Clemco TLR 100 Series User manual

TLR 100/300 SERIES
PNEUMATIC REMOTE CONTROLS
O. M. 22428
DATE OF ISSUE: 12/98
REVISION: E, 05/19
© 2019 CLEMCO INDUSTRIES CORP.
One Cable Car Dr.
Washington, MO 63090
Phone [phone]
Fax [phone]
Email: [email protected]
www.clemcoindustries.com
Do not use this equipment
before READING this
MANUAL and
UNDERSTANDING its
contents.
These WARNINGS are
included for the health
and safety of the operator
and those in the
immediate vicinity. Failure
to read and understand
these warnings can result
in injury or death.
Electronic files include a
preface containing the
same important
information as in the
orange cover.
WARNING

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 1
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
1.0 INTRODUCTION
1.1 Scope of Manual
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/p 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 cutoff switch (ACS) option. 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-100C, 1" w/piston outlet ................................ 07632
TLR-300C, 11/4" (11/2" inlet) w/piston outlet ......... 07633
TLR-100DC, 1" w/diaphragm outlet ...................... 07634
TLR-300DC, 11/4" (11/2" inlet) w/diaphragm out. ... 07635
1.1.2 This manual contains 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. Accessory manuals for
equipment that may be used with the remote controls
are shown below. Manuals are available on our
website at www.clemcoindustries.com.
Classic Blast Machine with Remote Controls ...... 22501
RLX Control Handle ............................................ 10574
Muffler Service ..................................................... 22322
1.1.3 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; it contains important safety
information about abrasive blasting that may not be
included in equipment operation manuals. The booklet
is available in both English and Spanish; to request
copies, email [email protected].
1.2 Safety Alerts
1.2.1 Clemco uses safety-alert signal words, based on
ANSI Z535.4-2011, 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 you to potential physical
injury hazards. Obey all safety
messages that follow this symbol to
avoid possible injury or death.
NOTICE
Notice indicates information that is considered
important, but not hazard-related, if not avoided,
could result in property damage.
CAUTION
Caution indicates a hazardous situation that, if
not avoided, could result in minor or moderate
injury.
W
ARNING
Warning indicates a hazardous situation that, if
not avoided, could result in death or serious
injury.
DANGER
Danger indicates a hazardous situation that, if
not avoided, will result in death or serious
injury.
1.3 Table of Contents
SUBJECT LOCATION
INTRODUCTION ......................................................... 1.0
Scope of Manual ......................................................... 1.1
Safety Alerts ................................................................ 1.2
Table of Contents ........................................................ 1.3
Components and General Description ........................ 1.4
Theory of Operation .................................................... 1.5
Abrasive Cutoff (ACS) Option .................................... 1.6
Electric Control Option ............................................... 1.7
Abrasive ...................................................................... 1.5
INSTALLATION ......................................................... 2.0
Install Valves onto Blast Machine .............................. 2.1
Set Up for Multiple Blast Machines Operating
From a Common Compressed-Air Supply .................. 2.2
Prepare Blast Hose and Control Hose Connections .. 2.3
Set Up for Optional ACS Feature ............................... 2.4
Install Compressed-Air Coupling and Air Hose ......... 2.5

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 2
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
OPERATION .............................................................. 3.0
Startup ........................................................................ 3.1
Blasting Attire ............................................................. 3.2
Pressurize Blast Machine to Start Blasting ................ 3.3
Operation of Optional Abrasive Cutoff Switch (ACS) ... 3.4
Stop Blasting .............................................................. 3.5
PREVENTIVE MAINTENANCE ................................. 4.0
Daily Inspection and Maintenance ............................. 4.1
Weekly Inspection and Maintenance ......................... 4.2
Periodic Inspection and Maintenance ......................... 4.3
Lubrication .................................................................. 4.4
SERVICE MAINTENANCE ......................................... 5.0
Inlet Valve .................................................................... 5.1
Piston Outlet Valve ...................................................... 5.2
Diaphragm Outlet Valve .............................................. 5.3
Abrasive Trap .............................................................. 5.4
Remove and Install Reusable Control-Hose Fittings .... 5.5
RLX Control Handle .................................................... 5.6
Metering Valve (for ACS systems only) ...................... 5.7
TROUBLESHOOTING ................................................ 6.0
Blasting does not start when the control-handle
lever is depressed .................................................... 6.1
Outlet valve won't exhaust or exhausts too slowly ......... 6.2
Optional ACS Feature ...................................................... 6.3
No abrasive when the ACS toggle is moved to ON blast
mode ..............................................................................6.3.1
Abrasive flow does not stop when ACS
toggle is moved to the OFF position ..........................6.3.2
REPLACEMENT PARTS ........................................... 7.0
Hose Safety Accessories ........................................... 7.1
TLR-100/300 Remote Control Systems ..................... 7.2
System Replacement Parts ........................................ 7.3
ACS System Replacement Parts ............................... 7.4
Abrasive Trap ............................................................. 7.5
1-1/2" Inlet Valve ........................................................ 7.6
1" Inlet Valve ............................................................... 7.7
1" Piston Outlet Valve ................................................. 7.8
1" Diaphragm Outlet Valve ......................................... 7.9
RLX Pneumatic Control Handle ............................... 7.10
1.4 Components and General Description
1.4.1 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), abrasive trap, RLX control
handle, 55 ft and 5 ft long twinline control hoses, two
control hose unions, and an 18" interconnecting hose.
1.4.2 Additional parts used with optional ACS cutoff
systems are shown in Figure 2. ACS systems include a 50
ft single-line hose, 18" long interconnecting 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.
Figure 1
Muffler (accessory, not
included with the remote
control s
y
stem
)
Pressure Regulator
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 2.3.6.
Orifice Fitting
Orifice Fitting
1/16" orifice as seen
from backside of fitting
Piston Type Outlet Valve
Diaphragm Outlet Valve Abrasive Trap
Inlet Valve
5 ft Twinline Hose (outbound side)
RLX Control Handle
3/16" x 18" Hose
Safety Petcock
Elbow Adaptor
50 ft Twinline Hose
Inbound side of twinline
Twinline Hose Unions (2)

