HP Hewlett Packard Respiratory Product 60 HP User Manual

CLEMCO SUPPLIED AIR RESPIRATOR  
MODEL 60 HP  
O.M. 10533  
690-0985  
09/85  
K, 05/15/98  
MC FILE NUMBER:  
DATE OF ISSUE:  
REVISION:  
WARNING  
Do not proceed with  
these instructions until  
you have READ the  
orange cover of this  
MANUAL and YOU  
UNDERSTAND its  
content.* These  
WARNINGS are  
included for the health  
and safety of the  
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 CE standards and does not carry the  
European CE-mark.  
operator and those in  
the immediate vicinity.  
© CLEMCO INDUSTRIES CORP.  
One Cable Car Drive  
*If you are using a Clemco  
Distributor Parts and Maintenance  
Guide refer to the orange warnings  
insert preceding the Index before  
continuing with the following  
instructions.  
Washington, MO 63090  
Phone (636) 239-4300  
Fax (636) 239-0788  
®
 
APOLLO 60 HP SUPPLIED-AIR RESPIRATOR  
Page 2  
toxic or hazardous dust is not restricted to blast  
operators. There may be an equal or greater  
danger 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 dis-  
ease or death without the use of properly de-  
signed, and maintained NIOSH-approved, sup-  
plied-air respirator equipment by blasting opera-  
tors and all personnel within the work site area.  
Leadpoisoningcancausedeath.OSHAhasstated  
that the permissible exposure limit of lead is 50  
micrograms per cubic meter of air (50 µg/m3),  
averaged over an 8-hour workday.  
! WARNING  
“Warning” is used to indicate a potentially haz-  
ardous situation which, if not avoided, could  
result in death or serious injury.  
! DANGER  
The Apollo supplied-air respirator system is ap-  
proved by NIOSH as a Type-CE, continuous-flow,  
abrasive blast, supplied-air respirator, in accor-  
dance with title 42 CFR Part 84. The NIOSH recog-  
nized assigned protection factor (APF) for any  
supplied-air respirator equipped with a loose-  
fitting hood or helmet and operated in a continu-  
ous 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 contami-  
nant level does not exceed 25 times the permis-  
sible exposure limit. However, in its Memoran-  
dum for Regional Administrators dated August  
30, 1995, OSHA has stated that select individual  
Type-CE continuous-flow, abrasive blast, sup-  
plied-air respirator models that pass stringent  
tests conducted by independent third party test-  
inglaboratorieswillbegrantedAPFvalueshigher  
thantheNIOSHrecognized25.Clemcocontracted  
with Los Alamos National Laboratory to conduct  
the independent testing. Based upon the results  
of these tests, OSHA will treat the Apollo Sup-  
plied-Air Respirator (NIOSH Approval TC-19C-  
130) as having an APF of 1000 times the permis-  
sibleexposurelimit, or50,000µg/m3whenusedin  
lead removal applications.  
“Danger” is used to indicate an imminently haz-  
ardous situation which, if not avoided, will result  
in death or serious injury.  
1.3  
Respiratory and Health Alerts  
! WARNING  
TOXIC DUST POISONING  
Research by the Occupational Safety and Health  
Administration (OSHA) has discovered potential  
risks of lead and other heavy metal poisoning to  
unprotectedabrasiveblastingoperatorsandother  
personnel who may be exposed to toxic dust in  
the abrasive blasting vicinity. Toxic dust is pro-  
ducedprimarilybytheremovalandbreakdownof  
lead or other heavy metal coatings during abra-  
sive blasting.  
The breakdown of toxic coatings and hazardous  
abrasive causes the contaminants to become  
airborne. Breathing toxic dust from lead or other  
heavy metal coatings may cause health and life  
threateningtoxicpoisoningandcandamagevital  
organs.Breathinghazardousdustproducedfrom  
silica abrasive may cause delayed life threaten-  
ing respiratory disease such as silicosis.  
The employer must provide and maintain appro-  
priateapprovedrespirators, inadditiontoprovid-  
ing operator training and employing required  
work site safety practices.  
To avoid any potential danger of respiratory in-  
jury, approved, supplied-air respirators must be  
worn at all times in the presence of any type of  
dust. The respirator must be maintained as de-  
scribed herein. Improper use of any respirator  
may cause life threatening respiratory disease,  
and immediate poisoning from toxic dust. Respi-  
rators should be removed only after the ambient  
airhasbeentestedwithadustmonitor,andfound  
to be safe to breathe.  
