RLX Control
Handle w/ ACS
50 Ft. Single Line
18 Inch Hose
Hose Union

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 4
© 2009 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 22428
2.4 Blast hose and control hose connections
WARNING
Where two or more blast machines are used,
care must be taken when tracing and
connecting control lines and blast hose. Cross
connecting control hose or blast hose could
lead to serious injury, death, or property
damage from unintentional actuation of a blast
machine. To prevent cross connecting blast
hose and control hose, the hoses should be of
equal lengths and the hoses and blast machine
couplings clearly marked, using optional hose
identification kits, part no. 15890 for use with
two blast machines, or part no. 15891 for up to
four machines. Mark each hose and
corresponding connection per the instructions
supplied with the kit, and carefully trace and
verify each connection before operating.
WARNING
Moist air that freezes could cause blockage at
the control handle or in the control lines.
Blockage could cause involuntary activation of
the remote controls, or prevent the controls
from deactivating upon release of the control
handle. This situation could result in serious
injury or death. If remote controls are operated
in freezing or near freezing weather, install a
Clemco Anti-Freeze Injector, stock no. 05537,
on the remote control air supply line.
2.4.1 Uncoil the blast hose and lay the 50-ft. twinline
hose alongside it.
2.4.2 Band the control handle to the blast hose close
to the nozzle holder, using the two nylon ties provided.
Once the control is firmly attached, clip the tie ends so
they will not snag the operator's clothing or interfere with
the operation of the control handle.
2.4.3 Attach the 50-ft. twinline hose to the two fittings
on the control handle. Either side of the hose can be
attached to either fitting.
2.4.4 Working from the control handle back, band or
tape the twinline hose to the blast hose every four to six
feet, and as close to the couplings as possible.
2.4.5 Make sure the coupling gaskets are in place and
not worn before connecting the blast hose to the quick
coupling on the blast machine. To prevent accidental
separation while under pressure, use safety lock-pins or
safety wire to lock the couplings together.
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 while under
pressure.
2.4.6 Screw the two hose unions into the unattached
fittings of the 50-ft. twinline hose.
2.4.7 Attach the 5-ft. twinline control hose to the inlet
valve as shown in Figure 1. One side of the hose
connects to the unused upper elbow, the other to the
orifice fitting. NOTE: When using a pressure regulator to
reduce blast pressure below 80 psi, relocate the orifice
upstream of the regulator as shown in the insert in
Figure 1, and plug the orifice port in the inlet valve. This
allows the pneumatic control circuit to operate at line
pressure.
2.4.8 Connect the other end of the 5-ft. twinline to the
hose unions on the 50-ft. twinline. Either side can
connect to either union.
2.4.9 Band the control hoses on the blast machine
side of the unions to the quick coupling nipple.
2.4.10 Make sure that all fittings are tight. Leaks will
cause the system to malfunction.
3.0 OPERATION
WARNING
Refer to the manuals listed in paragraph 1.1. Do
not operate this equipment before reading the
instruction manuals for all equipment.
3.1 Start-Up
3.1.1 Make sure that all hose connections are
secured with safety lock-pins and safety cables to
prevent accidental separation or disconnection.
3.1.2 Connect the blast machine to an air supply. The
compressor should be located upwind from the blasting

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 5
© 2009 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 22428
operation to prevent dust from entering the compressor
intake.
3.1.3 Make sure that the safety petcock located on the
Inlet Valve is open. The petcock is open when the
petcock lever is in-line with the petcock, as shown if
Figure 3.
Figure 3
WARNING
To prevent severe injury from accidental
activation of the blast machine, open the safety
petcock when the blast machine is not in use.
Opening the petcock prevents unintentional
blasting. The control handle can not activate
the machine when the petcock is open.
3.1.4 Make sure that the remote control handle lever
is in the up (no blast) position, and that the handle lever
and safety lock move freely.
WARNING
A separate manual is supplied with the remote
control handle. Do not operate the machine
before first reading the remote control handle
operating instructions.
3.1.5 Check to make sure that the handle lever will
not seal the opening on control handle, unless the safety
lever lock is pulled down.
WARNING
Malfunctioning control handles could cause
unintentional actuation of a blast machine, or
prevent a machine from deactivating upon
release. Malfunctioning control handles must
be taken out of service immediately and
repaired or replaced. Serious injury or death
can result from unintentional blasting.