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 3
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
1.4.3 A remote control system is an OSHA-required
safety device; it is required when an operator mans the
nozzle. The control handle, located near the blast
nozzle, is the activator of the remote control system.
When the operator intentionally or unintentionally
removes handheld pressure from the control handle,
the machine depressurizes and blasting stops. The
remote control system "fails to safe", which means if an
interruption in the control-air circuit occurs, for any
reason, the remote control deactivates the blast
machine and blasting stops.
Additional parts used with optional
ACS cutoff system.
Figure 2
W
ARNING
Never modify or substitute remote control
parts. Parts from other manufacturers are not
compatible with Clemco equipment. If ANY part
of the remote control system is altered,
involuntary activation can occur, causing
serious injury.
1.5 Theory of Operation
1.5.1 TLR-100 and TLR-300 remote controls are
pressure-release-style systems, which control the
pressurization and depressurization of the blast
machine. Pressurization, which starts blasting, occurs
when the operator presses the control handle, and
depressurization, which stops blasting, occurs when the
operator releases pressure on the control handle.
1.5.2 Clemco remote controls operate pneumatically
on a return-air principle (Refer to Figure 1). When
compressed air is supplied to the machine, control air
travels from the orifice fitting, down the outbound
twinline (shown shaded in Figure 1) and escapes
through an opening located under the control lever. As
long as the control lever remains up, air escapes
through the opening, and the normally closed inlet valve
remains closed and the normally open outlet valve
remains open (no blasting). When the control lever is
pressed, a rubber button seals the opening, forcing air
from the outbound side of twinline to return through the
inbound side. Pressure in the return line opens the inlet
valve and closes the outlet valve. This action
pressurizes the blast machine and begins the blasting
process. Releasing the handle exhausts the control air,
closing the inlet valve, and opening the outlet valve to
depressurize the blast machine and stop the blasting.
1.6 Abrasive Cutoff (ACS) Option
1.6.1 The abrasive cutoff switch is mounted on the
control handle. It closes the metering valve so that air
alone, without abrasive, exits the nozzle. This feature is
used to clear the blast hose and to blowdown the blast
surface. Refer to Section 3.4 for operation of the optional
ACS.
NOTE: The ACS feature requires a pneumatically
operated abrasive metering valve. It is not available
on Lo-Pot blast machines, which do not have
adequate clearance for the metering valve.
1.7 Electric Control Option
1.7.1 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 through pneumatic systems over longer
distances delays actuation time and could prevent fast,
safe depressurization time should an accident or an
emergency occur. For additional information contact
your local Clemco Distributor, visit
www.clemcoindustries.com, or email
[email protected].
Metering Valve
Valve may differ
from that shown.
ACS Switch Assembly
RLX Control
Handle w/ ACS
50 ft Single-Line
3/16" x 18" Hose
Hose Union

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 4
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
2.0 INSTALLATION
W
ARNING
Failure to observe the following procedure
before performing any service on a blast
machine or pneumatic accessories can cause
serious injury or death from the sudden release
of trapped compressed air:
1. Empty the blast machine of abrasive.
2. Depressurize the blast machine.
3. Lockout and tagout the compressed-air
supply.
4. Bleed the air-supply line to the blast machine.
Installation Note: To prevent thread galling and to
provide an airtight seal, use thread sealant on all
male NPT (pipe) threads.
2.1 Install Valves onto Blast Machine
2.1.1 Empty the blast machine of abrasive.
Depressurize the machine. Shut down the compressed-
air source. Bleed the air-supply line. Lockout and tagout
the air supply. Disconnect the air-supply line.
2.1.2 Remove the existing inlet valve and outlet valve
from the machine. The machine should resemble the
illustration in Figure 3. We recommend installing outlet
piping, as shown in the illustration.
Figure 3
2.1.3 Install the inlet valve and abrasive trap, as
shown in Figure 4. The directional arrow on the inlet
valve points toward the blast machine, indicating the
direction of air flow. The arrow on the abrasive trap
points away from the machine.
Figure 4
2.1.4 Install the piston or diaphragm outlet valve and
muffler, as shown in Figure 5.
Figure 5
W
ARNING
Clemco supplies an exhaust muffler with all blast
machines of 2-cuft 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 5.
If an application requires the muffler to be
removed, 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 that escapes
when the blast machine depressurizes.
1" x Close Nipple
Outlet piping
should consist of:
1" Pipe Plug
1" Tee
Inlet Piping
Use 1" with TLR-100
1-1/4" for TLR-300
To keep inlet piping close
to the machine, install an
elbow, as shown. Inlet
piping could go directly into
the tee. All illustrations are
shown with an elbow.
Abrasive Trap
The 1" x 3" nipple is
included with the trap. Install
the trap with the screen end
facing up and the cleanout
end facing down.
Inlet Valve
The 1-1/2" inlet valve includes
a bushing to install on 1-1/4"
piping. The 1" inlet valve does
not require a bushing to install
on 1" piping.
Muffler, accessory not supplied
with remote controls systems.
Muffler, accessory not
su
pp
lied with s
y
stem.
1" 90o St Elbow
Piston Outlet Valve
Attach the valve to the abrasive
trap; the directional arrow points
away from the trap.
Dia
p
hra
g
m Outlet Valve
Attach with bushing facing up.