Lead is one of several toxic dusts that may be  
present in an abrasive blasting operation. It is  
imperative that blasting contractors identify all  
material being removed by blasting, and obtain  
material safety data sheets (MSDS) for the blast-  
ingabrasivepriortoblasting. Itistheresponsibil-  
ity of the employer to identify all airborne con-  
taminantsintheblastvicinity, andensuretheydo  
not exceed the permissible exposure limit (PEL)  
Ref. 29 CFR 1910.1000 and 29 CFR 1926.62. Thor-  
ough examinations should be made by an indus-  
trial hygienist or other qualified professional to  
identify all contaminants generated by blasting  
and in the blasting vicinity.  
Toxic dust poisoning may also occur by eating,  
drinking, or smoking in a contaminated area, or  
by eating, drinking, or smoking in a non-hazard-  
ous 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 con-  
taminants before eating, drinking, or smoking  
outside the blast area.  
Exposure to dangerous levels of lead or other  
 
APOLLO 60 HP SUPPLIED-AIR RESPIRATOR  
Page 3  
This manual does not contain all the health and  
safety requirements regarding toxic and hazard-  
ous dust exposure. Obtain copies of the OSHA  
regulations and consult a safety professional  
and/or industrial hygienist for complete require-  
ments.  
1.5.1 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 main-  
tained at pressures between the minimum pressure as  
shown in the table in Section 4.2.4 and the maximum of  
100 psi.  
Within this manual we refer to hazardous or con-  
taminatedenvironments.Theseenvironmentscan  
be any place around the blast area that could  
contain toxic or hazardous dust.  
! WARNING  
If these warnings are not completely understood,  
or if further information is required, contact a  
local OSHA office. If any personnel in the abra-  
sive blasting vicinity cannot read or comprehend  
these warnings and the entire content of this  
instructional material, assign a qualified person  
to instruct them.  
Failure to maintain the minimum pressure at the  
pointofattachmentmayreduceairflowbelowthe  
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 respi-  
ratory disease.  
Additional information on abrasive blasting haz-  
ards titled “Preventing Silicosis and Death From  
Sandblasting”, Publication No. 92-102, is avail-  
able from:  
Publications Dissemination, DSDTT  
1.5.2 Usenomorethan12sectionsofrespiratorhoseto  
obtain a total maximum length of up to 300 feet, as noted  
in the table in Section 4.2.4.  
National Institute for Occupational Safety and Health  
4676 Columbia Parkway  
Cincinnati, OH 45226 (513) 533-8287  
1.4  
Cautions and Limitations  
1.5.3 The respirator is designed for specific use in  
abrasive blasting applications. Do not use in other opera-  
tions such as painting or welding.  
1.4.1 Not for use in atmospheres immediately danger-  
ous to life or health.  
1.6  
Protection  
1.4.2 Do not exceed maximum use concentrations es-  
tablished by regulatory standards.  
1.6.1 Assigned Protection Factor (APF): The NIOSH  
recognized assigned protection factor for any Type-CE  
respirator (the Apollo respirator is a Type-CE respirator) is  
25 times the permissible exposure limit (PEL). In other  
words, CE respirators should be used only in atmospheres  
in which the contaminant level does not exceed 25 times  
the PEL. However, based upon the results of independent  
testing, OSHA will treat the Apollo Supplied-Air Respirator  
as having an APF of 1000 times the PELwhen used in lead  
removal applications.  
1.4.3 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.  
1.4.4 Use only the pressure ranges and hose lengths  
specified in the instruction manual.  
1.4.5 Failure to properly use and maintain this product  
could result in injury or death.  
1.6.2 Head: The respirator protects the wearer’s head  
and neck from impact and from abrasion caused by re-  
bounding abrasive. The respirator meets physical require-  
ments for industrial head protection as stated in ANSI  
Z89.1-1997 as a Type I Class G protective helmet.  
1.4.6 All approved respirators shall be selected, fitted,  
used, and maintained in accordance with MSHA, OSHA,  
and other applicable regulations.  
1.4.7 Never substitute, modify, add, or omit parts. Use  
only exact replacement parts in the configuration as speci-  
fied by the manufacturer.  
1.6.3 Face: The Apollo 60 inner lens meets impact and  
penetration requirements under ANSI Z87.1-1989.  
1.4.8 Refer to users instructions, and/or maintenance  
manuals for information on use and maintenance of these  
respirators.  
1.6.4 Eyes: Apollo respirators do not provide primary  
eye protection. Wear approved eye protection with the  
respirator.  
1.5  
Special Use Limitations  
1.6.5 Hearing: Noise generated by the Apollo respirator  
and measured inside the helmet do not exceed 80 deci-  
 
APOLLO 60 HP SUPPLIED-AIR RESPIRATOR  
Page 4  
bels. (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.  
1.7.2 The respirator comes with one of four air control  
devices that permit safe, comfortable blast cleaning under  
various conditions.  