3.1.6 Start the compressor, and bring it up to
operating temperature and pressure. The pressure must
be more than 50 pounds per square inch (psi) but must
not exceed the blast machine pressure rating.
3.1.7 Fill the machine with screened, clean, dry
abrasive that is manufactured specifically for blasting.
3.1.8 Open the compressor air supply valve, to
pressurize the air supply line. Listen for noise that
indicates any open lines or leaks.
3.1.9 Do not allow anyone within 10 feet of the blast
machine except machine tenders who are appropriately
fitted with proper protective equipment. The blast
operator could pressurize and depressurize the machine
without warning.
WARNING
All persons except for the machine tender must
stay clear of the blast machine. The blast
operator could pressurize or depressurize the
machine at any time. The noise generated by
the sudden release of compressed air when the
machine is pressurized or depressurized, may
startle bystanders, and could vent abrasive
under pressure. Either condition could result in
injury. The machine tender must wear a suitable
respirator, plus satisfactory eye, face, and
hearing protection.
3.1.10 When the blast operator is ready, either the
operator or the machine tender stands away from the
concave filling head of the blast machine, and the
exhaust muffler and then close the safety petcock.
Closing the petcock prepares the machine for remote
operation, and activation by the control handle. Air
should be heard escaping from the orifice under the
control handle lever but nowhere else. The noise from
air escaping at the control handle is an audible signal,
warning that air is supplied to the blast machine, and will
activate if the control handle is pressed.
Open
Closed

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 6
© 2009 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 22428
3.2 Blasting
WARNING
Failure to wear approved respirators could
result in serious lung disease or death.
Abrasive blasting produces harmful dust. Do
not blast without the use of a properly fitted
and maintained NIOSH-approved, type CE
Supplied-Air Respirator that is approved for
abrasive blasting. Everyone in the blasting area
must wear an approved respirator. Dust
produced in the blasting area, and the loud
noise of air released at the blast machine and
nozzle requires that approved eye protection
and hearing protection be worn by anyone in
the blasting area.
3.2.1 Operators must wear appropriate protective
gear, including: abrasive-resistant clothing, leather
gloves, eye and hearing protection, and a NIOSH-
approved Type CE Supplied-Air Respirator.
3.3 Start Blasting
3.3.1 Hold the blast hose securely and point the
nozzle only at objects intended to be blast cleaned.
3.3.2 Pull back the safety lever lock and depress the
remote control handle. Within a few seconds the pop-up
valve will automatically pop up and the blast machine
will pressurize to start blasting.
CAUTION
Be prepared for the recoil from the blast hose.
Blasting will begin within a few seconds after
pressing the control handle lever.
WARNING
OSHA requires the use of remote controls on all
blast machines. To comply with OSHA
regulations, the remote control handle which
starts and stops the flow of air and abrasive,
must be held down manually. Do not tie down
the control handle lever 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. Serious injury or death
can result from uncontrolled blasting. Ref. 29
CFR 1910.244 (b)
3.4 Operation of abrasive cut-off switch
3.4.1 By moving the ACS toggle to the "OFF" (forward
toward the nozzle) position, air supply to the metering
valve is cut off, closing the valve and stopping the abrasive
flow. This allows the operator to have air alone coming
from the nozzle, to blow abrasive off the blasted surface.
The switch can be opened or closed any time but will not
activate the metering valve unless the control handle lever
is pressed.
Note: The purpose of the ACS is to blow off abrasive
from a blasted surface. Small amounts of abrasive
may come out the nozzle with the air. Any residual
abrasive will require blow off with clean air, or other
cleaning, prior to painting.
WARNING
People and the environment can tolerate only
limited amounts of toxins. Airborne dust could
increase exposure levels beyond permissible
limits. OSHA prohibits blowing abrasive or dust
with compressed air as a clean-up method for
lead based paint dust or other hazardous dust,
unless used in conjunction with a ventilation
system designed to capture the airborne dust
created by the compressed air, 29 CFR 1926 (h).
The ACS is not to be used as a clean-up method
that will cause dust to become airborne.
3.4.2 Blast Mode
3.4.2.1 Abrasive flow is "on" when the toggle is pointing
away from the nozzle (toward the "CYL" port). The
metering valve is open and the blast machine operates
normally, with air and abrasive coming out the nozzle.
