Clemco CAP-1 User manual

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.
AMBIENT AIR PUMP MODEL CAP-1
O.M. 21909
WARNING
MC FILE NUMBER: 2059-0898
DATE OF ISSUE: 04/01/77
REVISION: C, 12/08
© 2008 CLEMCO INDUSTRIES CORP.
One Cable Car Dr.
Washington, MO 63090
Phone [phone]
Fax [phone]
Email: [email protected]
www.clemcoindustries.com

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

CAP-1 AMBIENT AIR PUMP Page 1
© 2008 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 21909
1.0 INTRODUCTION
1.1 Scope of Manual
1.1.1 This manual covers set up, operation,
maintenance, troubleshooting, replacement parts, and
important warnings required for safe trouble free
operation of the Clemco CAP-1 Ambient Air Pump. Read
the entire manual before attempting operation of the
pump.
1.2 Hazard Alerts
1.2.1 Clemco uses signal words, based on ANSI
Z535.2-1991, to alert the user of a potentially hazardous
situation that may be encountered while operating this
equipment. ANSI's definitions of the signal words are as
follows:
This is the safety alert symbol. It is used to
alert the user of this equipment of potential
personal injury hazards.
Obey all safety messages that follow this symbol to
avoid possible injury or death.
CAUTION
Caution used without the safety alert symbol
indicates a potentially hazardous situation
which, if not avoided, may result in property
damage.
CAUTION
Caution indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
WARNING
Warning indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
DANGER
Danger indicatesanimminently hazardous
situation which, if not avoided, will result in
death or serious injury.
1.3 General Description
1.3.1 The CAP-1 Ambient Air Pump assembly is
shown in Figure 1. It includes a 115-volt, 3/4 hp drive
motor with supply cord, an oil-less rotary vane pump
unit, inlet filter/muffler, and outlet end plumbing
consisting of a relief valve, pressure gauge, air filter, and
disconnect. The (hose) disconnect is the attachment
point for the respirator hose.
Figure 1
Pressure Gauge
Inlet Filter
Outlet Filter
Disconnect
(Point of attachment
for respirator hose.)
Relief Valve
On - Off
Switch
115-Volt Cord with U-Ground Plug

CAP-1 AMBIENT AIR PUMP Page 2
© 2008 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 21909
1.3.2 The pump is an oil-less air pump designed to
convey respirable ambient air to low pressure,
continuous-flow, supplied-air respirators, approved by
NIOSH to operate at 10 psi.
1.3.3 The maximum continuous outlet pressure is 10
psi. The pump does not provide the pressure required to
operate air-volume control valves or temperature control
valves that require more than 10 psi. The pump is a
compatible air source for Clemco's Apollo LP (low-
pressure) Respirators.
WARNING
Observe all OSHA and NIOSH requirements and
limits for supplied-air respirators while
operating this pump. To ensure safe operation
and compatibility with the respirator, read the
owner's manuals and all instructions, labels,
and warnings relating to the pump and
respirator. Compare the air demand of the
respirator with the output of the pump prior to
using the pump.
WARNING
Air supply to the respirator must be 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)). The
pump filters are particulate filters. They do not
remove carbon monoxide or other toxic gases.
Air supplied to the pump intake must be at least
Grade D quality. If air quality is unknown,
consult a safety professional or industrial
hygienist. Poor quality air will cause serious
respiratory injury or death to the user.
1.4 Construction
1.4.1 The end plate, rotor and mounting bracket are
cast iron and steel. Consequently, any moisture that
accumulates in the pump will corrode the interior,
especially if it stands idle for a long period in a humid
environment. The vanes are made of hard precision
ground carbon.
2.0 SET-UP
2.1 Assembly
2.1.1 Connect the outlet plumbing assembly to the
elbow on the outlet port, as shown in Figure 1.
2.2 Initial Check
2.2.1 Make sure that all outlet fittings are tight.
2.2.2 Make sure the cap on the inlet filter is snug
against the felt filter media. Do not over-tighten.
2.2.3 Unscrew the metal bowl on the outlet filter.
Make sure the cartridge cap is snug against the
cartridge. Do not over-tighten.
WARNING
The outlet filter is the final air filtering media.
Do not operate the pump without the filter
cartridge in place and fully seated.
2.2.4 Before reattaching the metal bowl, make sure
the bowl gasket is in place in the filter body.
2.3 Placement
WARNING
To avoid risk of electrocution, do not use the
pump in an area where it could be exposed to
water or other liquids. If the pump is exposed to
the elements, it must be weather protected.
2.3.1 Take precautions to prevent contaminants from
entering the air pump's inlet. Locate the air pump inlet
away from all sources of contaminants, and in an area
that ensures the following conditions are continuously
met.
•The area must be free of harmful vapors and gases,
including carbon monoxide, found in engine
exhaust, and in any form of combustion.
•The area must be free of airborne contaminants
such as silica dust, generated from sandblasting,
and dust from lead or other heavy metals, produced
from the removal or application of coatings
containing toxic elements.
•Locate the pump away from any exhaust system
outlet, ventilation flue, vehicle traffic, or source of
fumes or particles of any kind.

