Clemco 600 User manual

APOLLO SUPPLIED-AIR RESPIRATOR
Helmet Model 600
Low Pressure 6 psi to 20 psi
O. M. 23929
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.
© 2014 CLEMCO INDUSTRIES CORP.
One Cable Car Dr.
Washington, MO 63090
Phone [phone]
Fax [phone]
Email: [email protected]
www.clemcoindustries.com
DATE OF ISSUE: November, 2003
REVISION: E, 03/14
WARNING
NOTICE
This supplied air respirator conforms to all NIOSH
specifications and standards and carries NIOSH
approval. As manufactured, this respirator
complies only with those foreign approvals that
accept NIOSH certification. Specifically, it has not
been manufactured to European standards
and does not carry the European mark.

PREFACE
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[I]
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• Employers are responsible for identifying all job site hazards, educating and training all persons who will operate and
maintain these products, and ensuring that all blast operators and their assistants understand the warnings and
information contained in these instructions relating to safe and proper operation and maintenance of this equipment.
• Serious injury or death can result from failure to comply with all Occupational Safety and Health Administration
(OSHA)regulations and all manufacturer’s instructions.
• This equipment is not intended for use in any area considered hazardous per National Electric Code NFPA 70 2011,
Article 500.
• Read this document and follow all instructions before using this equipment.


OSHA regulations relating to abrasive blasting are contained in the Code of Federal Regulations, Title 29 (29 CFR 1910 General Industry;
1915 Maritime; 1926 Construction). The most pertinent include: 1910.94 Ventilation, 1910.95 Occupational Noise Exposure, 1910.132
Personal Protective Equipment, 1910.133 Eye and Face Protection, 1910.134 Respiratory Protection, 1910.135 Head Protection,
1910.244 (b) Remote Controls. Consult www.osha.gov for complete information.

NO T I C E TO PURCHASERS AND U SE R S OF OUR
P R ODU C T S AND T H I S I N F O R M A T I ON A L M A T E R I A L
Clemco proudly provides products for the abrasive blast
industry and is confident that industry professionals will use
their knowledge and expertise for the safe and efficient use of
these products.
The products described in this material, and the information
relating to these products, are intended for knowledgeable,
experienced users.
No representation is intended or made as to: the suitability of
the products described here for any purpose or application, or
to the efficiency, production rate, or useful life of these
products. All estimates regarding production rates or finishes
are the responsibility of the user and must be derived solely
from the user’s experience and expertise, not from information
contained in this material.
It is possible that the products described in this material may
be combined with other products by the user for purposes
determined solely by the user. No representations are
intended or made as to the suitability of or engineering
balance of or compliance with regulations or standard practice
of any such combination of products or components the user
may employ.
Abrasive blast equipment is only one component of an
abrasive blasting job. Other products, such as air
compressors, air filters and receivers, abrasives, scaffolding,
hydraulic work platforms or booms, equipment for lighting,
painting, ventilating, dehumidifying, parts handling, or
specialized respirators or other equipment, even if offered by
Clemco, may have been manufactured or supplied by others.
The information Clemco provides is intended to support the
products Clemco manufactures. Users must contact each
manufacturer and supplier of products used in the blast job for
warnings, information, training, and instruction relating to the
proper and safe use of their equipment.
GENERAL INSTRUCTIONS
This material describes some, but not all, of the major
requirements for safe and productive use of blast machines,
remote controls, respirator systems, and related accessories.
All equipment and accessories must be installed, tested,
operated and maintained only by trained, knowledgeable,
experienced users.
The blast operator and all workers in the vicinity must be
properly protected from all job site hazards including those
hazards generated by blasting.
Work environments involving abrasive blasting present
numerous hazards. Hazards relate to the blast process from
many sources that include, but are not limited to, dust
generated by blasting or from material present on the surface
being blasted. The hazards from toxic materials may include,
but are not limited to, silica, cyanide, arsenic, or other toxins
in the abrasives or in the coatings, such as lead or heavy
metals. Other hazards from toxins include, but are not limited
to, fumes from coating application, carbon monoxide from
engine exhaust, contaminated water, chemicals or asbestos.
In addition, physical hazards that may be present include, but
are not limited to, uneven work surfaces, poor visibility,
excessive noise, and electricity. Employers must identify all
job site hazards and protect workers in accordance with
OSHA regulations.
Never modify Clemco equipment or components or
substitute parts from other manufacturers for any Clemco
components or parts. Any unauthorized modification or
substitution of supplied-air respirator parts violates OSHA
regulations and voids the NIOSH approval.
IMPORTANT
Contact Clemco for free booklets:
Blast Off 2 – Guide to Safe, Productive, and Efficient Abrasive
Blasting, and Abrasive Blasting Safety Practices – Guide to Safe
Abrasive Blasting.
Clemco Industries Corp. One Cable Car Drive Washington MO 63090
Tel: [phone] — Fax: [phone]
Email: [email protected]
Website: www.clemcoindustries.com

PREFACE
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[II]
OPERATIONAL INSTRUCTIONS
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OPERATOR SAFETY EQUIPMENT
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OSHA regulation 1910.134 requires appropriate respiratory protection for blast operators and workers in
the vicinity of blasting. These workers must wear properly-fitted, properly-maintained, NIOSH-approved,
respiratory protection that is suitable for the job site hazards. Blast respirators are to be worn only in
atmospheres not immediately dangerous to life or health from which wearers can escape without use of
the respirator.

The employer must develop and implement a written respiratory protection program with required
worksite- specific procedures and elements for required respirator use. The employer must provide
effective training to employees who are required to use respirators. The training must be comprehensive,
understandable, and recur annually, and more often if necessary.

NEVER use abrasives containing more than one percent crystalline silica. Fatal diseases, such as silicosis,
asbestosis, lead or other poisoning, can result from inhalation of toxic dusts, which include, but are not
limited to, crystalline silica, asbestos, and lead paint. Refer to NIOSH Alert 92-102; and OSHA CPL 03-00-007:
“National Emphasis Program – Crystalline Silica”, in which OSHA describes policies and procedures for
implementing a national emphasis program to identify and reduce or eliminate health hazards from exposure
to crystalline silica. Numerous topics associated with the hazards of crystalline silica in silica blasting sand
can be found on http:// osha.gov/. Clemco urges users of silica blasting sand to visit this website, and read
and heed the information it contains.

Always make sure the breathing air supply (respirator hose) is not connected to plant lines that supply
gases that include, but are not limited to, oxygen, nitrogen, acetylene, or other non-breathable gas. Never
modify or change respirator air line connections without first testing the content of the line for safe
breathing air. Failure to test the line may result in death to the respirator user.


• Breathing air quality must be at least GradeD,
as defined by the Compressed Gas Association
specification G-7.1, per OSHA Regulation 29 CFR
1910.134. When compressed air is the breathingair
source, a Clemco CPF (suitable sorbent bed filter)
should be used. Respirator hose connecting the
respirator to the filter must be NIOSH approved.
Non- approvedhose can cause illness from
chemicals employed to manufacture the hose.
• All workers must always wear NIOSH-approved
respirators when any dust is present. Exposure to
dust can occur when handling or loading abrasive,
blasting, cleaning up abrasive, or working in the
vicinity of blasting. Before removing the respirator,
test the air with a monitoring device to ensure it is
safe to breathe.
• Clemco respirators DO NOT removeor protect against
carbon monoxide or any other toxic gas. Monitoring
devices must be used in conjunction with the respirator to
ensure safe breathingair. Always locate compressors and
ambient air pumps where contaminatedair will not enter
the air intake.