3.4.3 Blow-Down
3.4.3.1 Abrasive flow is "off" when the toggle is pointing
toward the nozzle (toward the "EXH" port). With the
abrasive flow off, only air comes out the nozzle for blow-
down.
3.5 Stop Blasting
3.5.1 To stop blasting, release the control handle. The
outlet valve will open and the blast machine will
depressurize. The pop-up valve automatically drops
when air is expelled from the machine and pressure
equalizes.
3.5.2 When the control handle lever is released, the
safety lever lock will flip up to lock the handle lever in the
up (open) position.

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 7
© 2009 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 22428
3.5.3 Make sure that the control handle safety lever
lock is up, and that it prevents the handle lever from
engaging.
3.5.4 Always open the safety petcock during work
breaks and before filling the blast machine. Opening the
petcock prevents unintentional blasting.
WARNING
When approaching an idle blast machine, and
before loading the blast machine with abrasive,
always check to make sure the safety petcock
is open. This step is especially important if one
worker (a machine tender) loads the machine
with abrasive while another worker (the blast
operator) controls the blasting. The blast
operator could pressurize the machine before
the machine tender has moved away from the
machine. During pressurization abrasive could
be forced out of the top of the machine, and
cause injury.
3.5.5 When finished blasting, and after cleanup is
completed, remove the respirator outside of the
respirator-use area, where the air is safe to breathe.
4.0 PREVENTIVE MAINTENANCE
NOTE: These preventive maintenance instructions
pertain to the remote controls only. Read the owners
manuals for the blast machine and all blast accessories,
for inspection and maintenance schedules of that
equipment.
4.1 Daily
4.1.1 With the air off, before blasting, inspect the
following:
•Empty the abrasive trap and clean the abrasive trap
screen. Do this at least twice daily, or more often, if
the machine is frequently cycled. Failure to clean the
abrasive trap on a regular basis is a major cause of
system malfunction. See Section 5.4.
•Inspect the RLX Control Handle; look for the
following:
•The lever must not seal the opening on the control
unless the safety lever lock is pulled down.
•The handle lever must return to the "up"
position when released.
•The safety lever lock must return to the "up"
position when the handle lever is released.
•Both the handle lever and safety lever lock must
move freely with no drag or binding.
WARNING
Malfunctioning control handles could cause
unintentional actuation of a blast machine, or
prevent a machine from deactivating upon
release. Malfunctioning control handles must
be taken out of service immediately and
repaired or replaced. Serious injury or death
could result from unintentional blasting.
4.1.2 While blasting, do the following:
•Check the control handle for leaks.
4.2 Weekly
4.2.1 Inspect the following while blasting.
•Inspect all control hoses, and valves for leaks. If
leaks are found, stop blasting and repair.
4.3 Periodic Inspection
NOTE: Periodic inspection of the following items will
help avoid unscheduled down-time.
4.3.1 The remote control system is a safety device. To
be safe and to avoid unscheduled down-time, the
internal parts of the inlet valve, outlet valve, and
abrasive trap should be inspected periodically. Inspect
them for wear and lubrication of O-rings, pistons,
springs, seals, and castings. See Service Maintenance
in Section 5.
4.3.2 The control handle is the actuator of the remote
control system. Periodically clean around the springs,
handle lever, and safety lever lock to ensure that the unit
is free of abrasive and debris that could cause the
handle lever or safety lever lock to bind. See the RLX
Owners Manual for service instructions.
4.4 Lubrication
4.4.1 Once per week, while the air is off, put one or
two drops of lightweight machine oil in the inlet valve
through the safety petcock. This will lubricate the piston
and O-rings in the inlet and outlet valves.

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 8
© 2009 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 22428
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 Inlet Valve, Ref. Figure 6 (1-1/2″valve) or
Figure 7 (1″valve).
5.1.1 All service on the inlet valve must be done with
the air off and the air supply locked-out and tagged-out.
5.1.2 Bottom Section
5.1.2.1 Use a wrench to loosen the bottom cap until it
can be removed by hand.
5.1.2.2 Take care when removing the cap as the
spring(s) (two are used in the 1-1/2″inlet valve) and plug
assembly will drop from the opening. Do not allow them
to fall to the ground as that could damage the castings.