CAP-1 AMBIENT AIR PUMP Page 3
© 2008 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 21909
DANGER
DO NOT operate the pump in a flammable or
explosive atmosphere. An arc from the
electrical system will ignite flammable or
explosive gases.
•Locate the pump away from any source of heat, so
that cool air can circulate around the pump. During
operation the pump becomes hot. Do not operate
when ambient temperature exceeds 104o F.
•If the ambient air pump cannot be placed in an area
where clean, respirable air is guaranteed at all
times, use the optional air intake hose(s). A 50 ft. air
intake hose and up to five additional 50 ft. extension
(for a total maximum length of 300 ft.), hose may be
attached to the pump inlet, to draw air from an area
where clean respirable air is ensured.
WARNING
Clemco provides intake hose and hose
extensions as optional accessories. Do not
substitute with homemade hose or hard pipe.
Any inlet restrictions will cause rapid wear to
the pump and motor, and restrict air flow to the
respirator. Reduced air flow may result in
ingress of hazardous dust, fumes or gases,
exposing the user to immediate health risk and
subsequent respiratory disease and possible
death.
2.3.2 An ambient-air, carbon monoxide monitor is
recommended to safeguard against accidental transfer
of CO from engine exhaust or other sources that can
contaminate ambient air.
2.3.3 Rubber shock mounts are used to minimize
noise and vibration. Place the pump on a solid surface
that will not resonate.
2.4 Power Supply
2.4.1 Make sure the switch located on the back of the
motor is in the "OFF" position before plugging the cord
into a grounded 115-volt outlet that provides necessary
overload protection.
CAUTION
Extension cords may be used to a maximum
length of 100 feet, and must be at least 14-
gauge wire with ground.
WARNING
If the pump is to be permanently wired, make
sure the electric motor is properly grounded
and a qualified electrician familiar with national
and local electrical codes and safety standards
does the wiring.
2.5 Respirator Hose
2.5.1 Attach an approved respirator air supply hose
(and coupling if required) to the outlet plumbing
disconnect. If the disconnect is not compatible with that
of the approved respirator hose, remove the disconnect
and attach a compatible coupling to the 3/8″threads on
the filter body.
WARNING
Outlet couplings (the point of attachment) and
respirator hose must be NIOSH-approved for
use with the respirator. Use of non-approved
couplings and hose will void the NIOSH
approval of the respirator, and could restrict air
flow. Do not use bushings or reducers that
reduce the internal diameter of the plumbing.
Reduced air flow may result in ingress of
hazardous dust, fumes or gases, exposing the
user to immediate health risk and subsequent
respiratory disease and possibly death.
CAUTION
The hose disconnect coupling on the pump is
not equipped with a shut-off. Therefore, if the
respirator hose is disconnected from pump
while it is in operation, air will continue to flow
freely from the coupling. Any couplings added
to enable the use of other approved hose
should not have a shut-off valve. The reason
the coupling is not equipped with a shut-off
valve is to prevent excessive pressure build-up,
if the respirator hose were removed from the
pump before it is shut off.