Constant-Flow Connector (CFC): Provides non-adjust-  
able volume of supplied air, within the cfm range required  
by OSHA.  
1.7  
Description  
1.7.1 The Clemco Apollo 60 Supplied-Air Respirator is  
approved by the National Institute of Occupational Safety  
and Health (NIOSH).  
Air Control Valve (ACV): Enables the user to a d j u s t  
thevolumeofsuppliedair, withinthecfmrangerequiredby  
OSHA. It is for use in areas where the air temperature is  
comfortable.  
! WARNING  
Cool-Air Tube (CAT): Used in warm climates to enable  
the user to adjust supplied air to cooler temperatures.  
OSHA/NIOSH approval applies only when this  
supplied-air respirator is used as a complete  
system. Do not make any non-approved modifi-  
cation, deletion, or substitution. Non-approved  
components voids the NIOSH approval and may  
permit ingress of toxic and hazardous dust, and  
result in toxic poisoning and respiratory disease.  
ClimateControlTube(CCT):Enablestheusertoadjust  
supplied air to warmer or cooler temperatures.  
1.7.3 Low Pressure Conversion Kit: This optional ac-  
cessory kit contains parts and instructions to convert the  
Apollo 60 HP, (respirator for use with Grade “D” Com-  
pressed Air) to Apollo 60 LP (respirator for use with  
ambient air pump). The kit is listed in Section 10.1.  
Breathing-Air  
Tube Assembly  
Apollo 60  
Supplied-Air  
Respirator  
General Arrangement  
of Operator Safety  
and Comfort Components  
Carbon  
Monoxide  
Alarm  
Blast  
Suit  
Climate  
Control  
Tube  
Respirator  
Supply Hose  
Breathing-Air  
Source  
Blast Suit  
CPF-20  
Particulate  
Filter  
Figure 1.  
 
APOLLO 60 HP SUPPLIED-AIR RESPIRATOR  
Page 5  
3.2.1 The lens system is an important part of the respi-  
rator assembly. The helmet is supplied with an inner lens,  
secured by a thick rubber gasket. Held in place on top of  
theinnerlensbythewindowframeareuptofiveperforated  
outer lenses.  
2.0  
INSPECTION  
! NOTICE  
3.2.2 Check that the inner lens is in place. (See Section  
9.1)  
A Clemco respirator hose must be used with the  
Apollo Respirator. If one is not available, it must  
be ordered from an authorized distributor of  
Clemco products. Hoses are not included with  
respirators, because blast operators often are  
assigned personal respirators, while using com-  
mon respirator hoses.  
3.2.3 The perforated outer lenses are secured to the  
helmet by the window frame. As one lens becomes frosted  
during blasting, it can be torn off to expose the next lens.  
Check that the perforated outer lenses are in place. (See  
Section 9.2)  
3.3  
Belt  
2.1  
Component Checklist  
3.3.1 Using the spring clip attached to the Constant-  
FlowConnector, attachtheconnectortothebeltslide. This  
step is not required with alternate air control devices,  
because the Air Control Valve is furnished with a hook-on  
belt clip, and belts are attached to Cool Air Tubes and  
Climate Control Tubes.  
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  
Air Control Valve  
3.4  
Breathing Tube Assembly  
3.4.1 Attach the red end of the breathing tube to the  
threaded air inlet fitting at the back of the helmet.  
Cool-Air Tube  
Climate-Control Tube  
• Disconnect adaptor assembly  
3.4.2 Attach the swivel connector on the black end, to  
the Constant-Flow Connector, or alternate air control  
device.  
NOTE: Respirator hose (one or more alternate hoses)  
must be ordered separately.  
2.1.2 When all of these components are present, pre-  
pare the respirator for operation per Section 3.0.  
! WARNING  
The red end of the breathing tube must attach to  
the helmet, and the black end to the Constant-  
Flow Connector or alternate air control valve.  
Failure to properly attach the tube may increase  
noise levels beyond OSHA limits.  
3.0  
3.1  
3.2  
PREPARATION  
Adjust Helmet Suspension per Section 6.2.  
Lens Assembly  
3.4.3 Use the strap handle to carry or hang the respira-  
tor. Never hold, carry or hang the respirator by the breath-  
ing 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.  
! WARNING  
Never use the respirator without the fixed inner  
lens and perforated outer lenses in place. The  
fixed lens provides support for the window gas-  
ket. If the gasket is not adequately supported,  
leaks can occur which could permit entry of toxic  
and hazardous dust or abrasive into the helmet.  