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 5
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
2.1.5 Connect the 3/16" x 18" air hose between the
elbow fitting on the outlet valve and the elbow fittings
facing UP at the top of the inlet valve, as shown in
Figure 6.
N
R
SCEE
Figure 6
2.2 Set Up for Multiple Blast Machines Operating
From a Common Compressed-Air Supply
2.2.1 Where multiple blast machines are operating
from a single air source, install a ball cone check valve
at the air supply on each machine. Refer to the
illustration in Figure 7 to install a check valve on a blast
machine.
2.2.2 If the machines are positioned close together use
a receiver tank or manifold and run separate air lines to
each machine. The check valves may be located on the
receiver tank outlets if the air line goes directly to the blast
machine and nowhere else.
CAUTION
If multiple machines are operating from a
common compressed-air supply, and a
machine is under pressure when another
machine is pressurized, the sudden, increased
demand for air can reverse air flow from the
machine that is under pressure and
contaminate the compressed-air supply with
abrasive-laden air. Install check valves at the
piping inlet to prevent the reversal of air.
NOTE: Do not use a swing check valve, as the swing
gate may break in blast machine applications. When
installing the valve, make sure the directional arrow
is pointing in the direction of the air flow (toward the
machine).
Figure 7
2.2.3 Use a Clemco ball cone check valve noted
below to reduce pressure drop through the valve. A
smaller-size valve could restrict air movement and
reduce nozzle pressure.
 TLR-100 with 1" NPT inlet valve
Use 1-1/4" NPT check valve ....... Stock No. 02088
 TLR-300 with 1-1/2" NPT inlet valve
Use 1-1/2" NPT check valve ....... Stock No. 02296
2.3 Prepare Blast Hose and Control Hose
Connections
NOTE: Control hoses come with reusable hose
ends. Excess hose may be cut-to-fit and recoupled,
as explained in Section 5.5.
W
ARNING
Where two or more blast machines are used in
close proximity, care must be taken when
tracing and connecting control lines and blast
hose. Cross-connecting control hose or blast
hose can 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.
Use optional hose identification kits, stock no.
15890 for use with two blast machines, or stock
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.
Ball Cone Check Valve
Close Nipple
Use a standard 1-1/4" x 1"
pipe bushing, Clemco Stock
No. 01804, when installing on
a TLR-100, 1" inlet valve.
TLR-300 inlet valve does not
require a bushing.
3/16" x 18" Air Hose
Inlet Valve
Inlet Valve

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 6
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
W
ARNING
Moist air that freezes can cause blockage at the
control handle or in the control lines. Blockage
can cause involuntary activation of the remote
controls or prevent the controls from
deactivating upon release of the control handle.
This situation can 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.
2.3.1 Uncoil the blast hose and lay the 50 ft twinline
hose alongside it.
2.3.2 Band the control handle to the blast hose close
to the nozzle holder, as shown in Figure 8, using the two
nylon ties provided. After the control is firmly attached,
clip the tie ends to avoid snags or interference with the
operation of the control handle.
Figure 8
2.3.3 Attach the 50 ft twinline hose to the two fittings
on the control handle, as shown in Figure 9. Either side
of the hose can be attached to either fitting. When using
the ACS option, attach the single-line hose noted in
Section 2.4.1.
Figure 9
NOTE: When attaching Clemco twinline hose to a
Clemco inlet valve or control handle, either side of
the twinline hose can be attached to either twinline
fitting on the valves.
2.3.4 Working backward from the control handle,
band the twinline hose to the blast hose every four to six
feet and as close to the couplings as possible. NOTE:
When using the optional ACS feature, band all hoses
after the single ACS hose is attached to the RLX.
2.3.5 Temporarily connect the blast hose to the quick
coupling on the blast machine, as shown in Figure 10.
Figure 10
2.3.6 Attach the 5 ft twinline control hose to the inlet
valve, as shown in Figure 10; one side of the hose
connects to the unused upper elbow, the other side to
the orifice fitting. NOTE: When using a pressure
regulator to reduce blast pressure below 60 psi (80
psi when using a pneumatically operated abrasive
metering valve), relocate the orifice upstream of the
regulator, as shown in the insert in Figure 1, and plug
the orifice port in the inlet valve. Doing so provides
full line-pressure to the pneumatic control circuit.
2.3.7 Connect the two hose unions to the other end of
the 5 ft hose and place the ends next to the blast-hose
coupling.
2.3.8 Band the 5 ft twinline control hose, on the blast
machine side of the unions, to the quick-coupling nipple.
2.3.9 Attach the 50 ft twinline hose to the unions on
the 5 ft twinline.
RLX Control Handle
Nozzle Holder
Blast Hose
Twinline Control Hose
Either side of the twinline
can attach to either fitting
on the control handle.
Nylon Tie
A
brasive meterin
g
valve removed for clarit
y
.
Nylon Ties
RLX Control Handle
5 ft Twinline Hose
50 ft Twinline Hose
Blast Hose
Inlet Valve
Blast Machine Blast-Hose Coupling
Orifice Fittin
g
Hose Unions
Nylon Tie