• Always use Clemco lenses with Clemco respirators;
installing non-approvedlenses voids the NIOSH approval.
Respirator lenses aredesigned to protect the wearerfrom
rebounding abrasive; they do not protect against flying
objects, heavyhigh-speed materials, glare,liquids, or
radiation.
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INDUSTRY ORGANIZATIONS

For additional information, consult:
Occupational Safety and Health Administration (OSHA) - www.osha.gov
Compressed Gas Association (CGA) - www.cganet.com
TheSociety for Protective Coatings (SSPC) - www.sspc.org
National Association of Corrosion Engineers (NACE) - www.nace.org
American Society for Testing and Materials (ASTM) - www.astm.org
National Institute of Occupational Safety and Health (NIOSH) - www.niosh.gov
American National Standards Institute (ANSI) - www.ansi.org

PREFACE
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[III]
BLAST MACHINES AND REMOTE CONTROLS
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OSHA regulation 1910.169 describes the necessity of pressure relief valves on compressed air equipment. Do not
operate blast machines with air compressors that are not equipped with properly functioning pressure relief valves.
OSHA regulation 1910.244(b) requires the use of remote controls on blast machines.
Serious injury or death can result from many sources, among them:
Involuntary activation of the remote controls. Never modify or substitute remote control parts; parts are not
compatible among different manufacturers. Welding hose is not suitable for remote control hose. Its ID and material
composition make it unsafe for remote control use.
Exceeding the maximum working pressure. Clemco blast machines are built to ASME-code and carry a ‘U’ or ‘UM’
stamp, and National Board/serial number. Every machine is marked with its maximum working pressure. Never
exceed the maximum working pressure limits of the blast machine.
Uncontrolled blast stream. High-velocity abrasive particles will inflict serious injury. Always point the blast nozzle
in the direction of the blast surface only. Keep unprotected workers out of the blast area.
Welding on the blast machine. Never weld on the blast machine; welding voids the National Board approval and
may affect the dimensional integrity of the vessel.
Moving the blast machine. Never manually move a blast machine containing abrasive, any machine containing
abrasive must be moved with appropriate mechanical lifting equipment.
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HOSES, COUPLINGS, AND NOZZLE HOLDERS
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The inside diameter (ID) of air hoses, fittings, and connections
should be at least four times larger than the nozzle orifice size. Blast
hose ID should be three to four times the size of the nozzle orifice.
Example: a #6 nozzle (3/8” diameter orifice) calls for 1-1/2” ID blast
hose and 1-1/2” ID or larger compressor hose. All hose runs should be
kept as short as possible and run in as straight a line as possible to
reduce pressure loss.
To install, squarely cut the end of the hose so that it fits snugly
against the coupling or hose end shoulder. Always use the screws
recommended by the manufacturer ensuring that they do not
penetrate the inner wall. Make sure the couplings tightly fit the hose.
Install cotter pins at every connection or use couplings with built-in
lock-springs to prevent disengagement. Install safety cables at all
connections to prevent whipping if hoses disengage or blow out.
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MAINTENANCE AND REPAIR
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Completelyreadand follow all service instructions and recommended maintenance intervals. Always shut off compressor and
depressurize blast machine beforeperforming any maintenance. At everyservice interval, clean all filters, screens, and alarm systems. If
spring-loaded abrasive valves areused, always cage spring beforedisassembly.

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 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 areto
be freefrom defects in workmanship and materials for a
period of one yearfrom dateof shipment to buyer, but no warranty is
madethat the products arefit 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 madeavailable to the
customer upon request.
4. Theuse 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 freeof the
rightful claim of any third party by way of patentinfringement or the like.
6. This warranty is conditioned upon seller’s receipt within ten (10)
days afterbuyer’s discovery of a defect,of a written notice stating in
what specific material respects the product failed to meetthis
warranty. If such notice is timely given, seller will, at its option, either
modify the product or part to correct the defect,replacethe product or
part with complying products or parts, or refund the amount paid for
the defectiveproduct, any one of which will constitute the sole liability
of the seller and a full settlement of all claims. No allowance will be
madefor alterations or repairs made by other than those authorized
by seller without prior written consent of seller. Buyershall afford
seller prompt and reasonable opportunity to inspect the products for
which any claim is madeas abovestated.
Except as expressly set forth above,all warranties, express, implied
or statutory, including implied warranty of merchantability, are
herebydisclaimed.

PREFACE
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[IV]
DAILYSET‐UPCHECKLIST
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Make sure all blast operators are properly trained and suitably attired with a blast suit, safety boots, leather gloves, respiratory and hearing protection. Every day before start up,
check all equipment components, including piping, fittings, and hoses, and valves, for leaks, tightness, and wear. Repair or replace as needed. Use the following checklist.

1. PROPERLY-MAINTAINED AIR COMPRESSOR sized to provide
sufficient volume (cfm) at given pressure for nozzle and other tools. ADD 50%
volume (cfm) reserve to allow for nozzle wear. Use large compressor outlet and
air hose (at least 4 times the nozzle orifice diameter). For oil-lubricated
compressors, the employer shall use a high- temperature or carbon monoxide
alarm, or both, to monitor carbon monoxide levels. If only high-temperature
alarms are used, the air supply shall be monitored at intervals sufficient to
prevent carbon monoxide in the breathing air from exceeding 10 ppm. Follow
the manufacturer’s checklist and maintenance instructions.
2. BREATHING-AIR COMPRESSOR (or oil-less ambient air pump)
capable of providing Grade D quality air, located in a dust free area. Read # 1
above.
3. CLEAN, PROPERLY-MAINTAINED NIOSH-APPROVED SUPPLIED-AIR
RESPIRATOR
worn by blast operators, and other workers exposed to blast dust.
Make sure all respirator components are in place — all lenses, inner collar, and
cape. Thoroughly inspect all components for wear. The NIOSH approval (approval
number is listed in the owner’s manual) is for a complete assembly from point of
attachment on the CPF (sorbent bed) filter to the complete respirator. Substitution of
any part voids the NIOSH approval.
4. CARBON MONOXIDE MONITOR/ALARM installed at the CPF filter or
inside the supplied-air respirator for monitoring for the presence of deadly CO gas
and warning the operator(s) when the CO level reaches an unacceptable level.
When an ambient air pump is used for breathing air, a CO monitor provides a
measure of safety. Read # 1 above.
5. BREATHING-AIR FILTER (OSHA-REQUIRED sorbent bed filter) for
removal of moisture and particulate matter in the compressed air breathing-air
supply. Monitor the condition of the cartridge and replace when odor is detected or
at 3 month intervals, whichever comes sooner. The breathing air filter does NOT
detect or remove carbon monoxide (CO). Always install a CO monitor/alarm.
6. BLAST MACHINE (bearing U or UM stamp, National Board Number, and
Maximum Working Pressure) sized to hold a 30-minute abrasive supply. Examine
pop-up valve for alignment. Check piping, fittings, screens, valves for tightness,
leaks, and wear. Always ground the machine to eliminate hazard of static shock.
Install a blast machine screen to keep out foreign objects. Use a blast machine
cover if left outdoors overnight. Never exceed the maximum working pressure of the
vessel.
7. AIR LINE FILTER (moisture separator) installed as close as possible to the
blast machine inlet and sized to match the size of the inlet piping or larger air supply
line. Clean filter and drain often. Damp abrasive causes operational problems.

8. REMOTE CONTROLS are required by OSHA and must be in perfect
operating condition. Test and check all components to ensure all parts are present
and fully functional. Use genuine replacement parts. NEVER mix parts from different
manufacturers. Never use welding hose for remote control hose.