CAP-1 AMBIENT AIR PUMP Page 4
© 2008 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 21909
3.0 OPERATION
WARNING
Do not use this pump to supply air to any
respirator used in atmospheres immediately
dangerous to life or health.
WARNING
Do not use this pump to supply air to any
respirator for which the air demand is unknown.
Do not use with respirators that have approved
minimum pressure exceeding 10 psi. This pump
may not provide sufficient air volume to those
respirators. Do not use respirators that are not
NIOSH-approved.
CAUTION
The maximum recommended continuous
operating pressure for this pump is 10 psi. Do
not remove the relief valve or operate above 10
psi. Doing so will damage the motor and pump
unit.
3.1 Start-Up
3.1.1 If the pump is extremely cold, allow it to warm to
room temperature before starting. Start the pump by
positioning the switch to "ON". Do not operate in
ambient air temperatures in excess of 104 degrees
Fahrenheit (40 degrees C).
3.1.2 Attach the respirator hose to the pump, and run
the pump for several minutes to expel hose odor and
condensation from the hose, before connecting it to the
respirator.
3.1.3 Connect the hose to the respirator.
3.1.4 Check respirator hose and connections for
tightness and leaks.
3.1.5 Don the respirator in a clean non-hazardous
environment, free of contaminants, where the air is safe
to breathe.
WARNING
Do not don the respirator, or store it in a blast
contaminated or other contaminated
environment.
3.1.6 Enter the work area only after the respirator is
correctly fitted and in place, air is supplied to the
respirator, and all conditions specified by the respirator
manufacturer are met.
3.2 During Operation
3.2.1 During operation it is normal for the pump to
become hot. Some of the heat is transferred to the air,
causing it to become warmer than ambient. To prevent
excessive heat build-up in the respirator hose, stretch-
out the hose and keep it in shaded areas when possible.
Do not place the hose in direct sunlight, on hot surfaces,
or near any other source of heat.
WARNING
The end plate and shroud may become hot
enough during operation to burn skin. Do not
touch these parts until the pump has been
turned off and cooled.
3.2.2 If the air inside the respirator becomes
uncomfortably hot, coil the respirator hose in the bottom
of a large, covered, container filled with water and ice.
3.3 Shut-down
3.3.1 Remove the respirator outside the respirator-
use area and where the air is safe to breathe.
WARNING
Do not remove the respirator in a contaminated
environment except for emergency evacuation
when the use of the respirator hinders escape.
3.3.2 Shut off the pump when the respirator is not in
use. Stop the pump by positioning the switch to "OFF".
3.3.3 If the pump is used outdoors, move it indoors
when not in use.
3.4 Storage
3.4.1 The pump is made of material that is subject to
corrosion if left idle for a period of time, especially under
humid conditions.
3.4.2 Before storing the pump for an extended period,
disconnect the inlet filter and outlet plumbing, and allow
the pump to run open for at least 5 minutes before
shutting down.

CAP-1 AMBIENT AIR PUMP Page 5
© 2008 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 21909
3.4.3 Unplug the power cord, and plug the inlet and
outlet ports to prevent dirt and other contaminants from
entering the pump assembly.
3.4.4 Store the pump in a clean, dry environment.
4.0 ADJUSTMENTS
4.1 There are no adjustments on the CAP-1 air
pump.
CAUTION
The relief valve is set to open at 10 psi. Do not
attempt to adjust, remove, or otherwise alter the
relief valve. To do so will damage the motor and
pump unit.
5.0 MAINTENANCE
WARNING
The electric motor may be thermally protected,
and will automatically restart when the
protector resets. To prevent injury, disconnect
the power and make sure all rotating
components are at a standstill before servicing.
WARNING
The end plate and shroud may become hot
enough during operation to burn skin. Do not
touch these parts until the pump has been
turned off and cooled.
CAUTION
Never lubricate the oil-less air pump. The
carbon vanes and grease packed motor
bearings require no oil. The service life of the
vanes will be reduced by use of petroleum or
hydrocarbon products.
5.1 Inlet filter, Ref. Figure 2
Figure 2
5.1.1 The inlet filter ensures that no foreign particles
enter the pump inlet. A dirty filter restricts air flow, and if
not corrected could lead to possible motor overload,
poor performance and early pump failure.
5.1.2 Check the inlet filter for contamination every 100
hours of operation. To remove the filter media, unscrew
the cover plate, remove the filter media, and screen
assembly.
5.1.3 Remove the inner and outer screens from the
filter media.
5.1.4 Place the cleaned or new filter media between
the inner and outer screens. Replace the media at least
every 500 hours of operation. The ends of the filter
media must protrude past the screens. This assures a
tight seal against the cover plate and base.
5.1.5 Place the filter assembly on the base and
tighten the cover plate snugly against the filter. Do not
over-tighten.
CAUTION
Over-tightening the cover plate will damage the
screens.
Cover Plate
Inner Screen
Filter Media
Outer Screen
Base