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 7
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
2.3.10 Make sure that all fittings are tight. Leaks cause
the system to malfunction.
NOTE: When removing the blast hose from the
machine, disconnect the 50 ft twinline hose (and
optional ACS hose) at the unions.
When attaching the blast hose, make sure all twinline
fittings are tight. Make sure coupling gaskets are in
place and in good condition before connecting the blast
hose to the blast machine. Use safety lock pins or safety
wire to lock the couplings together and prevent
accidental separation while under pressure, and use
safety cables to prevent hose from whipping should
separation occur. Safety cables and lock pins are listed
in Section 7.1
W
ARNING
Hose disconnection while under pressure can
cause serious injury or death. Use safety lock
pins or safety wire to lock the couplings
together and prevent accidental separation while
under pressure. Use safety cables to prevent
hose from whipping should separation occur.
NOTE: When installing the optional ACS feature,
refer to Section 2.4 for additional instructions.
2.4 Set Up for Optional ACS Feature – Figure 11
2.4.1 Attach the 50 ft long single-line hose to the ACS
air switch located on the RLX control handle.
2.4.2 Attach the 18" long hose to the fitting on the
metering valve.
2.4.3 Use the remaining union to connect the 50 ft
hose to the 18" hose.
N
R
SCEE
Figure 11
2.5 Install Compressed-Air Coupling and Air Hose
2.5.1 Apply thread sealant to the male pipe threads of
an air fitting that is compatible with the air-supply hose, as
noted in Section 2.5.2, and install it onto the inlet valve, as
shown in Figure 12. The style of connection shown is for
reference only.
Figure 12
WARNING
Hose disconnection while under pressure can
cause serious injury or death. Use safety lock
pins or safety wire to lock twist-on (claw-type)
couplings together and prevent accidental
separation while under pressure and use
safety cables to prevent hose from whipping
should separation occur.
2.5.2 Attach an air line from the compressor to the
hose fitting installed on the blast machine inlet. For best
blasting performance, refer to the table in Figure 13 for
the minimum recommended hose size based on the
nozzle orifice size. A smaller diameter hose could result
in a reduction in nozzle pressure.
AIR LINE RECOMMENDATIONS
BASED ON NOZZLE SIZE
Nozzle Orifice
Size Recommended Air-Supply Line
No. 3, 3/16" 3/4" ID or larger
No. 4, 1/4" 1" ID or larger
No. 5, 5/16" 1-1/4" ID or larger
No. 6, 3/8" 1-1/2" ID or larger
No. 7, 7/16" 2" ID or larger
No. 8, 1/4" 2" ID or larger
Figure 13
Metering Valve
3/16" x 18" Hose
50 ft Single-Line Hose
ACS Switch
Hose Union
Metering valve may
differ from that shown.
RLX Control Handle
Inlet Valve
Ai
r
-Hose Fittin
g
Ai
r
-Su
pp
l
y
Hose
Safety Cable
Install adaptor onto air filter when filter is used.
Once installed, remove slack from the safety cable.
Apply thread sealant to
male pipe threads.

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 8
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
3.0 OPERATION
W
ARNING
Refer to the manuals listed in paragraph 1.1.2.
Do not operate this equipment before reading
the instruction manuals for all equipment.
3.1 Startup
3.1.1 Connect the air supply to the blast machine
inlet. The compressor should be located upwind from
the blasting operation to prevent dust from entering the
compressor intake.
3.1.2 Make sure that the safety petcock located on the
inlet valve is open to prevent unintentional blasting. The
petcock is open when the petcock lever is in-line with
the petcock, as shown in Figure 14.
Figure 14
W
ARNING
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 will not activate the
machine when the petcock is open.
3.1.3 Make sure the control-handle lever is in the up (no
blast) position, and that the lever and safety lock move
freely.
W
ARNING
A separate manual is supplied with the RLX
remote control handle. Do not operate the
machine before first reading the manual for the
control handle.
3.1.4 Check to make sure that the control lever will
not seal the opening on lever unless the safety lever-
lock is pulled down.
W
ARNING
A malfunctioning control handle can cause
unintentional actuation of a blast machine or
prevent a machine from deactivating upon
release. A malfunctioning control handle must
be taken out of service immediately and
repaired or replaced. Serious injury or death
can result from unintentional blasting.
3.1.5 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’s rated pressure.
3.1.6 Fill the machine with screened, clean, dry
abrasive that is specifically manufactured for abrasive
blasting. NOTE: Use only abrasives specifically
manufactured for blasting that are compatible with
the surface being blasted. Abrasives produced for
other applications may be inconsistent in size and
shape and produce an unsatisfactory finish, contain
particles that could jam the abrasive metering valve,
or cause irregular wear.
3.1.7 Slowly open the compressor air-supply valve to
pressurize the air-supply line. Listen for noise that
indicates any open lines or leaks.
3.1.8 Do not allow anyone around the blast machine
except the blast operator or machine tenders, who are
appropriately attired in approved personal protective
equipment, as noted in Section 3.2.
3.1.9 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 closes 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 lever but
nowhere else. The air escaping at the handle is an audible
signal that means air is supplied to the blast machine,
and it will activate when the control handle is pressed.
3.2 Blasting Attire
3.2.1 Operators and anyone else 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.
3.2.2 Don protective blasting attire outside the blast
area in a clean nonhazardous environment, free of
contaminants, where the air is safe to breathe.
Open
Closed