3.5  
Respirator Hose  
3.5.1 Use the disconnect adaptor assembly to attach  
the respirator hose to the Constant-Flow Connector, or  
alternate air control device. Using the adaptor provided,  
 
APOLLO 60 HP SUPPLIED-AIR RESPIRATOR  
Page 6  
4.1.3 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 regard-  
ing compressor use.  
connect the other end of the respirator hose to a respirable  
air source. If longer hose is required, it must be a NIOSH-  
approved Clemco respirator hose extension. Any 25 foot,  
50 foot and 100 foot respirator hoses can be added in any  
combinationtoproducethemaximumtotallengthasnoted  
in the table in Section 4.2.4.  
4.1.4 A breathing air type compressor must be used.  
The compressor must be equipped with necessary safety  
and monitoring devices, plus suitable in-line air filters and  
purifying equipment to assure breathing air quality. [Refer-  
ence OSHA Regulations 29 CFR 1910.134 (d), and 29  
CFR 1926.103 (f)].  
4.0  
AIR SUPPLY  
! WARNING  
4.1.5 If an oil-lubricated compressor is used, it must be  
equippedwithahigh-temperaturealarmorcarbonmonox-  
ide (CO) alarm, or both. If only a high-temperature alarm  
is used, the air from the compressor must be tested  
frequently for the presence of carbon monoxide. [Refer-  
enceOSHARegulations29CFR1910.134(d)and29CFR  
1926.103 (f)].  
Air supplied to this respirator system is critical to  
the safety of the user. Read this section carefully.  
Poor quality air will cause serious respiratory  
injury or death to the user. See Toxic Dust Poi-  
soning Warning in Section 1.3.  
4.1.6 Regardless of the air compressor type, precau-  
tions must be taken to prevent contaminants from entering  
throughthecompressorintake. Thecompressorinletmust  
be located away from all sources of toxic contaminants  
including carbon monoxide, which is found in engine  
exhaust, and in any form of combustion. No vehicles  
should be allowed near the compressor intake. Contami-  
nants can enter respiratory equipment through the com-  
pressor air inlet. This inlet must not be located near any  
exhaust system outlet, ventilation flue, or source of fumes  
or particles of any kind.  
4.1  
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.  
! WARNING  
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 in  
the breathing air will cause death to the user.  
4.1.7 The precautions described above also apply to  
portable compressors. In addition, in the case of engine-  
driven compressors, precautions must be taken to prevent  
engine exhaust gases from entering the air intake of the  
compressor. Compressor engine exhaust should be piped  
to a location safely downwind from the compressor air  
intake. Compressors vary in design and operation; there-  
fore, it is important that users carefully read the  
manufacturer’s operation and maintenance instructions  
before making modifications.  
! WARNING  
Do not use piston type, oil-bath, compressors for  
breathing air. These compressors could produce  
dangerous levels of carbon monoxide, which will  
cause death to the user.  
4.1.8 An appropriate air filter must be installed and  
regularly maintained to remove objectionable odors, as  
well as oil mist, water, pipe scale and other particulate  
matter.RefertoOSHARegulation1910.94(6).TheClemco  
CPF Air Filter complies with the regulation, and provides  
the pressure reducing valve referred to in the regulation.  
4.1.2 Breathingairusedtosupplytherespiratormustbe  
respirable breathing air and contain no less than 19.5  
volume-percent of oxygen. Breathing air shall also meet  
the requirements for Grade D or higher quality, as de-  
scribedinCompressedGasAssociationCommoditySpeci-  
fication pamphlet G-7.1., titled Commodity Specification  
For Air, published by Compressed Gas Association Inc.,  
Arlington, VA. (42 CFR Chapter 1).  
4.1.9 It is the owner’s and user’s responsibility to check  
the air supply. This includes the compressor, carbon  
monoxide alarms, air filters, and shut-down devices. An  
overheated compressor, or one that is in poor mechanical  
condition, may produce carbon monoxide. A carbon  
 
APOLLO 60 HP SUPPLIED-AIR RESPIRATOR  
Page 7  
monoxideremovalorconversionsystemmayalsobeused  
to ensure breathing air quality. The maximum allowable  
presence of carbon monoxide in Grade D breathing air is  
10 parts per million (ppm).  
Hose Minimum Pressure Setting, psi  
Length  
25 ft.  
CFC ACV  
CCT  
90  
90  
90  
95  
95  
100  
100  
100  
*
CAT  
65  
65  
65  
65  
70  
70  
70  
70  
75  
75  
75  
75  
85  
85  
85  
85  
90  
90  
90  
90  
95  
95  
95  
95  
90  
90  
90  
95  
95  
100  
100  
100  
*
50 ft.  
75 ft.  
4.2  
Air Volume and Pressure  
100 ft.  
125 ft.  
150 ft.  
175 ft.  
200 ft.  
225 ft.  
250 ft.  
275 ft.  
300 ft.  