CAP-1 AMBIENT AIR PUMP Page 6
© 2008 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 21909
5.2 Outlet Filter, Ref. Figure 3
5.2.1 Check the filter regularly to make sure the
cartridge is not blocked and causing an air restriction.
Figure 3
5.2.2 Replace the cartridge at least every 200 hours
of operation, sooner if a decrease of air is noted at the
respirator, if pressure increases above normal at the
gauge, or if the relief valve activates.
5.2.3 To remove the filter cartridge, unscrew the bowl
and bottom plate.
5.2.4 Inspect the gasket and replace if damaged.
5.3 Flushing, Ref. Figure 4
WARNING
Use Gast Flushing Solvent No. AH255B,
Locktite Safety Solvent, or equivalent to flush
the pump. DO NOT use kerosene or other
petroleum-based solvents. These solvents are
flammable, and may contaminate the pump with
harmful vapors.
5.3.1 Should excessive dirt, foreign particles,
moisture, or oil enter the pump, the vanes will act
sluggishly or break. If the pump is unused for a period of
time, surface-rust may develop in the pump and cause
the same condition. Flushing the pump normally
removes these contaminants.
5.3.2 Remove the inlet filter.
5.3.3 To prevent the flushing solvent from entering the
outlet filter and breathing air channel, remove the entire
outlet plumbing assembly up to but not including the 90o
st. elbow, as shown in Figure 4.
Figure 4
5.3.4 Point the outlet in a safe direction, away from
any objects.
5.3.5 With the pump running, pour about two
tablespoons of flushing solvent into the inlet port.
5.3.6 If necessary, repeat the flushing procedure. If
flushing has freed the vanes, continue with this section.
If flushing does not remedy the situation, inspect the
pump assembly per Section 5.4.
5.3.7 Run the pump until all traces of solvent odor
have disappeared. DO NOT REASSEMBLE UNTIL
DISCHARGE AIR IS FREE OF SOLVENT ODOR.
5.3.8 Reassemble the outlet assembly and respirator
hose.
5.4 Pump Inspection
5.4.1 Unplug the electric supply cord, or disconnect
the electrical power; lockout and tagout the power
supply, if the unit is permanently wired.
WARNING
Failure to disconnect the power source could
result in severe injury from the motor starting,
or injury or death from electrical shock.
Remove inlet filter
90o St. Elbow
Pour 2 tablespoons
flushing solvent into
inlet port.
Body
Gasket
Filter Cartridge
Bottom Plate
Bowl
Remove entire
outlet assembly

CAP-1 AMBIENT AIR PUMP Page 7
© 2008 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 21909
5.4.2 Remove the respirator hose.
CAUTION
Disassemble and reassemble the pump in a
clean environment; all parts should be clean
and dry.
5.4.3 Remove the six bolts holding the end plate to
the body, as shown in Figure 5.
5.4.4 Remove the end plate.
CAUTION
DO NOT remove the rotor or loosen any electric
motor through-bolts. Alignment and tolerances
are critical for the performance of the pump.
The motor, rotor and body are not field-
serviceable. Any service other than vane
replacement must be performed by an
authorized service facility. Contact Gast Mfg.
Corp., [phone] for a service facility
referral.
Figure 5
5.4.5 Before removing the vanes, note how the
beveled edges on the vanes conform to the contour of
the body bore, Ref. Figure 6. They must be reinstalled in
the same position.
Figure 6
5.4.6 Inspect the body for scoring. If severe scoring is
visible, or if bearings need replacement, or any further
maintenance is required, return the complete pump to
an authorized service facility.
5.4.7 The vanes could be worn or require further
cleaning. When reinstalling or replacing the vanes, face
the bevels in the proper direction as shown in Figure 6.
5.4.8 Reinstall the end plate, and tighten the bolts
holding the end plate to the body.
5.4.9 Before putting the pump back in service, check
all external accessories for wear and damage. Check
the inlet and outlet filters for contamination.
Screws (6)
Vane
End View
Correct Incorrect
Body
Body
Vane
Shroud
Remove the end plate only
Do not loosen or
remove through-bolts.
Body
End Plate
Shroud