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 9
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
W
ARNING
All dust is hazardous to breath. 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.
Obtain a safety data sheet (SDS) for the blast
abrasive to identify hazardous substances. Silica
sand (crystalline) can cause silicosis, lung
cancer, and breathing problems in exposed
workers. Slag abrasives may contain trace
amounts of toxic metals such as arsenic,
beryllium, and cadmium. Any abrasive dust has
potential to cause lung disease.
Abrasive blasting operations can create high
levels of harmful dust and noise. No dust is
safe to breathe. Failure to wear NIOSH-approved
respirators can result in serious lung disease or
death. The respirators must be properly fitted
and maintained. Use only NIOSH-approved, Type
CE supplied-air respirators approved for
abrasive blasting.
Loud noise generated by the use of
compressed air can cause hearing damage.
Everyone in the blasting area must wear
approved hearing protection.
During abrasive blasting, abrasive and dust
particles 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, eye protection, and hearing protection,
appropriate for the job site hazards.
It is the employer’s responsibility to train
employees to identify hazardous substances
and to provide suitable policies, procedures,
monitoring, recordkeeping, and personal
protective equipment.
3.2.3 When finished blasting and after cleanup is
completed, remove the respirator and protective clothing
outside the respirator-use area in a clean environment
where the air is safe to breathe.
3.3 Pressurize Blast Machine to Start Blasting
3.3.1 Don all protective blasting attire, per Section 3.2.
3.3.2 When the blast operator is ready to blast, the
operator or the machine tender must 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 opening under
the control lever but from nowhere else. The air
escaping at the control handle is an audible signal
meaning air is supplied to the blast machine, which will
activate when the control handle is pressed.
3.3.3 Hold the blast hose securely and point the
nozzle only toward objects intended to be blasted.
3.3.4 Fold down the safety lever-lock and press the
remote control handle, as shown in Figure 15. Within a
few seconds the pop-up valve will automatically close,
and the blast machine will pressurize to start blasting.
WARNING
Be prepared for the recoil from the blast hose.
Blasting should begin within a few seconds
after pressing the control lever.
Figure 15
WARNING
OSHA requires the use of remote controls on all
blast machines when an operator controls the
nozzle. To comply with OSHA regulations, the
remote control handle, which starts and stops
the flow of air and abrasive, must be held down
manually. Never 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).
Control Lever (locked up)
Fold down lever lock.
Press control lever
down to begin blasting.
Safety Lever-Lock
(
shown u
p
)

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 10
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
3.3.5 If the abrasive metering valve is closed as
instructed, only air will exit the nozzle. Adjust abrasive
flow as instructed in the blast machine’s operation
manual.
WARNING
OSHA requires the use of remote controls on all
blast machines when an operator controls the
nozzle. To comply with OSHA regulations, the
remote control handle, which starts and stops
the flow of air and abrasive, must be held down
manually. Never 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 the Optional Abrasive Cutoff
Switch (ACS) – Figure 16
3.4.1 The ACS allows the operator to open and close
the metering valve so that air alone without abrasive
exits the nozzle. Common uses for this feature are:
 Clearing abrasive from the blast hose when blasting
is finished. This is helpful in many applications and
necessary when the blast hose is vertical. It
prevents abrasive from collecting in low spots in the
blast hose, eliminating excessive abrasive slugging
at startup.
 Blowing abrasive off the blasted surface. NOTE:
Small amounts of residual abrasive may exit the
nozzle with the air, requiring blowing off or
otherwise cleaning surface outside the blasting
area prior to painting.
 When wetblasting with an injector or wetblast
attachment, the ACS is used to assist in drying the
surface after it is washed down.
3.4.2 The abrasive cutoff switch is situated directly
behind the control handle. The switch may be flipped
open or closed at any time, but it will not operate the
metering valve unless the control handle is pressed.
3.4.2.1 Blast Mode Moving the ACS toggle away from
the nozzle to the ON (CYL port) position sends control
air to the abrasive metering valve and opens the valve
so that the blast machine operates normally with air and
abrasive coming out the nozzle.
Figure 16
3.4.2.2 Blowdown Mode Moving the ACS toggle toward
the nozzle to the "OFF" position, exhausts the control-air to
the abrasive metering valve, closes the valve, and stops the
abrasive flow. This action allows air alone to exit the
nozzle, which is useful for clearing the blast hose before
shutting down, and blowing abrasive and water off the
blasted surface.
WARNING
OSHA sets exposure limits for people and the
environment. Airborne dust can increase the
exposure levels beyond permissible limits. OSHA
prohibits blowing with compressed air as a
cleaning method for lead-based paint dust or
other hazardous dust, unless the compressed air
is used in conjunction with a ventilation system
designed to capture the volume of airborne dust
created by the compressed air, 29 CFR 1926 (h).
The ACS is for blowing off abrasive from a
blasted surface, NOT for general area cleanup.
3.5 Stop Blasting
3.5.1 To stop blasting, release the control-handle
lever. The inlet valve closes, the outlet valve opens 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 lever is released, the safety
lever-lock will flip up to lock the control lever in the UP
(no blast) position. Make sure the safety lever-lock is UP
to prevent the control lever from engaging.
3.5.3 Always open the safety petcock during work
breaks and before filling the blast machine. Opening the
petcock prevents unintentional blasting.
Blast Mode
Toggle pointing away from nozzle
Blowdown Mode
Toggle pointing toward nozzle
ON
OFF