4.2.1 A pressure regulator and gauge must be installed  
at the point where the respirator hose is attached to the air  
source. The Clemco CPF Filter with regulator meets this  
requirement if the inlet pressure does not exceed 125 psi.  
See typical installation, Figure 1.  
*
*
*
*
*
*
! DANGER  
* Do not use these control devices at distances greater  
than 200 ft.  
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 maximum of 125 psi (65 to  
100 psi for the respirator only). Failure to comply  
with this warning will cause devices rated at  
lower pressures to explode under the high pres-  
sureofbottledair.Suchanexplosioncouldcause  
severe injury or death.  
! 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 (as stated in Section  
4.2.2). 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.  
4.2.2 Therespiratormustbesuppliedwith15cfm(cubic  
feet per minute) of Grade D breathing air at 65 to 100 psi  
(pounds per square inch). When using an alternate Cool-  
Air Tube or Climate Control Tube, the respirator must be  
supplied with 20 cfm of Grade D breathing air at 90 to 100  
psi.  
4.2.3 The pressure regulator must be adjusted to 65 to  
100 psi. Refer to the table in Section 4.2.4 to determine the  
minimum pressure, based on the total length of respirator  
hose, and choice of air control device. 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.  
5.0  
OPERATION  
! WARNING  
With the respirator on, leave the blast area  
immediately if any of the following conditions  
occur:  
4.2.4 Use the table below to determine the minimum  
pressure setting and maximum respirator hose length,  
based on the air control device as shown in Section 1.7.2.  
• Any part of the respirator system becomes  
damaged.  
• Any air monitoring alarm is activated.  
• Airflow 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.  
 
APOLLO 60 HP SUPPLIED-AIR RESPIRATOR  
Page 8  
5.1  
Prior to operation, thoroughly inspect and clean  
5.11  
When finished blasting and with cleanup, remove  
the helmet, breathing tube, respirator hose, air entry ports,  
and fittings of all dust and debris. Inspect the helmet  
suspension and adjust if necessary per Section 6.2.  
the respirator in a clean, non-hazardous environment  
where the air is safe to breathe.  
5.2  
Start the compressor and open the service valve  
! WARNING  
to pressurize the air supply line.  
Do not put the respirator on, 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.  
5.3  
Check air pressure at the point of attachment. Set  
the pressure between the minimum pressure assigned in  
Section 4.2.4 and the maximum of 100 psi. Pressure must  
be set with the respirator connected.  
5.4  
Check all safety, and breathing equipment used in  
conjunction with the respirator as recommended by the  
manufacturer.  
5.5  
Check respirator hoses and connections for tight-  
6.0  
6.1  
ADJUSTMENTS  
ness and leaks.  
5.6  
Put the respirator on in a clean non-hazardous  
Air Control Valve, alternate, Figure 2  
environment, free of contaminants, where the air is safe to  
breathe. When putting the respirator on or taking it off,  
keep it upright to prevent dust and abrasive from falling  
inside.  
Outlet End  
(top of unit)  
5.7  
Position the chin strap so it fits comfortably under  
Belt Clip  
the chin.  
Pull sleeve down  
and turn  
to adjust air flow  
5.8  
Positiontheknitcuffontheinnercollarsothatitfits  
snugly around the neck in turtleneck fashion, without any  
interference from clothing such as shirt collars. When  
correctly positioned the smaller elastic end of the collar  
must face up.  
Higher  
Lower  
Adjustment  
Sleeve  
Inlet End  
(bottom of unit)  
! WARNING  
Correctplacementoftheinnercollariscriticalfor  
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 collar and user’s neck.  
Figure 2.  
6.1.1 Clemco’s 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  
rangeof7to10cfmofbreathing-airwhenitissuppliedwith  
respirable air as noted in Section 4.0. To regulate the air  
supply, pull down and turn the large sleeve on the lower  
end of the valve in the desired direction to increase or  
decrease the air flow as needed. A soft hissing sound is  
normal when the air control valve is in operation as some  
air is allowed to escape underneath the sleeve to prevent  
the entry of dust into the adjustment mechanism.  
5.9  
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.  
5.10  
Put the belt and control valve on over the cape.  
Buckle the belt around the waist, and tighten it by pulling  
the belt end through the buckle insert.  
 
APOLLO 60 HP SUPPLIED-AIR RESPIRATOR  
Page 9  
6.2.5 Fastenthevinylsweatbandontothebuttonsofthe  
6.2  
HelmetSuspensionAdjustmentandReplacement,  
suspension.  
Figure 3  
6.2.6 Install the suspension strap before installing the  
suspension. Inserttheyellowendtabsintothecleftsonthe  
helmetshell.Whencorrectlyinstalled,thestrapisbetween  
the suspension and helmet shell and above the ears.  