5.1.2.3 Clean all parts and inspect for wear as follows:
•The small spring (only one used in 1″valve) is
approximately 1-11/16″long. If it is rusted or
compressed, replace it.
•The large spring (not used in 1″valve is
approximately 2-1/16″long. If it is rusted or
compressed, replace it.
•Inspect the valve plug washer, valve plug, and plug
retainer for damage. Replace all damaged parts.
When reassembling the valve plug assembly,
tighten the retainer enough to compress the washer,
but not so tight to cause it to bulge.
•Look into the lower opening in the valve body. If the
machined seat is worn, replace the body.
•Inspect the bottom cap seal, and replace if
damaged.
5.1.2.4 If the top section of the valve requires service,
go to Section 5.1.3, otherwise use the illustration in
Figure 6 or 7, and reassemble the valve in reverse
order.
5.1.3 Top Section
5.1.3.1 Remove the control hose and fittings from the
cylinder cap to ensure they are not damaged by a
wrench.
5.1.3.2 Use a large wrench to remove the cylinder cap.
5.1.3.3 If the bottom cap has not been removed,
remove it, and all other parts per Section 5.1.2.
5.1.3.4 Use a wooden hammer handle or similar object,
inserted into the bottom of the valve body, pushed
through the seat area, to drive the piston stem up. Doing
so will push the piston out the top of the valve body.
5.1.3.5 Inspect all items for wear and damage.
•The piston cup should fit snug against the cylinder
wall. If it does not, replace the piston assembly.
•The piston stem should be free of deep abrasion
and move freely in the stem bore. If it is badly
abraded, drags in the bore, or loose in the bore,
replace the piston assembly.
•If the piston stem O-ring is flattened, replace the O-
ring.
•Check the cylinder cap O-ring. Replace it if it is cut
or if it does not fit snugly on the cap recess.
5.1.3.6 Lubricate the cylinder wall and piston cup, with
lightweight machine oil or tool oil.
5.1.3.7 Install the piston into the cylinder. As the piston
cup contacts the cylinder it may be difficult to press into
place. Do not pound the piston, as it could damage the
cup. Rotating the piston while applying thumb pressure
eases assembly.
5.1.3.8 Use the illustration in Figure 6 or 7 and
reassemble the valve in reverse order.
5.1.4 Remove the lower twinline hose connection, and
remove the orifice fitting for inspection. Clean the 1/16″
orifice and reassemble the connection.
WARNING
The orifice fitting must not be removed,
modified, or substituted with another fitting.
Altering the orifice fitting may cause involuntary
activation of the blast machine or some other
malfunction which could result in serious injury
or death.

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 9
© 2009 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 22428
5.2 Piston Outlet Valve, Ref. Figure 9
See Section 5.3 to service the diaphragm outlet valve.
5.2.1 All service on the outlet valve must be done with
the air off and the air supply locked-out and tagged-out.
5.2.2 Remove the control hose from the valve bonnet.
5.2.3 Use a large wrench to loosen the bonnet from
the valve body, until it can be removed by hand.
5.2.4 As the bonnet is removed, lift it straight up until
the piston stem clears the spindle.
5.2.5 Remove the spindle, plug assembly, and spring
from the valve body.
5.2.6 Remove the piston from the bonnet, by pulling
the piston stem.
5.2.7 Inspect all parts for wear and damage as
follows:
•Inspect the valve plug washer, valve plug, and plug
retainer for damage. Replace all damaged parts.
When reassembling the valve plug assembly,
tighten the retainer enough to compress the washer,
but not so tight to cause it to bulge.
•Examine the body casting for wear. If the body or
the machined seat is worn, replace the body.
•Examine the spring guide-bolt and nylon washer. If
either is worn, replace both.
•The spring is approximately 1-5/8″long, if it is
abrasive worn, rusted, or compressed, replace it.
•The piston cup should fit snug against the bonnet’s
cylinder wall. If it does not, replace the piston
assembly.
•The piston stem should be free of deep abrasion
and move freely in the spindle bore. If it is badly
abraded, drags in the bore, or loose in the bore,
replace the piston assembly.
5.2.8 Lubricate the cylinder wall and piston cup, with
lightweight machine oil or tool oil.
5.2.9 Install the piston into the bonnet cylinder.
Cocking the piston so it enters the bonnet at a slight
angle, and rotating it while applying pressure makes
assembly easier. Do not push the piston fully into the
bonnet; the stem should be even with the opening.