9. BLAST HOSE should have an inside diameter sized to suit the blast nozzle.
The ID should be three to four times the size of the nozzle orifice diameter. Blast hose
should be arranged in as straight a line as possible from the blast machine to the
work area, avoiding sharp bends.

10. COUPLINGS AND NOZZLE HOLDERS should fit snugly on the hose and
be installed with manufacturer recommended screws. Coupling lugs must snap firmly
into locking position. Gasket must always be used to form a positive seal, and cotter
pins must be installed. Replace gasket when wear, softness or distortion is detected.
Check nozzle holder for thread wear; replace at any sign of wear. Install safety cables
at all connections.

11. NOZZLE orifice size should be checked and nozzle replaced when worn
1/16” from original size. (No. 5 nozzle has 5/16” orifice diameter; replace when it
measures 3/8”). Threads should be inspected daily for wear and nozzle should be
replaced when wear is detected. Always use a nozzle washer.

12. ABRASIVE must be a material specifically manufactured for blasting. It
should be properly sized for the job. Check material safety data sheet for free-
silica, cyanide, arsenic, lead and other toxins and avoid use when these toxic,
harmful substances are present.

SURFACE TO BE BLASTED should be examined for hazardous substances.
Take appropriate protective measures as required by OSHA to ensure the blast
operator, other workers in the vicinity, and any bystanders are properly protected.
©Clemco Industries Corp., Stock No. 20954P, 0692 Rev. F, 06/12
1. Air Com
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7. Air Line
Moisture
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5. CPF Air Filte
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6. ASME Code
Bl
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8. Remote
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9. Blast Hose 10. Hose Couplings and Safety Cables
11. Appropriately Sized Nozzle
12. Abrasive
4. External or
Helmet Mounted
Carbon Monoxide
Monitor /Alarm
2. Breathing Air Compressor for
High Pressure Respirators3. NIOSH Approved
Supplied-Air Respirator
or Ambient Air Pump for
Low Pressure Respirators

APOLLO LOW PRESSURE SUPPLIED-AIR RESPIRATOR Page 1
HELMET MODEL 600
© 2014 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 23929, Rev. E 03/14
1.0 INTRODUCTION
1.1 Scope of manual
1.1.1 This manual covers setup, operation,
maintenance, and replacement parts for Clemco Apollo
LP (low pressure) Series Supplied-Air Respirator:
Model 600 LP.
1.1.2 Read this entire manual and all accessory
manuals before setting-up and using the respirator.
Manuals for Clemco low pressure, ambient air pumps
that may be used with Apollo LP Respirators are
available on our web site, www.clemcoindustries.com,
Refer to Figure 1 for a typical set-up.
1.2 Safety Alerts
1.2.1 Clemco uses safety alert signal words, based
on ANSI Z535.4-2011, 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.
WARNING
Warning indicates a hazardous situation that, if
not avoided, could result in death or serious
injury.
DANGER
Danger indicatesahazardous situation that, if
not avoided, will result in death or serious
injury.
1.3 NIOSH Approval Number 19C-358
1.3.1 The Clemco Apollo Supplied-Air Respirator is
approved by the National Institute of Occupational
Safety and Health (NIOSH).
1.3.2 The NIOSH label shown below lists the Apollo
respirator approval numbers. An X on the approval line
indicates which components are approved for the
specific respirator. Do not use any non-approved
components with this respirator.

APOLLO LOW PRESSURE SUPPLIED-AIR RESPIRATOR Page 2
HELMET MODEL 600
© 2014 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 23929, Rev. E 03/14
WARNING
IOSH approval applies only when this
supplied-air respirator is used as a complete
system. Do not make any non-approved
modification, deletion, or substitution. Non-
approved components void the NIOSH
approval and may permit ingress of toxic and
hazardous dust, resulting in toxic poisoning
and respiratory disease.
1.4 OSHA Regulations
1.4.1 OSHA Regulation 29 CFR 1910.134 for
respiratory protection in General Industry is referenced
throughout this document. Respiratory protection
standards for Construction 29 CFR 1926.103 and for
Maritime 29 CFR-1915.154, 1917, and 1918 refer back
to 1910.134. The complete regulation is available
through the U.S. Dept. of Labor web site at
www.osha.gov.
1.4.2 OSHA Regulations 29 CFR 1910.134(a) and
(c) require the employer to establish and maintain a
comprehensive, written, respiratory protection program
administered by a suitably-trained program
administrator.
1.4.3 It is essential that the user be properly
instructed in the use and maintenance of the respirator.
This manual must be made available to all users of the
respirator, and the users must demonstrate their
understanding of its subject matter. Read the entire
manual before installing or operating the equipment.
1.4.4 The respirator must be supplied with respirable
air meeting requirements described herein. It is the
responsibility of the employer to provide quality
breathing-air to the respirator, and to establish a
program to ensure that the respirator is properly used
and maintained.
1.5 Respiratory and Health Alerts
WARNING
TOXIC DUST POISONING
Research by the National Institute For
Occupational Safety and Health (NIOSH) has
discovered risks associated with dust produced
during abrasive blasting operations including but
not limited to Lead, Silica, Antimony, Arsenic,
Beryllium, Cadmium, Chromium, Cobalt, Nickel,
Tin, Nitrate and Nitrite, to unprotected abrasive
blasting operators and other personnel who may
be exposed to toxic dust in the abrasive blasting
vicinity. These risks include debilitating lung,
blood, liver, kidney, and skin injuries, and even
death. Toxic dust is produced primarily by the
breakdown of the abrasive being used and the
surface being treated, during abrasive blasting.
The breakdown of toxic coatings and hazardous
abrasive causes the contaminants to become
airborne. Breathing toxic dust generated by the
abrasive or surface being treated can cause health
and life-threatening toxic poisoning and can
damage vital organs. Breathing hazardous dust
produced from silica and other abrasives can cause
delayed life-threatening respiratory disease.
It is imperative that blasting contractors identify all
material being removed by blasting, and obtain
material safety data sheets (MSDS) for the blasting
abrasive prior to blasting. It is the responsibility of
the employer to identify all airborne contaminants
in the blast vicinity, and ensure they do not exceed
the permissible exposure limit (PEL) Ref. 29 CFR
1910.1000 and 29 CFR 1926.62. Thorough site
hazard examinations should be made by A Certified
Industrial Hygienist, Certified Safety Professional or
other qualified professional to identify all
contaminants generated by blasting and in the
blasting vicinity.
Exposure to dangerous levels of toxic or hazardous
dust is not restricted to blast operators. There may
be an equal or greater danger present after the
blasting process due to lingering airborne dust
particles, and especially from dust generated
during cleanup activity. Heavy metal paint,
asbestos, sand or other silica, and other toxic
material dusts will cause serious lung disease or
death if not prevented through the use of properly
designed, and maintained NIOSH-approved,
supplied-air respirators worn by blasting operators
and all personnel within the work area. OSHA’s
regulations found primarily in 29CFR1910, Subpart
Z provides the permissible exposure limits for all
toxic and hazardous substances. It is the
responsibility of the employer to determine the
inhalation hazards associated with the abrasive
blasting being performed. Do not begin any
operations including abrasive blasting without
being trained by the employer and fully
understanding the hazards associated with the
work performed.
The Apollo supplied-air respirator system is
approved by NIOSH as a Type-CE, continuous-flow,

