Clemco 600 User manual

APOLLO SUPPLIED-AIR RESPIRATOR
Helmet Model 600
High Pressure 65 psi to 100 psi
O. M. 23930
© 2011 CLEMCO INDUSTRIES CORP.
One Cable Car Dr.
Washington, MO 63090
Phone [phone]
Fax [phone]
Email: [email protected]
www.clemcoindustries.com
MC FILE NUMBER: 2186-1103
DATE OF ISSUE: November, 2003
REVISION: E, 01/11
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.
Do not proceed with
these instructions until
you have READ the
orange cover of this
MANUAL and YOU
UNDERSTAND its
contents. *
These WARNINGS are
included for the health
and safety of the
operator and those in
the immediate vicinity.
*If you are using a Clemco Distributor
Maintenance and Part Guide, refer to
the orange warnings insert preceding
the Index before continuing with the
enclosed instructions.
Electronic files include a Preface
containing the same important
information as the orange cover.
WARNING

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

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

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

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

APOLLO HIGH PRESSURE SUPPLIED-AIR RESPIRATOR Page 1
HELMET MODEL 600
© 2011 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 23930
1.0 INTRODUCTION
1.1 Scope of manual
1.1.1 This manual covers setup, operation,
maintenance, and replacement parts for Clemco Apollo
HP (high pressure) Series Supplied-Air Respirator:
Model 600 HP.
1.1.2 Read this entire manual and all accessory
manuals before setting-up or using the respirator. The
following Clemco manuals are available for accessories
that may be used with the Apollo HP Respirator. They are
available on our web site www.clemcoindustries.com.
Refer to Figure 1 for a typical set-up.
Description Manual No.
CAT Cool-Air Tube........................................... 08956
Clem-Cool Air Conditioner .............................. 23837
CCT Climate Control Tube............................... 08850
CPF Inline Particulate Air Filter........................ 04143
CMS-1 Carbon Monoxide Monitor ................... 23301
CMS-2 Carbon Monoxide Monitor ................... 22925
1.2 Safety Alerts
1.2.1 Clemco uses safety alert signal words, based on
ANSI Z535.4-1998, to alert the user of a potentially
hazardous situation that may be encountered while
operating this equipment. ANSI’s definitions of the signal
words are as follows:
This is the safety alert symbol. It is used
to alert the user of this equipment of
potential personal injury hazards.
Obey all safety messages that follow this
symbol to avoid possible injury or death.
CAUTION
Caution used without the safety alert symbol
indicates a potentially hazardous situation
which, if not avoided, may result in property
damage.
CAUTION
Caution indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
WARNING
Warning indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
DANGER
Danger indicatesanimminently hazardous
situation which, if not avoided, will result in
death or serious injury.
1.3 NIOSH Approval Number 19C-130
1.3.1 The Clemco Apollo Supplied-Air Respirator is
approved by the National Institute of Occupational
Safety and Health (NIOSH).
1.3.2 The NIOSH label shown below lists the Apollo
respirator approval number. An X on the approval line
indicates which components are approved for the
specific respirator. Do not use any non-approved
components with this respirator.