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 11
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
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 can pressurize the machine before the
machine tender has moved away from the
machine. During pressurization, abrasive can
be forced out of the top of the machine, and
cause injury.
3.5.4 When finished blasting and after cleanup is
completed, remove the respirator and protective clothing
outside the blasting area, in a clean environment where
the air is safe to breathe.
4.0 PREVENTIVE MAINTENANCE
NOTE: The following preventive maintenance
instructions pertain to the remote controls only.
Read the manuals for the blast machine, control
handle, and all blast accessories for their inspection
and maintenance.
4.1 Daily Inspection and Maintenance
4.1.1 With the air OFF, before blasting do 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. Refer to Section 5.4.
 Inspect the RLX control handle; look for the
following:
 The control lever must not seal the opening on
the control handle unless the safety lever-lock is
pulled down.
 The control lever must return to the UP position
when it is released.
 The safety lever-lock must return to the UP
position when the control lever is released.
 Both the control lever and safety lever-lock must
move freely with no drag or binding.
W
ARNING
A malfunctioning control handle can cause
unintentional actuation of a blast machine or
prevent a machine from deactivating upon
release. A malfunctioning control handle must
be taken out of service immediately and
repaired or replaced. Serious injury or death
can result from unintentional blasting.
4.1.2 During blasting, do the following:
 Check the control handle for leaks.
4.2 Weekly Inspection and Maintenance
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 and Maintenance
NOTE: Periodic inspection of the following items will
prevent unscheduled downtime.
4.3.1 The remote control system is a safety device; for
safety and to avoid unscheduled downtime, periodically
inspect the internal parts of the inlet valve, outlet valve,
and abrasive trap. Inspect for wear and lubrication of O-
rings, pistons, springs, seals, and castings. Refer to
Section 5.0: Service Maintenance.
4.3.2 The control handle is the actuator of the remote
control system. Periodically clean around the springs,
control lever, and safety lever-lock to ensure that the unit
is free of abrasive and debris that could cause the
control lever or safety lever-lock to bind. Refer to the
RLX 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 12
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
5.0 SERVICE MAINTENANCE
W
ARNING
To avoid serious injury from the sudden release
of trapped compressed air, observe the
following before performing any maintenance:
1. Depressurize the blast machine.
2. Turn OFF the compressed-air supply.
3. Bleed the air-supply line to the blast
machine.
4. Lockout (be certain the air supply is OFF
and that it cannot be started while work is in
process) and tagout (be certain the air
supply is clearly marked to prevent re-
starting while work is in process) the
compressed-air supply.
5.1 Inlet Valve
All service on the inlet valve must be done with the air
OFF and the air supply locked-out and tagged-out. It is
not necessary to remove the valve from the blast
machine.
5.1.1 Bottom Section – Figure 17
5.1.1.1 Use a pipe wrench to loosen the bottom cap
until it can be removed by hand.
5.1.1.2 Use care when removing the cap as the
spring(s) (two are used in the 1-1/2 inlet valve) and plug
assembly could drop from the opening. Do not allow
them to fall to the ground, as damage to the castings
could occur.
5.1.1.3 Clean all parts and inspect for wear as follows:
 The small spring (the only one used in 1" valve) is
approximately 1-11/16" long. If it is rusty or
compressed, replace it.
 The large spring (not used in 1" valve) is
approximately 2-1/16" long. If it is rusty 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 it if
damaged.
*Items included in service kit.
Figure 17
5.1.1.4 Remove the lower twinline hose connection and
remove the orifice fitting for inspection. Clean the 1/16
orifice and reassemble the connection.
W
ARNING
For proper operation, the orifice fitting must
always be in place. Do not modify it or
substituted another fitting. Altering the orifice
fitting may cause involuntary activation of the
blast machine or some other malfunction that
can result in serious injury or death.
5.1.1.5 If the top section of the valve requires service,
continue to Section 5.1.2. Otherwise, refer to the
illustration in Figure 17 to reassemble the valve in
reverse order.
5.1.2 Top Section – Figure 18
5.1.2.1 Remove the control hose and fittings from the
cylinder cap to prevent damaged by a wrench.
5.1.2.2 Use a pipe wrench to remove the cylinder cap.
5.1.2.3 If the bottom cap has not been removed, remove
the cap and all parts in the bottom section, per Section 5.1.1.
5.1.2.4 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 rod up. Doing
so will push the piston out the top of the valve body.
For replacement parts, refer to Sections:
 7.6 for 1-1/2" inlet valve part
 7.7 for 1" inlet valve parts
One used in 1" valve.
Two used in 1-1/2" valve.
Bottom Cap
*Bottom Cap Seal
*Valve Plug
*Valve Plug Washer
Orifice Fitting
*Plug Retainer
Elbow
*Spring(s)
1/16" Orifice

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 13
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
5.1.2.5 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 rod should be free of deep abrasion and
move freely in the rod’s bore. If it is badly abraded,
drags in the bore, or is loose in the bore, replace the
piston assembly.
 If the piston rod O-ring is flattened, replace the O-ring.
 Inspect the cylinder cap O-ring. Replace it if it is cut
or if it does not fit snugly into the recess at the end
of the threads.
*Items included in service kits.
Figure 18
5.1.2.6 Lubricate the cylinder wall and piston cup with
lightweight machine oil or tool oil.
5.1.2.7 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 that could damage
the cup; make sure the lower lib of the cup does not curl
in or get cut. Rotating the piston while applying thumb
pressure makes assembly easier.
5.1.2.8 Refer to the illustrations in Figure 17 and 18 to
reassemble the remainder of the valve in reverse order.
5.2 Piston Outlet Valve – Figure 19
To service the diaphragm outlet valve, refer to Section 5.3.
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. It is not necessary to remove the valve from the
blast machine.
5.2.2 Remove the control hose from the valve
bonnet’s elbow adaptor. NOTE: The elbow adaptor and
plug do not need to be removed unless they need to
be replaced.
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 To remove the bonnet, lift it straight up until the
piston rod clears the spindle guide.
5.2.5 Remove the plug and spindle guide, plug
assembly, and spring from the valve body.
5.2.6 Remove the piston from the bonnet by pulling
the piston rod.
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, rusty, or compressed, replace it.
 The piston cup should fit snugly against the bonnet’s
cylinder wall. If it does not, replace the piston assembly.
 The piston rod should be free of deep abrasion and
move freely in the spindle guide’s bore. If the piston
or stem is badly abraded, drags in the bore, or is
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’s 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 rod should be flush 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 plug and spindle guide 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 rod 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.
Elbow Adaptor
Safety Petcock
Does not need to
be removed unless
it is to be replaced.
*Cylinder Cap O-Ring
Cylinder Cap
Piston Rod O-Ring
Piston Cup
Piston Rod
For replacement parts,
refer to Sections:
 7.6 for 1-1/2" inlet
 7.7 for 1" inlet
Elbow Adaptor
Piston Assembly