5.2.10 Place the spring over the guide-bolt, and place
the plug assembly (retainer down) on the spring.
5.2.11 Place the spindle in the body. The large opening
faces down, and fits over the plug fins. The spindle
shoulder will not rest on the valve body due to the force
of the spring.
5.2.12 To assemble the bonnet to the valve body, first
insert the piston stem into the spindle guide hole. While
keeping the bonnet, spindle, and body aligned, screw
the bonnet onto the body. If all parts are correctly
aligned, the body will screw-on hand tight until it is
seated.
NOTE: If the bonnet does not screw on hand tight,
do not force it. Recheck alignment and repeat.
5.2.13 After the bonnet is fully seated on the body,
tighten the assembly with a wrench.
5.2.14 Attach the control hose to the fitting on the
bonnet.
5.3 Diaphragm Outlet Valve, Ref. Figure 10
See Section 5.2 to service the piston outlet
valve.
5.3.1 All service on the outlet valve must be done with
the air off and the air supply locked-out and tagged-out.
5.3.2 Remove the cap by unscrewing the four cap
screws.
5.3.3 Remove the diaphragm and inspect it for
damage. Replace as necessary.
5.3.4 Inspect the seat in the body. If worn, replace the
body.
5.3.5 Reassemble in reverse order.
5.4 Abrasive Trap
5.4.1 All service on the abrasive trap must be done
with the air off and the air supply locked-out and tagged-
out.
5.4.2 Clean abrasive trap screen and trap twice daily.
NOTE: Failure to clean the abrasive trap on a regular
basis is a major cause of system malfunction.
5.4.3 To check the abrasive trap screen, loosen the
top thumb screw and swing the lock bar off the cap, and
remove the cap.
5.4.4 Remove the screen and inspect it for wear and
blockage. Replace it when it is clogged or worn. Keep
spare screens on hand. Do not install the screen in the
trap until the bottom section of the trap is cleaned per
the following instructions.

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 10
© 2009 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 22428
5.4.5 To clean the bottom section of the trap, loosen
the bottom thumb screw and swing the lock bar off the
bottom cap, and then remove the cap.
5.4.6 Empty all abrasive from the bottom and top
sections.
5.4.7 Install the screen in the top section. The small
end of the screen must face up.
5.4.8 Reassemble the top and bottom caps. Make
sure the screen gasket is in place in the top cap, and the
O-rings are in place on both caps before assembly.
5.5 Control handle
5.5.1 A separate manual is provided for the control
handle. Follow instructions in the manual.
5.6 Metering Valve (for ACS systems only)
5.6.1 A separate manual is provided for the metering
valve. Follow instructions in the manual.
6.0 TROUBLESHOOTING
NOTE: This section applies to the remote control
system only. See the appropriate manual for
troubleshooting the blast machine, control handle,
and accessories.
WARNING
To avoid serious injury or death, observe the
following when troubleshooting the remote
controls:
•Turn off the air, and lockout and tagout the
air supply.
•When checking the controls requires air,
always enlist the aid of another person to
operate the control handle while holding the
nozzle securely and pointing it in a safe
direction.
•Never strap down the remote control handle
lever in the operating position.
6.1 Blasting does not start when the control
handle is depressed
6.1.1 Make sure that the air supply is on and all
supply valves are open.
6.1.2 Make sure the safety petcock is closed.
6.1.3 Check for air leaks in control hose, fittings, and
control handle. (RLX Control Handle is covered in
Owners Manual No. 10574)
6.1.4 Check for air escaping from the opening under
the control handle. If no air is escaping, the orifice on the
inlet valve (Figure 6, item 4, or Figure 7, item 4) or the
line from the orifice to the control handle is blocked and
must be cleared.
6.1.5 Open the safety petcock and depress the control
handle. Air should come from the petcock. If it doesn't,
check the following:
•The opening on the control handle is not being
sealed off.
•The control handle leaks.
•The line from the control handle to the upper fitting
on the inlet valve is blocked.
•If a diaphragm outlet valve is used, check the
diaphragm for a rupture.
If air does rush out, then the inlet valve is not
functioning. Turn off the air supply and service it per
Section 5.1, disassemble the valve, clean and lubricate
it, and replace all worn or damaged parts.