APOLLO HIGH PRESSURE SUPPLIED-AIR RESPIRATOR Page 2
HELMET MODEL 600
© 2011 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 23930
WARNING
NIOSH approval applies only when this
supplied-air respirator is used as a complete
system. Do not make any non-approved
modification, deletion, or substitution. Non-
approved components void the NIOSH approval
and may permit ingress of toxic and hazardous
dust, resulting in toxic poisoning and
respiratory disease.
1.4 OSHA Regulations
1.4.1 OSHA Regulation 29 CFR 1910.134 for
respiratory protection in General Industry is referenced
throughout this document. Respiratory protection
standards for Construction 29 CFR 1926.103 and for
Maritime 29 CFR-1915.154, 1917, and 1918 refer back
to 1910.134. The complete regulation is available
through the U.S. Dept. of Labor web site at
www.osha.gov.
1.4.2 OSHA Regulations 29 CFR 1910.134(a) and (c)
require the employer to establish and maintain a
comprehensive, written, respiratory protection program
administered by a suitably-trained program administrator.
1.4.3 It is essential that the user be properly instructed
in the use and maintenance of the respirator. This
manual must be made available to all users of the
respirator, and the users must demonstrate their
understanding of its subject matter. Read the entire
manual before installing or operating the equipment.
1.4.4 The respirator must be supplied with respirable
air meeting requirements described herein. It is the
responsibility of the employer to provide quality
breathing-air to the respirator, and to establish a
program to ensure that the respirator is properly used
and maintained.
1.5 Respiratory and Health Alerts
WARNING
TOXIC DUST POISONING
Research by the National Institute For
Occupational Safety and Health (NIOSH) has
discovered risks associated with dust produced
during abrasive blasting operations including but
not limited to Lead, Silica, Antimony, Arsenic,
Beryllium, Cadmium, Chromium, Cobalt, Nickel,
Tin, Nitrate and Nitrite, to unprotected abrasive
blasting operators and other personnel who may
be exposed to toxic dust in the abrasive blasting
vicinity. These risks include debilitating lung,
blood, liver, kidney, and skin injuries, and even
death. Toxic dust is produced primarily by the
breakdown of the abrasive being used and the
surface being treated, during abrasive blasting.
The breakdown of toxic coatings and hazardous
abrasive causes the contaminants to become
airborne. Breathing toxic dust generated by the
abrasive or surface being treated can cause health
and life-threatening toxic poisoning and can
damage vital organs. Breathing hazardous dust
produced from silica and other abrasives can
cause delayed life-threatening respiratory disease.
It is imperative that blasting contractors identify all
material being removed by blasting, and obtain
material safety data sheets (MSDS) for the blasting
abrasive prior to blasting. It is the responsibility of
the employer to identify all airborne contaminants
in the blast vicinity, and ensure they do not exceed
the permissible exposure limit (PEL) Ref. 29 CFR
1910.1000 and 29 CFR 1926.62. Thorough site
hazard examinations should be made by A Certified
Industrial Hygienist, Certified Safety Professional or
other qualified professional to identify all
contaminants generated by blasting and in the
blasting vicinity.
Exposure to dangerous levels of toxic or hazardous
dust is not restricted to blast operators. There may
be an equal or greater danger present after the
blasting process due to lingering airborne dust
particles, and especially from dust generated
during cleanup activity. Heavy metal paint,
asbestos, sand or other silica, and other toxic
material dusts will cause serious lung disease or
death if not prevented through the use of properly
designed, and maintained NIOSH-approved,
supplied-air respirators worn by blasting operators
and all personnel within the work area. OSHA’s
regulations found primarily in 29CFR1910, Subpart
Z provides the permissible exposure limits for all
toxic and hazardous substances. It is the
responsibility of the employer to determine the
inhalation hazards associated with the abrasive
blasting being performed. Do not begin any
operations including abrasive blasting without
being trained by the employer and fully
understanding the hazards associated with the
work performed.
The Apollo supplied-air respirator system is
approved by NIOSH as a Type-CE, continuous-flow,
abrasive blast, supplied-air respirator, in
accordance with title 42 CFR Part 84. The NIOSH

APOLLO HIGH PRESSURE SUPPLIED-AIR RESPIRATOR Page 3
HELMET MODEL 600
© 2011 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 23930
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.
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.

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© 2011 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 23930
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 4.4.
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 4.4.
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
One of the following air-control devices with belt:
Constant-flow connector (CFC): Provides non-
adjustable volume of supplied air, within the cfm
range required by OSHA.
Air-control valve (ACV): Enables the user to
adjust the volume of supplied air, within the cfm
range required by OSHA. It is for use in areas
where the air temperature is comfortable.
Clem-Cool air conditioner: Used in warm
climates to enable the user to adjust supplied air
to cooler temperatures.
Cool-air tube (CAT): Used in warm climates to
enable the user to adjust supplied air to cooler
temperatures.
Climate-control tube (CCT): Enables the user to
adjust supplied air to warmer or cooler
temperatures.
Quick disconnect and male adaptor, used to connect
the respirator hose to the air-control device.
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.
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.
Carbon Monoxide Monito
r
Breathin
g
Tube Assembl
y
Point of Attachment
Res
p
irator Hose
CPF In-Line Particulate Filter with
pressure regulator and gauge
Air Inlet Port, (Supply with
Grade “D” or better quality
res
p
irable air
)
Belt and Alternate Ai
r
-Control Device
Some items are positioned for clarity. The filter and monitor
must be protected from the blasting environment.
Apollo Helmet Assembly
Model 600

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© 2011 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 23930
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
selected air-control device.
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 3/8"ID respirator hose.
3.4.2 Apply Teflon tape to the 1/4" NPT threads on the
3/8" hose to 1/4" pipe adaptor as shown in Figure 3, and
connect it wrench-tight to the female disconnect.
Figure 3
3.4.3 Attach the adapter/disconnect assembly to one
end of the respirator hose.
3.4.4 Using the 3/8"hose to 3/8"pipe adaptor
provided, connect the other end of the respirator hose to
a respirable air source.
3.4.5 Connect the disconnect end of the respirator
hose to the air-control device.
3.4.6 If longer hose is required, it must be a NIOSH-
approved Clemco 3/8"respirator hose extension. Use any
25-foot, 50-foot and 100-foot Clemco respirator hoses in
any combination as noted in the table in Section 4.4, not
to exceed 300 ft. or 12 individual hose lengths.
Air-Control Device
(Alternate ACV control
valve shown)
Connect the molded-on
swivel to the air-control
device.
Breathin
g
Tube Assembl
y
Connect the clamped-on
swivel to the helmet’s
inlet fitting.
Strap Handle
Female Disconnect
3/8" Hose to 1/4" Pipe Adaptor
Respirator Hose
3/8" Hose to 3/8" Pipe Adaptor
Connect to
p
oint of attachment
Apply Teflon tape to 1/4" NPT threads