Suspension Strap  
Button A  
White Plastic Tabs  
(rear)  
6.2.7 Install the suspension by inserting the four white  
plastic tabs into the clefts on the shell. The tabs must fully  
seat in their respective locators.  
6.2.8 Try the helmet on for fit and readjust if necessary.  
Vinyl  
Sweatband  
6.2.9 Check that the chin strap is in place, then reattach  
the cape onto the helmet following the instructions in  
Section 9.4.  
White Plastic  
Tabs  
(front)  
Head Band  
Tongue  
7.0  
7.1  
MAINTENANCE PROGRAM  
Basic Service  
Headband  
Size Slots  
Front Holder  
Button B  
Front Band  
Lugs  
7.1.1 A program for maintenance and care of the respi-  
rator must be established based on application, working  
conditions, and hazards involved, and include the follow-  
ing basic service.  
Figure 3.  
• Inspection for defects (including a leak check)  
• Cleaning and disinfecting  
• Repair (service maintenance)  
! WARNING  
• Storage  
The suspension maintains a fixed distance be-  
tween the head and the helmet. It is critical that  
the suspension is properly installed, and ad-  
justed as described, to provide maximum head  
protection and comfort.  
Equipment must be properly maintained to retain its origi-  
naleffectiveness.[ReferenceOSHARegulations1910.134  
(f)].  
7.2  
Inspection  
7.2.1 Inspect respirators before and after each use.  
Inspection shall include a check for tightness of connec-  
tions and the condition of the lenses, suspension, cape  
and elastic parts, breathing tube, respirator hoses and  
connectors, Constant-FlowConnectororalternateaircon-  
trol valve or temperature control valve. [Reference OSHA  
Regulations 1910.134 (f)(2)].  
6.2.1 RemovethecapefromthehelmetperSection9.4.  
6.2.2 Remove and discard the old suspension and  
suspension strap by extracting the plastic tabs from the  
wedge-shaped clefts in the shell.  
6.2.3 Unfasten the vinyl sweatband from the two lower,  
outside buttons (A and B in Figure 3).  
7.2.2 The respirator hoses, breathing tube, air entry  
ports, and fittings must be checked for dust contamination,  
and cleaned before making connections.  
6.2.4 The suspension fits head sizes 6.5 to 8. Head  
sizesaremarkedontheheadbandslots.Slidetheheadband  
tongue through the front holder until the desired head size  
is reached. It is important that the adjustment be made  
evenly on both sides. Press the selected slots firmly onto  
the lugs on the front band.  
7.2.3 The helmet suspension is a very important com-  
ponent 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 6.2)  
 
APOLLO 60 HP SUPPLIED-AIR RESPIRATOR  
Page 10  
store it in a clean, dry place. [Reference OSHA Regula-  
tions 1910.134 (f)(5)].  
7.2.4 Periodically inspect and clean the foam filter and  
screen in the alternate air control valve. Replace the foam  
filter at first sign of blockage or deterioration. (See Section  
9.8)  
7.2.5 The inner collar is a very important factor in  
controlling air escape from the helmet and preventing  
ingress of dust. The elastic properties of the collar are  
intended to provide a snug fit on the user’s neck. The collar  
must be replaced before it is stretched to the point where  
it no longer fits snugly around the neck.  
8.0  
CLEANING  
! 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 mate-  
rials used in any part of the respirator.  
7.2.6 The outer cape provides protection from rebound-  
ing abrasive and from abrasive ingress into the helmet.  
Inspect the outer cape frequently for wear. Replace the  
cape before holes are worn through, or any wear occurs  
that prevents the cape from providing the protection for  
which it is intended.  
8.1  
Outer Cape  
7.3  
Cleaning and Disinfecting  
8.1.1 The cape can be machine washed using warm  
water and mild detergent. Dry in a clothes dryer at the  
lowest temperature setting. Do not dry clean. See Section  
9.4 for removal and installation instructions.  
7.3.1 Respirators must be cleaned and disinfected as  
frequently as necessary to ensure that proper protection is  
providedtothewearer. Respiratorsusedbymorethanone  
person must be cleaned and disinfected after each use.  
See Section 8.0 for cleaning instructions. [Reference  
OSHA Regulations 1910.134 (b)(5); 1910.134 (f)(3)].  
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.  
7.4  
Repair (Service Maintenance)  
7.4.1 Replacement or repairs shall be done only by  
trained persons, using genuine Clemco parts designed for  
the respirator. No attempt shall be made to replace com-  
ponents or to make adjustment or repairs beyond the  
manufacturer’s recommendations. See Sec. 9.0 for ser-  
viceinstructions.[ReferenceOSHARegulations1910.134  
(f)(4)].  