APOLLO LOW PRESSURE SUPPLIED-AIR RESPIRATOR Page 3
HELMET MODEL 600
© 2014 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 23929, Rev. E 03/14
abrasive blast, supplied-air respirator, in
accordance with title 42 CFR Part 84. The NIOSH
recognized assigned protection factor (APF) for
any supplied-air respirator equipped with a loose-
fitting hood or helmet and operated in a
continuous flow mode is 25, based upon the
NIOSH Respirator Decision Logic (Pub. No. 87-
108). In other words, any Type-CE respirator
should be used only in atmospheres in which the
contaminant level does not exceed 25 times the
permissible exposure limit. However, OSHA
revised its existing Respiratory Protection
standard in 2006 to add APFs and Maximum Use
Concentration (MUC) provisions. APF means the
workplace level of respiratory protection that a
respirator or class of respirators is able to provide
to workers. OSHA placed a table reflecting the
appropriate APF for various respirators in 29CFR
1910.134(d)(3)(i)(A). OSHA also provides a free
publication titled “Assigned Protection Factors”
(reference number “OSHA 3352-02 2009”) to assist
the user and their employer in understanding the
selection of respirators based on APFs and MUCs.
This section of the OSHA regulations allow the
employer to assign an APF of 1000 to all Apollo
Series Respirators based on the simulated
workplace protection factor studies Clemco has
performed. These studies are available for
download from Clemco’s Website
www.clemcoindustries.com, under the “Safety
Info” tab
The employer must provide and maintain
appropriate approved respirators, in addition to
providing operator training and employing
required work site safety practices.
To avoid any potential danger of respiratory injury,
approved, supplied-air respirators must be worn at
all times in the presence of any type of dust. The
respirator must be maintained as described
herein. Improper use of any respirator may cause
life threatening respiratory disease, and immediate
poisoning from toxic dust. Respirators should be
removed only after the ambient air has been tested
with a dust monitor, and found to be safe to
breathe.
Toxic dust poisoning also may occur by eating,
drinking, or smoking in a contaminated area, or by
eating, drinking, or smoking in a non-hazardous
area before thorough washing of hands and face.
Do not eat, drink or smoke in the blast area.
Thoroughly wash hands and face to remove
contaminants before eating, drinking, or smoking
outside the blast area.
This manual does not contain all the health and
safety requirements regarding toxic and hazardous
dust exposure. Obtain copies of the OSHA
regulations and consult a safety professional
and/or industrial hygienist for complete
requirements.
Within this manual we refer to hazardous or
contaminated environments. These environments
can be any places around the blast area that could
contain toxic or hazardous dust.
If these warnings are not completely understood, or
if further information is required, contact a local
OSHA office. If any personnel in the abrasive
blasting vicinity cannot read or comprehend these
warnings and the entire content of this instructional
material, assign a qualified person to instruct
him/her.
Additional information on abrasive blasting hazards
titled “Preventing Silicosis and Death From
Sandblasting”, Publication No. 92-102, is available
from:
Publications Dissemination, DSDTT
National Institute for Occupational Safety and Health
4676 Columbia Parkway
Cincinnati, OH 45226 [phone]
1.6 Cautions and Limitations
A - Not for use in atmospheres containing less than 19.5
percent oxygen.
B - Not for use in atmospheres immediately dangerous
to life or health (IDLH).
C - Do not exceed maximum use concentrations
established by regulatory standards.
D - Air-line respirators can be used only when the
respirators are supplied with respirable air meeting the
requirements of CGA G-7.1 for Grade D or higher quality.
E - Use only the pressure ranges and hose lengths
specified in the user’s instructions.
J - Failure to properly use and maintain this product
could result in injury or death.
M - All approved respirators shall be selected, fitted,
used, and maintained in accordance with OSHA and
other applicable regulations.
N - Never substitute, modify, add, or omit parts. Use
only exact replacement parts in the configuration as
specified by the manufacturer.

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O - Refer to user’s instructions, and/or maintenance
manuals for information on use and maintenance of
these respirators.
S - Special or critical user’s instructions, and/or specific
use limitations apply. Refer to instruction manual before
donning.
1.7 S – Special or Critical User’s Instructions
1.7.1 Air pressure at the point of attachment (the
point of attachment is where the respirator supply hose
is connected to the respirable air source) must be
maintained at pressures between the minimum and
maximum pressure as shown in the table in Section 4.2.
WARNING
Failure to maintain the minimum pressure at
the point of attachment may reduce air flow
below the minimum flow required by OSHA.
Reduced air flow may result in ingress of
hazardous toxic dust, subjecting the user to
immediate health and life threatening
poisoning and subsequent respiratory disease.
1.7.2 Couple no more than the maximum number of
sections and total maximum lengths of respirator hose
as noted in the table in Section 4.2.
1.7.3 The respirator is designed for specific use in
abrasive blasting applications. Do not use in other
operations such as painting or welding.
1.8 Protection
1.8.1 NIOSH recognized Assigned Protection Factor
(APF) for the Apollo type CE respirator is 25 times the
permissible exposure limit (PEL). In other words, NIOSH
recommends the Apollo type CE respirators should only
be used in atmospheres in which the contaminant level
does not exceed 25 times the PEL. However OSHA's
2006 revised Respirator Standard allows an exception for
type CE respirators which have validated third party
testing for use up to 1000 APF. In order not to be in
violation of OSHA 1000 APF the end-user must have a
copy of this validated testing. A copy of Clemco validated
testing may be downloaded from the "Safety Info" tab on
our website, www.clemcoindustries.com.
1.8.2 Head: The respirator protects the wearer’s head
and neck from impact and from abrasion caused by
rebounding abrasive. The respirator meets physical
requirements for industrial head protection as stated in
ANSI Z89.1-2003 as a Type I, Class G protective
helmet.
1.8.3 Face and Eye: The Apollo inner lens meets
impact and penetration requirements under ANSI Z87.1-
1989.
1.8.4 Hearing: Noise generated by the Apollo
respirator, and measured inside the helmet does not
exceed 80 decibels. (42 CFR part 84.140) When any
exterior noise causes the internal noise level to exceed
80 decibels, the user must wear additional hearing
protection. A variety of hearing protectors can be worn
with the respirator.
2.0 INSPECTION
NOTE: A Clemco respirator hose is part of the approval
assembly, and must be used with the respirator. Hoses
are not included with all respirators because blast
operators are often assigned personal respirators, while
using common respirator hoses. If a hose is not
available, it must be ordered from an authorized
distributor of Clemco products.
2.1 Component Checklist
2.1.1 Make sure that all the respirator components are
present. Each respirator box should contain the
following:
Helmet with chin strap, suspension and cape
attached
Breathing tube assembly
Constant-flow connector
NOTE: If the respirator does not include an approved
Clemco respirator hose, and if one is not at the work site
for use with the respirator, one or more alternate hoses
must be ordered separately.
2.1.2 When all of these components are present,
prepare the respirator for operation per Section 3.0.

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Figure 1
3.0 PREPARATION
3.1 Adjust Helmet Suspension per Section 6.1.
3.2 Prepare Lens System
WARNING
Never use the respirator without a complete
lens system in place. A complete lens system
includes the fixed inner lens and intermediate
lens. The fixed, inner lens provides support for
the window gasket. If the gasket is not
adequately supported, leaks can occur which
could permit entry of toxic and hazardous dust
or abrasive into the helmet.
3.2.1 The lens system is an important part of the
respirator assembly. The helmet is supplied with an
inner lens that is secured by the lens gasket. To protect
the inner lens, an intermediate lens and perforated outer
lenses are securely held in position by the window
frame. Always use an inner lens and an intermediate
lens with the respirator. The perforated outer lens is
optional, and protects the intermediate lens from rapid
frosting.
3.2.2 When the perforated outer lenses are correctly
installed, as one lens becomes frosted during blasting, it
can be torn off to expose the next lens. To protect the
inner lens, make sure the perforated and/or intermediate
lens(es) are in place per Section 9.1.
Apollo Helmet Assembly
Model 600
NOTE: The air pump must be located to
ensure the intake draws Grade D or higher
quality respirable air. If air quality at the
pump’s intake cannot be assured use an
intake hose extension to draw air from an
area where clean, respirable air is certain.
Breathin
g
Tube Assembl
y
Point of Attachment
Constant Flow Connector
Res
p
irator Hose
Ambient Air Pump
Some items are positioned for clarity.
The air pump must be protected from the blasting environment.