6.1.6 Close the safety petcock, and press the control
handle lever. Check that no air escapes through the vent
hole on the cylinder body of the inlet valve body. Air
escaping from this vent indicates a worn piston in the
inlet valve. See Section 5.1.
6.1.7 With the compressor off and the blast machine
depressurized, check the nozzle for blockage.
6.2 Outlet valve won't exhaust or exhausts too
slowly.
6.2.1 Clean or replace abrasive trap screen. Clean
screen twice daily.
6.2.2 Check to make sure that the lower fitting on inlet
valve (Figure 6, item 4 or Figure 7, item 4) has not been
switched for a fitting with a full flow orifice. The orifice on
the 1/8" NPT end of the fitting must be 1/16" diameter.
6.2.3 Make sure the inlet valve closes. If it does not
seal-off incoming air, the valve requires service.
6.2.4 Disassemble the piston outlet valve, clean and
lubricate it. Replace all worn or broken parts.
6.2.5 Clean or replace the muffler element or muffler.
The procedure to service the muffler is covered in
Muffler Service Instruction No. 22322.

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 11
© 2009 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 22428
6.3 No abrasive flow when the ACS toggle is
moved to "ON"position.
6.3.1 Make sure the metering valve’s flow control
handle is in the open position.
6.3.2 Check for leak or blockage in the single line hose
or fittings from the control handle to the metering valve.
6.3.3 Obstruction in abrasive valve or valve requires
service. See metering valve manual.
6.3.4 Machine empty.
6.4 Abrasive flow does not stop when ACS toggle
is moved the "OFF"position.
6.4.1 Brass filter on ACS switch clogged.
6.4.2 Metering valve requires service.
7.0 REPLACEMENT PARTS
7.1 TLR-100/300 Remote Control Systems
Standard Remote Control Systems (without ACS)
Description Stock No.
TLR-100, 1" w/ piston outlet valve .........................01935
TLR-300, 1-1/4" w/ piston outlet valve ...................01936
TLR-100D, 1" w/ diaphragm outlet valve ...............03449
TLR-300D, 1-1/4" w/ diaphragm outlet valve .........03448
Remote Control Systems with ACS
Description Stock No.
TLR-100-C, 1" w/ piston outlet valve .....................21152
TLR-300-C, 1-1/4" w/ piston outlet valve ...............21153
TLR-100D-C, 1" w/ diaphragm outlet valve ...........21154
TLR-300D-C, 1-1/4" w/ diaphragm outlet valve .....21155
7.2 System Replacement Parts, Figure 4
Item Description Stock No.
1. Outlet valve, 1" piston ...............................01967
2. Outlet valve, 1" diaphragm ........................03371
3. Inlet valve 1" ..............................................01980
4. Inlet valve 1-1/2" .......................................01995
5. Abrasive trap .............................................02011
6. RLX control handle ...................................10565
7. Hose, 3/16" x 18" coupled ........................02454
8. Hose, 5' Twinline coupled .........................01952
9. Hose end, reusable ...................................01943
10. Hose, 50' Twinline coupled ....................... 01951
11. Union, Twinline hose ................................ 01944
12. Elbow, 1/4" NPT adaptor .......................... 02513
Figure 4
7.3 ACS Systems Replacement parts, Figure 5
All other parts are the same as shown in Section. 7.2
and Figure 4. Refer to the RLX manual for replacement
parts for the ACS Control. Refer to the metering valve
manual for metering valve replacement parts.
Item Description Stock No.
1. RLX Control handle w/ ACS switch........... 07625
2. Hose, 50' single line coupled .................... 03087
3. Hose, 3/16" x 18" coupled ........................ 02454
4. Union, Twinline hose ................................ 01944
Figure 5
2
8
1
11
6
9
7
3, 4
10
512
3
4
1
2

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 12
© 2009 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 22428
7.4 1-1/2" Inlet Valve, Figure 6
Item Description Stock No.