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3.5 CMS-3 CO Monitor Option, Respirator Mounted
The Clemco supplied air respirator model Apollo 600 HP
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.
4.0 COMPRESSED-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.
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 compressed air source. Take special care to abide
by all warnings from the compressor manufacturer
regarding compressor use, and from the cylinder and air
supplier for breathing-air cylinders and their use.
4.1.5 A Clemco CPF filter may be installed and if
regularly maintained will remove objectionable odors, as
well as oil mist, water, pipe scale, and other particulate
matter.
4.2 Breathing-Air From Cylinders
4.2.1 Using cylinders (high-pressure air-bottles)
requires special knowledge of their use and compliance
with OSHA Regulations. Refer to 29 CFR 1910.134(h)
and (i) and 49 CFR part 173, and part 178.
DANGER
Operators must never use or operate breathing-
air cylinders, without proper pressure reducing
devices, and training on their use. Breathing
cylinders are under extremely high air pressure.
Improper use could cause cylinders or
accessories to rupture, resulting in severe
injury or death.
4.2.2 The employer shall ensure that cylinders used to
supply breathing air to respirators meet all requirements
which may include, but are not limited to, their testing
and maintenance, certificate of analysis for air quality,
and moisture.

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4.2.3 Cylinders must be equipped with a properly
maintained pressure reducing valve that reduces
pressure to the approved pressure range of the
respirator. See 4.4.
4.3 Breathing-Air from Compressors
4.3.1 The employer shall ensure that air from
compressors used to supply breathing air to respirators
meets the requirements in 29 CFR 1910.134.(i)(5).
4.3.2 Precautions must be taken to prevent
contaminants from entering through the compressor
intake: Ref. 29 CFR 1910.134.(i)(5)(i). The compressor
inlet must be located away from all sources of toxic
contaminants including carbon monoxide, which is found
in engine exhaust (including the exhaust from the
compressor’s engine), and in any form of combustion.
No vehicles should be allowed near the compressor
intake. Contaminants can enter respiratory equipment
through the compressor air inlet. This inlet must not be
located near any exhaust system outlet, ventilation flue,
or source of fumes or particles of any kind.
4.3.3 The compressed-air supply system must be
equipped with suitable in-line air-purifying sorbent beds
and filters, and be maintained to further ensure
breathing air quality: 29 CFR 1910.134 (iii).
4.3.4 If the breathing-air supply is from a non-oil-
lubricated compressor, the employer shall ensure that
the carbon monoxide levels in the breathing air do not
exceed 10 ppm: 29 CFR 1910.134 (i)(6).
4.3.5 If an oil-lubricated compressor is used, the
employer shall use a high-temperature alarm or carbon
monoxide (CO) 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: 29 CFR 1910.134 (i)(7).
S-Special or Critical User’s Instructions
4.4 Air Volume and Pressure
4.4.1 Operating Pressure
4.4.1.1 HP respirators operate within the pressure
range of 65 and 100 psi (pounds per square inch), as
shown in the table in this section. Maintaining the correct
operating pressure at the point of attachment ensures
the correct air flow to the respirator.
4.4.1.2 The Clemco CPF Inline Particulate Filter with
regulator meets this requirement for a regulator and
gauge, provided the inlet pressure does not exceed 150
psi. See typical installation, Figure 1.
DANGER
Do not connect the Apollo Respirator or CPF
Filter, or any other regulator or filter, to bottled-
air that does not have a pressure reducing
valve that reduces pressure to the maximum
operating pressure of the respirator of filter it
services. Failure to comply with this warning
will cause devices rated at lower pressures to
explode under the high pressure of bottled-air,
and cause severe injury or death.
4.4.1.3 Use the following table to determine the
minimum pressure settings and maximum respirator
hose length, based on the air-control device as shown in
Section 2.1.1. Adjust the pressure with the respirator
hose and respirator attached. If the regulator is adjusted
with static pressure (no air flow), pressure may drop
below the required pressure when the respirator is
connected, and may result in low air flow. Setting the
pressure as instructed will provide a minimum of 7 cfm to
the respirator.
Hose
Length Minimum Pressure Setting, psi
CFC ACV Clem- Cool
CAT
CCT
25 ft. 65 85 90 90 90
50 ft. 65 85 90 90 90
75 ft. 65 85 90 90 90
100 ft. 65 85 95 95 95
125 ft. 70 90 95 95 95
150 ft. 70 90 95 95 95
175 ft. 70 90 95 95 95
200 ft. 70 90 95 95 95
225 ft. 75 95 * * *
250 ft. 75 95 * * *
275 ft. 75 95 * * *
300 ft. 75 95 * * *
NOTE: Use any combination of hose shown to provide a
maximum of 300 ft., but not to exceed 12 individual hose
lengths.
* Do not use these control devices at distances
greater than 200 ft.
4.4.2 Air Volume
4.4.2.1 When using a CFC constant-flow connector or
ACV air valve, the respirator must be supplied with 15
cfm (cubic feet per minute) of Grade D breathing air at