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3.3 Breathing Tube Assembly
CAUTION
Note the directional flow arrows on the labels at
both ends of the breathing tube. The flow
arrows indicate the direction of air flow to the
helmet. Flow arrows must point toward the
helmet. Failure to properly attach the breathing
tube may damage the tube's acoustical foam,
which will block air flow, or it may increase
noise levels beyond OSHA limits.
3.3.1 The breathing tube has a clamped-on end and a
molded-on end. Attach the clamped-on end to the
threaded air inlet fitting at the back of the helmet as
shown in Figure 2. Do not over-tighten; hand-tight is
sufficient.
3.3.2 Attach the molded-on swivel connector to the
constant-flow connector.
Figure 2
CAUTION
Use the strap handle to carry or hang the
respirator. Never hold, carry or hang the
respirator by the breathing tube. Mishandling
the respirator in this manner may damage the
tube or helmet inlet. Any leaks or breaks in the
breathing tube will alter the air flow through the
respirator and affect user’s safety and comfort.
3.4 Respirator Hose
WARNING
OSHA regulations 29 CFR 1910 and 29 CFR
1926 require that respirator air line couplers be
incompatible with air lines for non-respirable
use. This incompatibility prevents inadvertent
supply of respirators with potentially
hazardous, non-respirable gases or oxygen. It
is the employer's or facility owner's
responsibility to comply with the regulation.
3.4.1 Respirator hose must be NIOSH-approved
Clemco 1/2"ID respirator hose.
3.4.2 If longer hose is required, it must be a NIOSH-
approved Clemco 1/2"respirator hose extension. Use
50-foot or 100-foot Clemco respirator hoses in any
combination as noted in the table in Section 4.2, not to
exceed 300 ft. or three individual hose lengths.
3.4.3 Attach the female disconnect end of the
respirator hose to the constant-flow connector. The male
end attaches to the ambient air pump.
3.5 CMS-3 CO Monitor Option, Respirator Mounted
The Clemco supplied air respirator model Apollo 600 LP
is NIOSH approved with the accessory CMS-3 personal
carbon monoxide alarm, but NIOSH has not evaluated the
function of the CMS-3 personal carbon monoxide alarm.
3.5.1 Place the transparent mounting strip on the
inside of the inner lens, and into the same window
gasket groove as the inner lens. Position it so it is within
peripheral vision toward the side of the window opening.
3.5.2 Remove backing from the Velcro®hook tape
and adhere it to the center of the mounting strip (the loop
tape adheres to the monitor).
3.5.3 Attach the monitor to the strip and don the
helmet to make sure the monitor alarm light is visible
from inside the helmet.
3.5.4 Remove the monitor and prepare it for operation
per instructions supplied with the monitor.
3.5.5 Remove the monitor to do any service or
calibration, including turning the monitor on and off. Do
this to make sure the monitor is fully functional before
placing it inside the helmet.
Constant-Flow Connector
Connect the molded-on
swivel to the constant-flow
connecto
r
Breathin
g
Tube Assembl
y
Connect the clamp-on
swivel to the helmet’s
inlet fitting.

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4.0 AIR SUPPLY
WARNING
Air supplied to this respirator system is critical
to the safety of the user. Read this section
carefully. Poor quality air or low air volume will
cause serious respiratory injury or death to the
user. See Toxic Dust Poisoning Warning in
Section 1.5.
WARNING
This respirator is intended for use with (low
pressure) ambient air pumps. Do not use
compressors or high pressure cylinders
(bottles) as an air source for this respirator. Air
supplied from compressors poses hazards,
especially from carbon monoxide that are not
covered in these instructions. High pressure
cylinders require special knowledge for their
use and compliance, details of which are not
covered in these instructions.
4.1 Air Quality
4.1.1 The quality of air supplied to the respirator is
extremely critical to the safety of the user. Special care
must also be taken to avoid accidental connection to any
other gas lines; such as, oxygen, acetylene, or nitrogen.
DANGER
Never connect a breathing-air line to an air
source that has not been tested for gas and
particulate contamination. The presence of
unacceptable levels of carbon monoxide (CO)
or other gases, or oxygen deficiency in
breathing air will cause death to the user.
4.1.2 The employer is responsible for ensuring that
breathing air shall meet the requirements for Grade D or
higher quality, as described in Compressed Gas
Association Commodity Specification pamphlet G-7.1.,
titled Commodity Specification For Air, published by
Compressed Gas Association Inc., Chantilly, VA.
Website: www.cganet.com (29 CFR 1910.134 (i)).
4.1.3 Limiting characteristics of Grade D air, at the
time of publication of this manual are as follows:
Carbon Dioxide ............. maximum of 1000 ppm
Carbon Monoxide .............. maximum of 10 ppm
Odor ................................. *No pronounced odor
Oil (hydrocarbons) .............maximum of 5 mg/m3
Oxygen .............................between 19.5 - 23.5%
* Specific measurement of odor in gaseous air is
impractical. Air may have a slight odor but the
presence of a pronounced odor renders the air
unsatisfactory.
4.1.4 Prior to using the respirator, read the owner’s
manual and all instructions, labels, and warnings relating
to the ambient air pump.
WARNING
The air pump must be located where Grade D or
higher quality respirable air is ensured. If air
quality at the pump’s intake cannot be assured,
use an intake hose extension to draw air from
an area where clean, respirable air is certain.
Any toxic air entering the pump will enter the
respirator and will cause severe illness or death
to the user.
4.1.5 Take precautions to prevent contaminants from
entering through the air pump's inlet filter. Locate the air
pump's inlet filter away from all sources of contaminants
including carbon monoxide, which is found in engine
exhaust, and in any form of combustion. Place the pump
in an area away from vehicle traffic. Do not locate the
pump's inlet filter near any exhaust system outlet,
ventilation flue, or source of fumes or particles of any
kind. If the ambient air pump cannot be placed in an
area where respirable air can be guaranteed, use an air
inlet extension hose as specified by the pump
manufacturer to bring air from an area where clean
respirable air is ensured.
S – Special or Critical User’s Instructions
4.2 Air Volume and Pressure
4.2.1 LP respirators are for use with ambient pumps,
which provide 6 to 20 cfm of Grade D air at pressures
shown in table in Section 4.2.2. Maintaining the correct
operating pressure at the point of attachment ensures
the correct air flow to the respirator.
4.2.2 Use the following table to determine the
minimum and maximum pressure settings and maximum
respirator hose length. Adjust the pressure with the
respirator hose and respirator attached. If the regulator
is adjusted with static pressure (no air flow), pressure
may drop below the required pressure when the