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 with warm water and  
mild detergent. Tumble dry in a clothes dryer at the lowest  
temperature setting. Do not dry clean.  
7.5  
Storage  
8.3  
Sweatband and Suspension  
7.5.1 Daily Storage  
8.3.1 The sweatband, suspension, suspension strap,  
and chin strap should be washed using warm water and  
mild detergent. See Section 6.2 for removing the suspen-  
sion.  
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  
providedonthetop.Donottuckthecapeinsidethehelmet.  
Let the cape hang loose to allow air to circulate, to dry  
condensation from the cape and from inside the helmet.  
8.4  
Helmet Assembly  
8.4.1 The helmet assembly should be wiped clean with  
mild detergent and water. DO NOT IMMERSE THE HEL-  
MET IN WATER! While this does not permanently dam-  
age the helmet, it will require an extended drying period.  
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 then 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  
8.4.2 Caremustbeusedtopreventabrasiveentrywhen  
putting on or removing the respirator and when changing  
lenses. Vacuum the inside of the helmet to remove any  
abrasive.  
 
APOLLO 60 HP SUPPLIED-AIR RESPIRATOR  
Page 11  
8.4.3 If the acoustical foam on the inside of the helmet  
becomessoiled, itcanbewipedwithadampclothorpulled  
off and replaced.  
Locating Tabs  
Perforated Outer Lens  
Lens Pull Tab  
8.5  
Inner Lens  
Window Frame  
8.5.1 Inner lenses should be replaced when dirty or  
scratched; however mild detergent and water can be used  
to clean the inner lens. Volatile solutions such as alcohol,  
gasoline or ammonia must not be used to clean this lens.  
Allow the lens to air dry; cloth and towels can scratch the  
lens surface.  
Inner Lens  
Hinge  
Inner Lens Gasket  
Lens Replacement  
9.0  
SERVICE MAINTENANCE  
Figure 4.  
! CAUTION  
9.2.2 Preparing lenses in the following manner will  
permit lenses to be pulled off easily by a user wearing  
heavy gloves.  
Clean the respirator of dust and media before  
maintenance. All maintenance must be done in a  
clean environment away from dust and media.  
Doing so will help prevent ingress of dust and  
contaminants.  
9.2.3 Placeuptofivelensesonacleanflatsurface. Fold  
up the tab of each lens except the first and last, so that the  
tab of each lens is against the back of the one over it.  
9.2.4 Unlatch and open the window frame and remove  
all remnants of old lenses.  
9.1  
Replacing Inner Lens  
9.1.1 Unlatch and open the window frame.  
9.2.5 Pick up the stack of prepared lenses. They will be  
installed with the straight side toward the top of the helmet,  
and the pull tabs toward the hinged end of the window  
frame. See Figure 4.  
9.1.2 Working from inside the helmet, pull up the win-  
dow gasket lip and push the gasket and lens out the front  
of the window opening.  
9.2.6 Drop only the top lens tab through the window  
frame opening at the window frame hinge end. The tab of  
the bottom lens (inside lens) should not go through the  
window frame opening. Placing the lenses in this manner  
will prevent unintentional removal of the last perforated  
lens and prolong the life of the inner lens. Allow all the  
lenses to drop in place between the locating lugs on the  
window frame. The lens perforations should line up close  
to the window frame opening when the frame is closed and  
latched.  
9.1.3 Remove the old lens from the gasket and replace  
with new lens.  
9.1.4 Place the new lens and gasket over the window  
opening. From the inside of the helmet, work the gasket lip  
back onto the helmet.  
9.1.5 Smooth out wrinkles in the gasket on the inside of  
the helmet.  
9.1.6 To maximize the wear life of the inner lens do not  
remove the last perforated outer lens. (See Section 9.2)  
The respirator must never be used without the inner lens  
in place.  
9.3  
Suspension  
9.3.1 To replace and adjust suspension, see Section  
6.2.  
9.2  
Replacing Perforated Outer Lenses, Figure 4  
9.4  
Outer Cape  
9.2.1 Uptofiveouterlensescanbeinstalledatonetime.  
For maximum visibility, install only enough lenses to last  
during a work period.  
9.4.1 When the cape becomes soiled or requires re-  
placement, it can easily be removed as follows.  
 
Page 12  
APOLLO 60 HP SUPPLIED-AIR RESPIRATOR  
9.4.2 Separate the Velcro tabs on the back of the cape.  
See Figure 5.  
closed. When replacing the window frame the acoustical  
foam inside the helmet should also be replaced.  
9.7  
9.7.1 Replace the chin strap when worn.  
9.8 Filter Kit  
Chin Strap  
Air Inlet  
Fitting  
9.8.1 A filter kit is available for the alternate Air Control  
Valve. When the foam filter becomes soiled or deterio-  
rates, pry out the retaining ring with a small screwdriver.  