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65 to 100 psi. When using an alternate temperature
control device, the respirator must be supplied with 20
cfm of Grade D breathing air at 90 to 100 psi.
WARNING
The compressor must provide adequate output
and the plumbing between the compressor and
the point of attaching the respirator hose must
have sufficient capacity to supply the volume of
air at the pressure required. Restricted air flow
will cause discomfort to the user, and may
result in ingress of hazardous and toxic dust,
subjecting the user to health and life
threatening toxic poisoning and long term
respiratory disease and death.
4.4.3 Pressure Conversion Kit
4.4.3.1 This optional accessory kit contains parts and
instructions to convert an Apollo 600 respirator from high
pressure (65 to 100 psi) to low pressure (6 to 20 psi).
The kit is listed in Section 10.4.
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 Start the compressor and open the service valve
to pressurize the air-supply line.
5.3 Check air pressure at the point of attachment.
Set the pressure within the minimum pressure assigned
in Section 4.4 and the maximum of 100 psi. Pressure
must be set with the respirator connected.
5.4 Inspect all safety and breathing equipment used
in conjunction with the respirator as recommended by
the manufacturer.
5.5 Inspect respirator hoses and connections for
tightness and leaks.
5.6 Don the respirator in a clean non-hazardous
environment, free of contaminants, where the air is safe
to breathe.
5.7 When donning and removing the respirator,
keep it upright to prevent dust and abrasive from falling
inside. Holding the chin strap while donning the helmet
will make it easier to position it once the helmet is on.
5.8 Position the chin strap so it fits comfortably
under the chin.
5.9 Position the knit cuff on the inner collar so that it
fits snugly around the neck in turtleneck fashion and
without any interference from clothing or long hair. When
correctly positioned, the smaller elastic end of the collar
must face up.
WARNING
Correct placement of the inner collar is critical
for providing the protection for which the
respirator is designed. The collar must be
positioned and maintained without any
interference from items such as hair, facial hair,
or shirt collars, between the inner collar and
user’s neck.
5.10 Pull the cape down to fully extend it and connect
the four elastic straps (two on each side) under the
arms, and tighten using the slides provided.
5.11 Put on the belt and control valve 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.
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.
6.2 Air-Control Valve, alternate, Figure 4
Refer to the manuals listed in Section 1.1.2 for other
alternate air devices.
Figure 4
6.2.1 Clemco’s ACV air-control valve allows the user
to increase or decrease the volume of breathing-air while
wearing the supplied-air respirator. The valve provides a
range of 7 to 10 cfm of breathing-air when the respirator
is supplied with respirable air as noted in Section 4.4.
6.2.2 To regulate the air flow, turn the control knob
"clockwise" to decrease air flow, or "counterclockwise" to
increase air flow. NOTE: If the knob is turned fully
clockwise to minimum flow, turning the knob one full turn
counterclockwise increases the flow to maximum.
Turning the knob more than one revolution
counterclockwise will not increase air flow.
Control Knob
Turn knob clockwise to decrease
air flow; turn counterclockwise to
increase flow.
Air-Control Valve

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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, constant-flow
connector, alternate air-control valve or temperature-
control valve.
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).
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 on 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. Do not 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.

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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.
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 5
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.

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© 2011 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 23930
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.
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 the 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 5
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.
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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9.2.2 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.
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 8, Item 27) 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.

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© 2011 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 23930
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 6.
Note that the cape retaining spring is between the
helmet retaining grooves, and the band extends over
both rims.
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 7. 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 6. Position the cape so the back
seam aligns with the center of the back of the helmet.
Figure 6
9.4.6 Place the attachment band over the cape as
shown in Figure 6. 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.
Figure 7
9.5 Removing and Replacing the 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.
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.
Helmet Shell
Cape Retaining
S
p
rin
g
Ca
p
e Band
Band encapsulates cape
and shell rim rid
g
es.
TO RELEASE
Cape