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respirator is connected, and may result in low air flow.
Setting the pressure as instructed will provide a
minimum of 7 cfm to the respirator.
Total Hose
Length
Maximum Number
of Hose Sections
Pressure (psi)
Min. Max.
50 feet 1 6 to 10
100 feet 2 8 to 14
200 feet 2 11 to 20
300 feet 3 15 to 20
NOTE: Use any combination of hose shown to provide a
maximum of 300 ft., but not to exceed three individual
hose lengths.
4.2.3 Pressure Conversion Kit
4.2.3.1 This optional accessory kit contains parts and
instructions to convert an Apollo 600 respirator from low
pressure (for use with an ambient air pump) to high
pressure (Grade “D” Compressed Air). The kit is listed in
Section 10.1.
5.0 OPERATION
WARNING
Except for emergency evacuation when the use
of the respirator hinders escape, keep the
respirator on and leave the respirator-use area
immediately if any of the following occur:
Any part of the respirator system
becomes damaged
Any air monitoring alarm is activated
Air flow into the respirator is reduced or
stops
Breathing becomes difficult
At the first sign of dizziness, nausea,
fever, illness or injury
Any contamination is noted by taste,
smell or vision inside the respirator
Vision becomes impaired
Any irritation is noted
5.1 Prior to use, thoroughly inspect and clean the
helmet, breathing tube, respirator hose, air entry ports,
and fittings of all dust and debris. Inspect the helmet
suspension and if necessary adjust it per Section 6.1.
5.2 Begin the operation of the ambient air pump per
the manufacturer’s instructions.
5.3 Check air pressure at the point of attachment.
Set the pressure within the minimum and maximum
pressures assigned in Section 4.2. Pressure must be set
with the respirator connected.
5.4 Inspect all safety and breathing equipment used
in conjunction with the respirator as recommended by
the manufacturer.
5.5 Inspect respirator hoses and connections for
tightness and leaks.
5.6 Don the respirator in a clean non-hazardous
environment, free of contaminants, where the air is safe
to breathe.
5.7 When donning the respirator or taking it off,
keep it upright to prevent dust and abrasive from falling
inside. Holding the chin strap while donning the helmet
will make it easier to position it once the helmet is on.
5.8 Position the chin strap so it fits comfortably
under the chin.
5.9 Position the knit cuff on the inner collar so that it
fits snugly around the neck in turtleneck fashion, and
without any interference from clothing or long hair. When
correctly positioned, the smaller elastic end of the collar
must face up.
WARNING
Correct placement of the inner collar is critical
for providing the protection for which the
respirator is designed. The collar must be
positioned and maintained without any
interference from items such as hair, facial hair,
or shirt collars, between the inner collar and
user’s neck.
5.10 Pull the cape down to fully extend it and connect
the four elastic straps (two on each side) under the
arms, and tighten using the slides provided.
5.11 Put on the belt and constant-flow connector over
the cape. Buckle the belt around the waist, and tighten it
by pulling the belt end through the buckle insert.

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5.12 When finished blasting, and after cleanup is
completed, remove the respirator outside the respirator-
use area and where the air is safe to breathe.
WARNING
Do not don the respirator, or store it in a blast
contaminated environment. Do not remove the
respirator in a contaminated environment
except for emergency evacuation when the use
of the respirator hinders escape.
NOTE: The quick disconnect coupling on the end of the
respirator hose is not equipped with a shut-off.
Therefore, if the hose is disconnected from the respirator
while the pump is in operation, air will continue to flow
freely from the hose. After removing the respirator in a
clean environment, the air pump should be shut off.
6.0 ADJUSTMENTS
6.1 Suspensions
WARNING
The suspension maintains a fixed distance
between the head and the helmet. It is critical
that the suspension is properly installed, and
adjusted as described, to provide maximum
head protection and comfort.
6.1.1 Web Suspension with Sweatband
6.1.1.1 Remove the cape from the helmet per Section
9.4. NOTE: After the initial adjustment, minor
adjustments may be made without removing the cape.
6.1.1.2 Try on the helmet for fit and adjust the
suspension by turning the adjustment knob clockwise to
decrease the size, or counterclockwise to increase the
size. The suspension fits head sizes 6.5 to 8.
6.1.1.3 Reattach the cape to the helmet by following the
instructions in Section 9.4.
6.1.2 Padded Suspension (side pads)
6.1.2.1 The helmet comes with two side pads of
different thickness. The standard, black/grey pad is
installed in the helmet, the black/blue pad is loose.
Black/Grey (Standard) Side Pad: This pad fits most
head sizes.
Black/Blue: This pad fits smaller head sizes.
6.1.2.2 Try on the helmet for fit. If the helmet fits too
loosely, replace the standard pad with the thicker,
black/blue pad. Note: the grey and blue sides are
Velcro®receptive and are placed against the helmet
shell. The black side is facing the inside of the helmet.
6.1.2.3 Reattach the cape to the helmet by following the
instructions in Section 9.4.
7.0 MAINTENANCE PROGRAM
7.1 Basic Service
7.1.1 A program for maintenance and care of the
respirator must be established based on application,
working conditions, and hazards involved, and include
the following basic service.
• Inspection for defects (including a leak check)
• Cleaning and disinfecting
• Repair (service maintenance)
• Storage
Equipment must be properly maintained to retain its
original effectiveness. Reference OSHA Regulation 29
CFR 1910.134 (h).
7.2 Inspection
Inspection must be done in compliance with OSHA
Regulation 29 CFR 1910.134 (h)(3).
7.2.1 Inspect respirator before and after each use,
and during cleaning. Inspection shall include a check for
tightness of connections and the condition of the lenses,
suspension, cape and elastic parts, breathing tube,
respirator hoses and connectors, and constant-flow
connector.
7.2.2 Inspect the respirator hoses, breathing tube, air
entry ports, and fittings for dust contamination; make
sure they are clean before making connections.
7.2.3 The helmet suspension is very important for
maintaining maximum hard hat and respiratory
protection. It must be inspected for fit and wear on a
daily basis, and replaced immediately at the first sign of
wear (See Section 6.1 for adjustment and Section 9-3 for
replacement).

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7.2.4 The inner collar is very important for controlling
air escape from the helmet and preventing ingress of
dust. The elastic collar should fit snugly around the
user’s neck. Replace the collar when it no longer fits
snugly around the neck.
7.2.5 The outer cape provides protection from
rebounding abrasive and from abrasive ingress into the
helmet. Inspect the outer cape frequently for wear.
Replace the cape before holes appear, or any wear
occurs that prevents the cape from providing the
protection for which it is intended.
7.3 Cleaning and Disinfecting
Cleaning and disinfecting must be done in compliance
with OSHA Regulation 29 CFR 1910.134 (h)(1).
See Section 8.0 for cleaning instructions.
7.3.1 A respirator issued for the exclusive use of an
employee shall be cleaned and disinfected as often as
necessary to be maintained in a sanitary condition.
7.3.2 Shared respirators must be cleaned and
disinfected before being worn by different individuals.
7.4 Repairs (Service Maintenance)
Repairs must be done in compliance with OSHA
Regulation 29 CFR 1910.134 (h)(4).
7.4.1 The employer shall ensure that respirators that
fail an inspection or are otherwise found to be defective
are removed from service, adjusted, repaired or
discarded in accordance with the following procedures:
7.4.2 Adjustments and repairs must be made only by
appropriately-trained persons, and only with genuine
Clemco NIOSH-approved parts designed for the
respirator. No attempt shall be made to substitute
components or to make adjustment or repairs beyond
the manufacturer’s recommendations. See Sec. 9.0 for
service instructions.
7.5 Storage
Storage of the respirator must be done in compliance
with OSHA Regulation 29 CFR 1910.134 (h)(2).
7.5.1 Daily Storage
7.5.1.1 When the respirator is not in use, it must be
stored in a clean, dry area. Hang the respirator by the
strap provided on the top. Do not tuck the cape inside
the helmet. Let the cape hang loose to allow air to
circulate, and condensation on the cape and inside the
helmet to dry.
7.5.2 Long-term Storage
7.5.2.1 After inspection, cleaning, and thorough drying,
and after necessary repairs are made, the cape should
be tucked inside the helmet. The respirator shall be
placed in a plastic bag and the bag sealed to keep out
dust and moisture. Place the bag in a clearly-marked
carton and store it in a clean, dry place.
8.0 CLEANING and DISINFECTING
NOTE: Unless otherwise stated all cleaning and
disinfecting should be done in accordance to OSHA
Regulation 29 CFR-134 App. B-2.
CAUTION
Follow washing instructions as described in
this section. Do not use any caustic chemicals
or solvents that may be irritating or harmful to
the user, or which change the properties of the
materials used in any part of the respirator.
8.1 Outer Cape
8.1.1 See Section 9.4 for removal and installation
instructions.
8.1.2 Machine wash in warm water with mild
detergent. Dry in a clothes dryer at the lowest
temperature setting. Do not dry clean.
8.2 Inner Collar
8.2.1 The removable inner collar should be frequently
washed to remove build-up of dirt that accumulates from
normal perspiration and air moisture. For general
hygiene, daily washing is recommended.
8.2.2 The inner collar may be either washed or
replaced separately or with the outer cape. To wash
separately, unzip the collar and machine wash in warm
water with mild detergent. Tumble dry in a clothes dryer
at the lowest temperature setting. Do not dry clean.

