AIR-PURIFYING RESPIRATOR

Series 4000
FULL FACEPIECE
WARNING
DO NOT USE this respirator until you completely read and understand this instruction manual. You are
required to inspect your respirator prior to putting it into field service. Please refer to the inspection
procedures in this manual.

I. INTRODUCTION NOTE
This manual provides instruction in the use and mainte- Maintenance or operating procedures and tech-
nance of the SPERIAN Series 4000 Full Facepiece Air- niques or information considered important enough
Purifying Respirator. You must read and understand to emphasize.
this manual and be trained in the proper use of this
respirator before wearing it in a contaminated at- III. DESCRIPTION
mosphere. This SPERIAN air purifying respirator consists of a
full facepiece made of pliable silicone rubber with two
The following table lists the current models available. threaded connectors for attaching particulate filters, gas
Model Description and vapor cartridges, and cartridge/filter combinations
410010 Small Facepiece, Blue, 4-Strap as required for specific contaminant protection.
410015 Small Facepiece, