Clemco TLR-50 Operating Manual

MC FILE NUMBER: 123-0477
DATE OF ISSUE: 04/01/77
REVISION: H, 03-04

1/2" REMOTE CONTROLS

MODEL TLR-50

O.M. 03358

WARNING

Do not proceed with
these instructions until

© CLEMCO INDUSTRIES CORP.

One Cable Car Dr.

Washington, MO 63090

Phone [phone]

Fax [phone]

Email: [e-mail]

www.clemcoindustries.com

you have READ the
preface 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.

Keep this manual for
future reference

®

PREFACE

WARNING

• 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

WARNING

• Blast operators and others working in the vicinity of

abrasive blasting must always wear properly­maintained, 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

I

PREFACE

working in the vicinity of blast jobs; and cleanup of expended
abrasive. Prior to removing respirator, an air monitoring
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 non­approved air hose can subject the operator to illness caused by
the release of chemical agents used in the manufacture of non­approved 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

WARNING

• 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.

II

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.

PREFACE

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: [e-mail] • Website: www.sspc.org

National Association of Corrosion Engineers (NACE)

1440 South Creek Drive, Houston TX 77084
Phone: [phone] • FAX [phone]

Email: [e-mail] • Website: www.nace.org

American Society for Testing and Materials (ASTM)
100 Barr Harbor Dr., West Conshohocken, PA 19428

Phone [phone] • FAX [phone]
Email: [e-mail] • Website: www.astm.org

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.

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

NOTICE

WARRANTY

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

WARNING

• 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

III

and CO monitor or both. If CO monitor is not used, air MUST
be tested FREQUENTLY to ensure proper air quality.

□ 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.

PREFACE

□ 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.

□ 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.

2. Breathing Air Compressor

2. Ambient Air Pump

(or)

for low pressure

respirator

1 Air Compressor

3. NIOSH
Approved

Supplied-Air

Respirator

□ 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.

11. Silica-free Abrasive

7. Remote
Controls

6. Air Line
Filter

5. ASME Coded
Blast Machine

4. CPF Air-Filter

IV

10. Appropriately
Sized Nozzle

8. Blast Hose

9. Hose Couplings and
Safety Cables