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8.3 Suspensions
8.3.1 Web Suspension with Sweatband
8.3.1.1 Refer to Section 9.3.1 for removing and
replacing the suspension. Wash the sweatband,
suspension, and chin strap with warm water and mild
detergent. Rinse with clean water. Remove excess
water with a towel and allow to air-dry.
8.3.2 Padded Suspension
8.3.2.1 Refer to Section 9.3.2 for removing and
replacing padded suspension.
8.3.2.2 Wash the suspension pads, suspension web,
and chin strap with warm water and mild detergent.
Rinse with clean, warm water.
8.3.2.3 Squeeze pads to remove excess water. Wrap
pads in a towel and squeeze to remove additional water.
All items may be air-dried or tumble-dried at the lowest
possible setting.
8.4 Helmet Assembly
8.4.1 The helmet assembly should be wiped clean
with a cloth dampened with water and mild detergent.
Do not immerse the helmet in water. While this will not
permanently damage the helmet, it will require an
extended drying period.
8.4.2 Care must be taken to prevent abrasive entry
when donning and removing the respirator and when
changing lenses. Vacuum the inside of the helmet to
remove any abrasive.
8.4.3 If the acoustical foam on the inside of the helmet
becomes soiled, it can be wiped with a damp cloth or
pulled off and replaced.
8.5 Disinfecting
8.5.1 Washing the respirator as instructed also
disinfects it. Additional disinfecting may be done before
and/or after use by wiping the surfaces with a
commercial disinfecting wipe or spray.
9.0 SERVICE MAINTENANCE
CAUTION
To prevent recontamination of the respirator,
clean the respirator of dust and abrasive before
maintenance. All maintenance must be done in
a clean environment away from dust and
abrasive, and outside the respirator use area.
9.1 Lens Options and Replacement Procedures
Refer to Figure 3
Fixed Inner Lens: Replaceable lens required by OSHA,
must be used with all lens systems. Refer to Section
9.2 for replacement of fixed inner lens.
Non-Perforated Intermediate lens: Protects the inner
lens and supports the perforated outer lens.
Perforated Outer Lens: Use in multiples (up to three)
over intermediate lens. For high-abrasion applications
and/or the convenience of tearing off frosted lenses
during the work period.
Rectangular Lens: Protects inner lens.
NOTE: Choose one of the following lens system options
a. Fixed inner – one intermediate – up to three
perforated outer lenses.
b. Fixed inner – one intermediate – no perforated outer.
c. Fixed inner – one rectangular – no perforated outer.
9.1.1 Perforated Outer Lenses
For maximum visibility, install only enough lenses to last
during a work period, but no more than three. Preparing
lenses in the following manner will permit the outer
lenses to be torn off while blasting to expose a fresh lens
as needed, while preserving the innermost perforated
lens to protect the intermediate lens.
9.1.1.1 Stack up to three lenses on a clean, flat surface.
Arrange them with the flat-edge at the top and the pull-
tabs on the left. Fold up the pull-tab on the center lens
up, so the pull tab is against the top lens.
9.1.1.2 Unlatch the window frame and remove remnants
of old lenses.
9.1.1.3 Inspect the window gasket and inner lens. If
necessary replace per Section 9.2.

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9.1.1.4 Place the stack of lenses inside of the opened
window frame. Align them with the straight edge toward
the top of the frame, and pull-tabs at the hinged end.
9.1.1.5 Insert the pull-tab of the outermost lens through
the frame opening. The pull-tab of the innermost lens
should remain on the inside. Placing the pull-tabs as
described will prevent unintentional removal of the last
lens and prolong the life of the intermediate lens.
Figure 3
9.1.1.6 Secure the lenses to the frame by pressing the
lens mounting holes on the pull-tab end of the lenses
onto the mushroom-shaped locating lugs. The slots on
the other end of the lenses fit over the locating lugs on
the latch end of the frame.
9.1.1.7 Using the same locators, install the intermediate
lens atop the perforated lenses while the window frame
is open.
9.1.2 Intermediate Lens
9.1.2.1 Unlatch and open the window frame, and
remove the old lens.
NOTE: It is not necessary to use perforated outer
lenses, but they will protect the intermediate lens when
rapid frosting occurs. If outer lenses are used, they must
be installed before the intermediate lens, per Section
9.1.1.
9.1.2.2 Inspect the window gasket and inner lens. If
necessary replace per Section 9.2.
9.1.2.3 Align the new lens with the straight edge toward
the top and round mounting holes on the hinge end of
the frame.
9.1.2.4 Secure the lens to the frame by pressing the
round mounting holes onto the mushroom shaped
locating lugs. The oval holes on the other end of the lens
fit onto the lugs on the latch end of the frame.
9.1.2.5 Close and latch the window frame.
9.1.3 Rectangular Cover Lens
9.1.3.1 Open the window frame and remove the old
lens.
9.1.3.2 Place a new lens between the locating lugs and
close and latch the window frame to secure.
9.2 Removing and Replacing the Inner Lens and
Window Gasket
Note: The following instructions explain the method of
first installing the gasket onto the helmet, and then the
lens. Spraying a small amount of water or food grade
silicone into the gasket grooves will reduce friction and
ease installation. Alternatively, install the lens into the
window gasket and then install the lens and gasket onto
the helmet as an assembly.
9.2.1 Replace the inner lens when it becomes dirty or
scratched.
9.2.2 Remove the outer cape to ease the installation.
9.2.3 Unlatch and open the window frame.
9.2.4 Working from inside the helmet, pull up on the
window gasket lip and push out the gasket and lens
through the front of the window opening.
9.2.5 Remove the old lens from the gasket.
9.2.6 Inspect the window gasket, and replace it if
damaged.
9.2.7 Place the gasket over the window opening. Align
the notch in the gasket with the tab at the bottom of the
helmet window opening. Keeping the notch and tab aligned
ensures the gasket is centered on the window opening.
9.2.8 From the inside of the helmet, work the gasket
lip onto the helmet. Smooth out wrinkles in the gasket on
the inside of the helmet.
9.2.9 Insert one end of the lens into the gasket
groove. The lens must be fully seated into the groove.
9.2.10 Work the lens into the groove until it is
completely seated into the gasket’s groove.
Insert pull-tabs through the opening
Secure the lens to the frame
by pressing the holes over
the locating lugs
Locating lugs
Locating lugs