(-) 1-1/2" Inlet Valve, complete ......................01995
1. Petcock 1/4" NPT ......................................01993
2. Elbow, 1/4" NPT adaptor ...........................02513
3. Elbow, 1/8" brass street ............................03993
4. Adaptor 1/8" NPT with 1/16" orifice ...........01945
5. Bottom cap ................................................02001
6.* Spring, inner, 5/8" x 1-11/16" long (1) .......01982
7.* Gasket, bottom cap (1) ..............................02006
8.* Spring, outer (1) ........................................02000
9. Valve body .................................................01996
10. Valve plug ..................................................01999
11.* Washer, valve plug (2) ..............................01998
12.* Retainer, valve plug washer (1) ................02002
13.* O-Ring, 7/16" OD (1) .................................02008
14. Piston and rod assembly ...........................02003
15.* O-Ring 2-1/4" OD (1) .................................02007
16. Cylinder cap ..............................................01997
(-) Service kit, includes items marked *,
quantity is shown in ( ) ...............................01927
Figure 6
7.5 1" Inlet Valve, Figure 7
Item Description Stock No.
(-) 1" Inlet Valve, complete ............................01980
1. Petcock 1/4" NPT ......................................01993
2. Elbow, 1/8" NPT adaptor ..........................02827
3. Elbow, 1/8" brass street ............................03993
4. Adaptor 1/8" NPT with 1/16" orifice ..........01945
5. Bottom cap ................................................01985
6.* Spring, 5/8" x 1-11/16" long (1) .................01982
7.* Seal, bottom cap (1) .................................01989
8. Valve plug .................................................01984
9. Valve body ................................................01981
10.* Washer, valve plug (2) ..............................01969
11.* Retainer, valve plug washer (1) ................01986
12.* O-Ring 3/16" ID x 1/16" (1) .......................01992
13. Piston and rod assembly ..........................01987
14.* O-Ring 1-3/4" OD (1) ................................01990
15. Cylinder cap ..............................................01983
(-) Service kit, includes items marked *,
quantity is shown in ( )...............................01929
Figure 7
1
15*
13*
16 2
14
9
4
3
12* 11*
6*
7*
10
8*
5
2
1
2
3
4
5
6*
7*
8
9
10*
11*
12*
13
14*
15
2

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 13
© 2009 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 22428
7.6 Abrasive Trap, Figure 8
Item Description Stock No.
(-) Abrasive Trap, complete ...........................02011
1.* Screen (3) .................................................02012
2.* O-Ring (2) .................................................02013
3. Cap ............................................................02014
4. Body ..........................................................02015
5. Lock bar ....................................................02016
6. Screw, 3/8" NC x 1" thumb .......................03289
7. Shoulder screw, 3/8" x 3/8" .......................03291
8.* Gasket, screen, 1/8" thick (1) ...................02434
9.* Decal, clean screen (1) .............................02129
(-) Service kit, includes items marked *,
quantity is shown in ( ) ..............................01925
Figure 8
7.7 1" Piston Outlet Valve Figure 9
Item Description Stock No.
(-) 1" Piston Outlet Valve, complete .............. 01967
1. Elbow, 1/4" NPT adaptor .......................... 02513
2. Plug, 1/4" NPT .......................................... 01950
3. Bonnet ...................................................... 01970
4. Piston and rod assembly .......................... 01976
5. Plug and spindle guide ............................. 01971
6.* Valve plug (1) ........................................... 01972
7.* Washer, valve plug (2) ............................. 01969
8.* Retainer, valve plug washer (1) ................ 01986
9. Valve body ................................................ 01968
10.* Spring, 7/16" x 1-5/8" long (1) ................... 01974
11.* Nylon washer (1) ...................................... 01979
12.* Cap screw, 3/8-NC x 3/4" (1) .................... 03251
(-) Service kit, includes items marked *,
quantity is shown in ( )............................... 01928
Figure 9
2
4
5
6*
8*
9
12*
7*
11*
10*
3
1
5
7
6
3
2*
4
7
8*
3
5
6
2*
1*
9*

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 14
© 2009 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 22428
7.8 1" Diaphragm Outlet Valve Figure 10
Item Description Stock No.
(-) 1" Diaphragm Outlet Valve, complete .......03371
1. Nipple, 1" x close .......................................01701
2. Diaphragm .................................................06149
3. Lockwasher, 1/4" .......................................03117
4. Cap screw, 1/4-NC x 1" hh ........................03053
5. Cap, diaphragm outlet ...............................03393
6. Body, diaphragm outlet .............................06135
7. Bushing, 1-1/4" x 1" ...................................01804
Figure 10
7.9 RLX Pneumatic Control Handle
Refer to RLX Control Handle Manual No. 10574
for RLX replacement parts.
7
2
6
5
1
3 4