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 14
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
NOTE: If the bonnet does not screw on hand tight,
do not force it; recheck alignment and repeat
assembly.
Figure 19
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 – Figure 20
To service the piston outlet valve, refer to Section 5.2.
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. It is not necessary to remove the valve from the
blast machine.
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.
Refer to Section 7.9 for replacement parts.
Figure 20
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 – Figure 21
WARNING
To avoid serious injury from the sudden release
of trapped compressed air, all service on the
blast machine must be done with the air OFF, the
air supply locked out and tagged out, and the air-
supply line bled.
NOTE: Failure to clean the abrasive trap on a regular
basis is a major cause of system malfunction. Clean
the abrasive trap screen and empty the trap at least
twice daily.
5.4.1 To check the abrasive trap screen, loosen the
thumb screw on the upper lock bar, swing the lock bar
off the cap, and remove the cap.
5.4.2 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:
5.4.3 To clean the bottom section of the trap, loosen
the thumb screw on the lower lock bar, swing the lock
bar off the lower cap, and then remove the cap.
5.4.4 Empty all abrasive from the bottom and top
sections.
5.4.5 Install the screen in the top section. The
smallest diameter end of the screen must face up, as
shown in Figure 21.
Valve Body
Diaphragm
Cap
Cap Screw
Lock Washer
*Items included in service kit.
Refer to Section 7.8 fo
r
re
p
lacement
p
arts.
1/4" NPT Plug
Elbow Adaptor
Valve Bonnet
Plug and Spindle Guide
Piston Cup
*Valve Plug
Piston Rod
*Valve Plug
*Valve Plug Retainer
*Spring
Valve Body
*Nylon Washer
*Cap Screw (guide bolt)
Plug
Assembly
Piston Assembly

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 15
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
5.4.6 Reassemble the upper and lower caps.
NOTE: The upper and lower caps are identical
except the screen gasket is glued into the upper
cap. Make sure the screen gasket is in place in the
upper cap and the O-rings are in place on both caps
before assembly.
SCREEN
L
C
O
EANUT
Make sure the screen gasket is in the upper cap.
* Items included in service kit.
Refer to Section 7.5 for replacement parts.
Figure 21
5.5 Remove and Install Reusable Control-Hose
Fittings ‒ Figure 22
5.5.1 Control hoses may be shortened and cut to length
as follows:
1. Remove the hose end by placing the sleeve in a vise
or use a backup wrench on the sleeve to prevent it
from turning. Unscrew the insert by turning it
counterclockwise.
2. Turn sleeve clockwise to remove from the hose.
3. Cut hose to length.
4. Lubricate inside and outside of hose with SAE 20 or
equal oil.
Figure 22
5. Turn sleeve counterclockwise to install on hose. Do
not overtighten the sleeve; stop tightening as soon as
the hose bottoms out against the sleeve’s internal
shoulder, and back it out 1/4 turn. Overtightening will
cause the hose to curl inward and could cause
blockage.
6. Push end of insert into sleeve and turn clockwise to
tighten until the insert hex is against the sleeve.
5.6 RLX Control Handle
5.6.1 A separate manual is provided for the control
handle. Refer to manual 10575 to service the RLX
Control Handle.
5.7 Metering Valve (for ACS systems only)
5.7.1 A separate manual is provided for the metering
valve. Follow instructions in the manual to service the
metering valve.
6.0 TROUBLESHOOTING
NOTE: This section applies to the remote control
system only. Always refer to the appropriate section
of this manual, or manuals for accessory equipment,
when troubleshooting and before servicing the
equipment.
W
ARNING
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 air is required to check the controls,
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 lever is depressed
6.1.1 Does the blast machine pressurize? If it does,
refer to the troubleshooting section of the blast-machine
operation manual.
Upper Cap
Upper Lock Bar
Thumb Screw
*Screen
Lower Lock Bar
*Cap O-Ring
*Screen Gasket
Lower Cap
*Cap O-Ring
Sleeve
Insert
Control Hose
Install
Remove
Install
Remove