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9.2.11 Install the intermediate and outer lenses, and
latch the window frame.
9.2.12 To maximize the wear life of the inner lens, do
not use without an intermediate lens. The respirator
must never be used without the inner lens in place.
9.2.13 Attach the outer cape.
9.3 Removing and Replacing Suspensions
9.3.1 Web Suspension with Sweatband
9.3.1.1 Remove and discard the old suspension by
extracting the plastic suspension tabs from the mounting
slots in the helmet shell.
9.3.1.2 Inspect and if necessary replace the chin strap
before installing the suspension. When correctly
installed, the chin strap is between the suspension and
helmet shell.
9.3.1.3 Inspect the metal, suspension clips located on
the helmet’s suspension mounts. Replace them if they
are loose or missing.
9.3.1.4 Place the suspension under the chin strap and
then secure the suspension by inserting the plastic tabs
into their respective mounts. The tabs must fully seat in
the mounts.
9.3.1.5 Try on the helmet for fit and adjust the
suspension by turning the adjustment knob clockwise to
decrease the size, or counterclockwise to increase the
size. The suspension fits head sizes 6.5 to 8.
9.3.1.6 Reattach the cape to the helmet by following the
instructions in Section 9.4.
9.3.2 Padded Suspension
9.3.2.1 All pads are held in place with strips of adhesive
backed, hook and loop fastener material. Remove the
side and middle pads by pulling them free of the hook-
fastener strips.
9.3.2.2 Remove the suspension web, by extracting the
plastic tabs from their respective mounting slots. While
holding the top pad in place, pull the webbing to
separate it from the top pad.
9.3.2.3 To remove the top pad, hold the air baffle
partition (Figure 6, Item 13) in place, and pull the pad to
separate it from the partition.
9.3.2.4 Inspect the chin strap, and if necessary replace
it before installing the suspension.
9.3.2.5 Inspect the metal suspension clips located on
the helmet’s suspension mounts. Replace them if they
are loose or missing.
9.3.2.6 Make sure the air baffle partition is correctly
located, before installing the top pad. Align the pad while
pressing it into place against the fastener strip.
9.3.2.7 Place the suspension web under the chin strap
and then secure the suspension by inserting the plastic
tabs into their respective mounts; the tabs with the stripe
on the strap go on the side mounts.
9.3.2.8 Align the middle pad so the elastic cord is
toward the back and the center of the pad is centered to
the suspension web. Press the pad to engage the
fastener strip, minor repositioning may be needed to fully
seat the pad.
9.3.2 9 The grey (standard) or blue (for smaller head
sizes) sides of the side pads are Velcro®receptive, and
are attached by pressing them onto the fastener strips.
The black side faces toward the inside of the helmet.
9.3.2.10 Reattach the cape to the helmet by following
the instructions in Section 9.4.
9.4 Removing and Replacing the Outer Cape
9.4.1 To ensure correct reattachment of the cape and
attachment band, refer to the cross section in Figure 4.
Note that the cape retaining spring is between the
helmet retaining grooves, and the band extends over
both rims.
Figure 4
Helmet Shell
Cape Retaining
S
p
rin
g
Ca
p
e Band
Band encapsulates cape
and shell rim rid
g
es.
Cape

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9.4.2 When the cape becomes soiled or requires
replacement, it can easily be removed as follows:
9.4.3 Push the release-lever on the cape attachment
buckle as shown in Figure 5. While pushing the lever,
pull the tensioning strip out of the buckle, and remove
the attachment band.
9.4.4 Detach the cape from the helmet.
9.4.5 Install the cape by stretching it over the lower
helmet rim, so the cape spring rests between the ridges
as shown in Figure 4. Position the cape so the back
seam aligns with the center of the back of the helmet.
Figure 5
9.4.6 Place the attachment band over the cape as
shown in Figure 4. When correctly positioned, the buckle
is on the window hinge side of the helmet, and the
tensioning strip points toward the front.
9.4.7 Ratchet the buckle to tighten the band, making
sure the cape and band remain in position as the band is
tightened.
9.5 Inner Collar
9.5.1 The inner collar controls air escape from the
helmet and prevents ingress of dust.
9.5.2 The elastic properties of the collar provide a
snug fit around the user’s neck. The inner collar must be
replaced before it is stretched to the point where it no
longer fits snugly on the user’s neck. The collar unzips
from the outer cape for replacement or washing. See
Section 8.2 for cleaning instructions.
9.6 Window Frame and Latch
9.6.1 The window frame or latch must be replaced
when it becomes difficult to maintain a seal. When
replacing the window frame or latch, the acoustical foam
inside the helmet should also be replaced.
9.7 Chin Strap
9.7.1 Replace the chin strap when worn or when it
loses its elasticity.
9.8 Air-Inlet Fitting
9.8.1 Use a wrench to remove the old fitting.
9.8.2 Apply a drop of cyanoacrylate (super glue) to
one end of the new fitting, and screw the glued end
hand-tight into the helmet.
9.8.3 Connect the breathing tube and use the tube for
leverage to tighten the inlet fitting. Do not use a wrench
to tighten the fitting, as it may damage the helmet. Leave
the breathing tube connected until the cyanoacrylate has
set.
9.9 Air Baffle Partition
9.9.1 Remove the cape and suspension per Sections
9.3 and 9.4.
Push release-lever on
buckle.
While pushing release-
lever, remove tensioning
stri
p
from buckle.
Insert tensioning strip into buckle.
Ratchet buckle to ti
g
hten.
TO ATTACH
TO TIGHTEN
TO CONTAIN STRIP
Tuck tensioning strip
under window frame.
TO RELEASE

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9.9.2 Pull the partition to remove it from the helmet.
9.9.3 Place a new partition into the helmet, with the
break to the back and pointing toward the inlet fitting.
When the partition is positioned correctly, the break
should point down at a slight angle, gradually tapering
toward the helmet shell.
9.9.4 Align the partition’s center notches with the
retaining bosses. Apply pressure on the partition to snap
it into the bosses. Working from the center, snap the
partition in place toward the front and back.
9.9.5 Replace the suspension and cape.
10.0 REPLACEMENT PARTS
WARNING
Use of any non-Clemco replacements parts may
permit ingress of hazardous contaminants, and
may cause injury, disease, or death to the user.
OSHA Regulation 29 CFR 1910.134(H)(4)(i)
requires the use of the respirator
manufacturer’s NIOSH-approved parts
designated for the respirator. Using any parts
listed in this section made by any manufacturer
other than Clemco voids the NIOSH approval,
and voids Clemco’s warranty.
10.1 Supplied-Air Respirator Systems and
Accessories
Respirator Systems
Description Stock No.
Apollo 600 LP Respirator with Web Suspension
less respirator hose.......................................... 24010
with 50-foot respirator hose.............................. 24011
Apollo 600-LP DLX Respirator with Padded Suspension
less respirator hose.......................................... 25195
with 50-foot respirator hose.............................. 25210
Accessories
Description Stock No.
Constant-flow connector, LP with belt ................... 21777
Pressure conversion kit, LP to HP
Converts Apollo 600 LP, low pressure
(ambient air) respirator, to high pressure
(Grade “D” Compressed Air) respirator............... 22080
DLX padded suspension kit
includes everything needed to replace padded
suspension, or to convert from web suspension
to DLX padded suspension................................. 25189
Hearing protection muffs,
Low profile noise reduction muffs
for use with web suspension w/sweatband only.
May not work with all head sizes ........................23886
Do-rag, washable head scarf ................................. 23814
CMS-3 CO monitor package ..................................24612