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© 2008 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 21909
6.0 TROUBLESHOOTING
WARNING
To avoid the risk of injury from electrical shock,
all electrical troubleshooting should be
performed by a qualified electrician.
6.1 Low Pressure at Pump
6.1.1 Make sure the pressure gauge is operational.
Replace if faulty.
6.1.2 Make sure the outlet filter bowl gasket is in place
and that it is not worn, and the bowl is tight against the
gasket.
6.1.3 Check the outlet plumbing for leaks.
6.1.4 Inlet filter media dirty. Remove and clean, or
replace.
6.1.5 Optional intake hose blocked or collapsed.
Make sure the intake hose is unobstructed.
6.1.6 Vanes sticking. Flush.
6.1.7 Vanes worn. Replace.
6.1.8 Dust in pump. Flush.
6.1.9 Motor not running at full RPM. Check power
supply and wiring.
6.1.10 Make sure the pressure range of the respirator
is compatible with the pump.
6.2 High Pressure at Pump
6.2.1 Outlet filter cartridge dirty. Replace.
6.2.2 Restriction (such as a pinch or kink) in respirator
hose. Check hose.
6.3 Pump Overheating
6.3.1 Dirty inlet and/or outlet filter. Clean or replace.
6.3.2 Optional intake hose blocked or collapsed.
Make sure the intake hose is unobstructed.
6.3.3 Relief valve stuck closed. If outlet pressure is
above 10 psi, the relief valve should open. If it does not
open, replace it.
6.3.4 Dust in pump. Flush.
6.3.5 Faulty power supply.
6.3.6 Undersized or too long an extension cord. Cord
must be at least 14-gauge wire, and maximum length of
100 feet.
6.4 Motor Overload
6.4.1 Dirty inlet and/or outlet filter. Clean or replace.
6.4.2 Intake hose blocked or collapsed. Make sure the
intake hose is unobstructed.
6.4.3 Relief valve stuck closed. If outlet pressure is
above 10 psi, the relief valve should open. If it does not
open, replace it.
6.4.4 Restriction (such as a pinch or kink) in respirator
hose.
6.4.5 Dust in pump. Flush.
6.4.6 Motor not running at full RPM. Check power
supply and wiring.
6.4.7 Undersized or too long an extension cord. The
cord must be at least 14-gauge wire, and maximum
length of 100 feet.
6.5 Motor Fails to Start or Slows Down
6.5.1 Check power supply for open breakers or blown
fuses.
6.5.2 Make sure the supply voltage conforms to the
requirements on the motor data plate.
6.5.3 If anything appears to be wrong with the motor,
contact an authorized service facility.
6.5.4 Dirt in pump assembly. Flush the pump; if
flushing does not correct the condition, inspect the
vanes, rotor and body.

CAP-1 AMBIENT AIR PUMP Page 9
© 2008 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 21909
6.6 Low Pressure at the Respirator
6.6.1 Inlet or outlet filter dirty. Replace.
6.6.2 Leaks at outlet plumbing. Check fittings and
outlet filter for leaks.
6.6.3 Blockage, kink, or break in respirator hose.
Check hose.
6.6.4 Respirator pressure not compatible with air
pump. Check respirator operating pressure; it must be
approved to operate at 10 psi.
6.7 High Pressure at the Respirator
6.7.1 Respirator pressure not compatible with air
pump. Check respirator operating pressure; it must be
approved to operate at 10 psi.
7.0 Warranty
7.1 The ambient air pump is warranted to be free of
defects in materials and workmanship by the
manufacturer for a period of one year from the original
date of shipment from Clemco Industries Corp. This
warranty does not apply to any damage or defect
resulting from negligent or improper assembly or use of
the product, or from any alterations or attempted repair
by any persons other than an authorized agent. The
warranty is extended to the pump only, and does not
include any add-on accessories such as filters and
fittings. All warranty claims should be made by
contacting the manufacturer for the name and location of
the nearest service facility. Return the pump prepaid,
and include a written explanation of the failure, and
return shipping information.
Contact:
Gast Manufacturing Corp.
2300 Highway M-139
Benton Harbor, MI 49023
Tel: [phone]
FAX: [phone]
Website: www.gastmfg.com

CAP-1 AMBIENT AIR PUMP Page 10
© 2008 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 21909
8.0 ACCESSORIES and REPLACEMENT PARTS
Never substitute, modify, add, or omit parts. Use only
genuine replacement parts in the configuration as
specified by the manufacturer.
8.1 Optional Accessories
Item Description Stock No.
(-) Intake hose kit, 50 ft. .................................21837
(-) Extension kit, intake hose, 50 ft. ...............21838
(-) Elevated intake stack kit ............................21839
8.2 Replacement Parts, Figure 7
Item Description Stock No.
(-) CAP-1 Ambient Air Pump ..........................22383
1. Filter media, inlet filter ...............................21830
2. Filter cartridge, outlet filter .........................15030
3. Gasket, outlet filter bowl ............................21831
4. Gauge, 1/4″pressure, 0 - 30 psi ...............21832
5. Relief valve ................................................21833
6. Disconnect, 3/8″........................................21834
7. Vanes, set of 4 ..........................................21835
8. Inlet filter assembly ...................................21836
9. Outlet filter assembly .................................24204
Figure 7
8
2
3
4
5
6
7
1
9