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 16
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
6.1.2 Make sure the compressor is on and all air-
supply valves to the machine are open.
6.1.3 Make sure the safety petcock on the inlet valve
is closed.
6.1.4 With the control lever up, check for air escaping
through the opening under the lever. If no air is
escaping, the orifice fitting on the inlet valve (refer to
Figure 23) is blocked, or the outbound line from the
orifice to the control handle is blocked and must be
cleared.
Figure 23
6.1.5 Check the rubber button on the control handle
for wear or damage, and make sure the rubber totally
seals the opening when the handle is pressed. (RLX
control handle is covered in Manual No. 10574).
6.1.6 Press the control lever. Feel for and listen for air
leaks any place on the handle. No air should escape
when the control lever is pressed. If there is a leak, it
must be located and repaired.
6.1.7 Press the control lever and check control hoses
and fittings for air leaks.
6.1.8 Open the safety petcock and press the control
lever; air should come out of the petcock. If air does not
come out the petcock:
 Make sure the rubber bumper seals the opening on
the control handle when the handle is pressed.
 Check for air leaks in the control handle.
 Check the line from the control handle to the upper
fitting on the inlet valve for blockage.
 If a diaphragm outlet valve is used, check the
diaphragm for split or damage.
If air does come out the petcock, the inlet valve is not
functioning. Turn OFF the compressed-air supply and
service the valve, per Section 5.1.
6.1.9 Close the safety petcock and press the control
lever. Make sure 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 or piston O-ring in
the inlet valve. Refer Section 5.1.
6.1.10 Insufficient-size air-supply hose or reduced-size
fittings between the compressor and blast machine.
Inside diameter of air-supply hose should be three to
four times the diameter of the nozzle.
6.1.11 Dirty element in optional air filter. Inspect filter
element.
6.1.12 Pop-up valve stuck, or internal piping worn or
out of alignment. Inspect internal piping.
6.2 Outlet valve won't exhaust or exhausts too
slowly
6.2.1 Abrasive trap screen blocked, or abrasive trap
needs to be emptied. Empty the trap and clean the
screen at least twice daily. Replace the screen as
needed. Refer to Section 5.4.
6.2.2 Exhaust muffler blocked. Clean or replace the
muffler element or muffler. The procedure to service the
muffler is covered in Muffler Service Instruction No.
22322.
6.2.3 After releasing the control handle, open the
safety petcock on the inlet valve:
 If the machine does depressurizes, control air
remains in the control lines. Refer to Paragraphs
6.2.4, 6.2.5, 6.2.6, and 6.2.7.
 If the machine does not depressurize, the inlet valve
is not fully closing or the outlet valve is not fully
opening. Refer to Paragraphs 6.2.8, 6.2.9, and
6.2.10.
6.2.4 Check the pneumatic adaptor gasket on the
control handle for swelling, which restricts air flow
through the handle exhaust opening. The RLX control
handle is covered in Manual No. 10574.
6.2.5 Inspect the exhaust opening in the control-handle
pneumatic adaptor; make sure it is clear of obstruction that
restricts air from escaping through the opening.
6.2.6 Check for blockage in the control hose.
6.2.7 Inspect the orifice fitting on inlet valve (refer to
Figure 23) and make sure it 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.
6.2.8 Make sure the inlet valve closes when the
control handle is released. If it does not seal off
incoming compressed air, the valve requires service.
Refer to Section 5.1.
Orifice Fitting
1/16" Orifice
Inlet Valve

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 17
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
6.2.9 Make sure the piston outlet valve fully opens
when the control handle is released. If it does not,
service the valve, per Section 5.2.
6.2.10 Diaphragm in optional diaphragm outlet valve
has taken a set toward the blast machine. Refer to
Section 5.3 and reverse the diaphragm.
6.3 Optional ACS Feature
6.3.1 No abrasive when the ACS toggle is moved to
ON blast mode
6.3.1.1 Machine empty of abrasive. Check abrasive level.
6.3.1.2 Make sure the metering valve’s abrasive flow
control is in the open position.
7.3.1.3 Make sure the ACS toggle is pointing in the ON
position, away from the nozzle.
6.3.1.4 Check for leak or blockage in the single-line hose
or fittings between the control handle’s ACS switch and the
metering valve.
6.3.1.5 Obstruction in abrasive valve or valve requires
service. Refer to the metering valve manual for operation
of the metering valve.
6.3.2 Abrasive flow does not stop when ACS toggle
is moved to the OFF position
6.3.2.1 Brass filter on ACS switch clogged. Inspect filter
for blockage.
6.3.2.2 Metering valve requires service. Refer to the
metering valve manual for operation of the metering valve.
7.0 REPLACEMENT PARTS
7.1 Hose Safety Accessories ‒ Figure 24
NOTE: Spring-lock pins are affixed to nylon
couplings. When connecting two nylon coupling
together, make sure the coupling lock pins are at
180 degrees (pins should enter the open hole of the
adjoining coupling). One lock pin, as shown in Figure
24, is used when connecting a nylon coupling to a metal
coupling, and two lock pins are used when connecting
two metal couplings together.
Item Description Stock No.
1. Safety cable
for 1-1/2" to 3" OD hose ........................ 15013
for 1-1/2" to 4" OD hose ........................ 27405
2. Lock pin, coupling (package of 25) .......... 11203
Figure 24
7.2 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-100C, 1" w/ piston outlet valve ...................... 21152
TLR-300C, 1-1/4" w/ piston outlet valve ................ 21153
TLR-100DC, 1" w/ diaphragm outlet valve ............ 21154
TLR-300DC, 1-1/4" w/ diaphragm outlet valve ...... 21155
1
2

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 18
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
7.3 System Replacement Parts ‒ Figure 25
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 25
7.4 ACS System Replacement Parts – Figure 26
All other parts are the same, as shown in Section 7.3
and Figure 25. 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 26
7.5 Abrasive Trap – Figure 27
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. Screw, 3/8" x 3/8" shoulder ....................... 03291
8.* Gasket, screen, 1/8" thick (1) ................... 02434
9.* Label, "clean screen twice daily" (1) ......... 02129
10. Nipple, 1" NPT x 3" long ........................... 01703
(-) Service kit, includes items marked *,
quantity is shown in ( ) .............................. 01925
Figure 27
7
2
8
1
11
6
10
3, 4
9
5 12
3
4
1
2
6
3
2*
4
7
8*
3
5
6
2*
1*
9*
7
5
10

TLR-100/300 SERIES PNEUMATIC REMOTE CONTROLS Page 19
© 2019 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 22428, Rev. E, 05/19
7.6 1-1/2" Inlet Valve – Figure 28
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
17. Nipple 1-1/4" NPT x close ......................... 01717
18. Bushing, 1-1/2" NPT x 1-1/4" .................... 01805
(-) Service kit, includes items marked *,
quantity is shown in ( ) ............................... 01927
Figure 28
7.7 1" Inlet Valve – Figure 29
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
16. Nipple, 1" x close ...................................... 01701
(-) Service kit, includes items marked *,
quantity is shown in ( ) ............................... 01929
Figure 29
2
1
15*
13*
16
14
17
4
3
12*
11*
6*
7*
10
8*
5
2
9
18
5
2
1
2
3
4
6*
7*
8
9
10*
11*
12*
13
14*
15
16