Remove the screen and dirty filter. Replace all three items  
with parts supplied in the kit.  
Notch  
10.0  
10.1  
REPLACEMENT PARTS  
Cape Removal  
Supplied-Air Respirator Systems  
and Alternate Accessories  
Velcro Tab  
Figure 5.  
Respirators do not include alternate respirator  
hoses shown in Section 10.2. Respirator hose must  
be ordered separately.  
9.4.3 Slide the ends of the cape to the notch. Continue  
sliding one end of the cape out of the groove until the entire  
cape is detached from the helmet.  
Item Description  
Stock No.  
(-)  
(-)  
(-)  
(-)  
Apollo 60 HP Respirator,  
w/constant-flow connector................. 21300  
Apollo 60 HP Respirator,  
w/air control valve.............................. 10505  
Apollo 60 HP Respirator,  
w/cool-air tube ................................... 10508  
Apollo 60 HP Respirator,  
w/climate control tube........................ 10509  
Air control valve with belt ......................... 04440  
Cool-air tube with belt .............................. 04410  
Climate control tube with belt .................. 04411  
Filter kit, air control valve ......................... 04381  
Low pressure conversion kit.  
9.4.4 Toinstallthecape, separatetheVelcrotabsonthe  
cape and slide one end into the groove on the bottom edge  
of the cape attachment strap at the point where the groove  
is notched. Continue sliding the cape around the bottom of  
the helmet until the entire cape is completely into the  
groove. NOTE! Spraying a non-toxic silicone-base lubri-  
cant into the groove will reduce friction and ease assem-  
bly.  
(-)  
(-)  
(-)  
(-)  
(-)  
9.4.5 Join the Velcro tabs at the notch.  
9.5  
Inner Collar  
Converts Apollo 60 HP (high pressure)  
(Grade “D” Compressed Air)  
respirator to LP (low pressure,  
9.5.1 The inner collar is a very important factor in  
controlling air escape from the helmet and preventing  
ingress of dust.  
ambient air) respirator ....................... 22079  
9.5.2 The elastic properties of the collar are intended to  
provide a snug fit on the user’s neck. The inner collar must  
be replaced before it is stretched to the point where it no  
longer fits snug against the neck. The collar unzips from  
the outer cape for replacement or washing. See Section  
8.2 for cleaning instructions.  
9.6  
Window Frame  
9.6.1 The window frame must be replaced when it  
becomes difficult to maintain a seal, or to keep the latch  
 
Page 13  
APOLLO 60 HP SUPPLIED-AIR RESPIRATOR  
11.  
12.  
13.  
Gasket, window........................................ 04452  
Inner lens, .040" package of 5 ................. 04367  
Outer lens, .0075", perforated,  
10.2  
Supplied-Air Respirator, Figure 6  
Item Description  
Stock No.  
package of 25 .................................... 04361  
Window frame kit ..................................... 08741  
Chin strap................................................. 04460  
Handle strap............................................. 03623  
Suspension .............................................. 10532  
Cape attachment strap ............................ 10534  
Cape with inner collar .............................. 04435  
Breathing tube assembly w/molded ends 21550  
Washer, breathing tube, package of 6..... 04370  
Inner collar kit........................................... 08740  
Window latch kit ....................................... 04368  
O-Ring, .864" ID x 1.004" OD .................. 21561  
1.  
Constant-flow connector, HP (alternate),  
14.  
15.  
16.  
17.  
18.  
19.  
20.  
21.  
22.  
23.  
24.  
without belt ........................................ 21415  
Belt assembly, 2" ..................................... 04430  
Respirator hose, 3/8" x 25 ft. (alternate),  
2.  
3.  
includes items 6 and 7....................... 04397  
Respirator hose, 3/8" x 50 ft. (alternate),  
4.  
5.  
includes Items 6 and 7 ...................... 04415  
Respirator hose, 3/8" x 100 ft. (alternate),  
includes items 6 and 7....................... 04398  
Adaptor, 3/8" hose to 3/8" pipe ................ 00022  
Union, 3/8" hose to 3/8" hose .................. 01020  
Disconnect, 1/4" female ........................... 00025  
Adaptor, 3/8" hose to 1/4" pipe ................ 01019  
Acoustical foam kit, sides ........................ 04369  
6.  
7.  
8.  
9.  
10.  
(10)  
(16)  
(23)  
(18)  
(11)  
(12)  
(13)  
(14)  
(17)  
(8)  
(9)  
(15)  
(22)  
(24)  
(6)  
(20)  
(2)  
(19)  
(21)  
(1)  
(3, 4, 5)  
(7)  
Figure 6.  
 

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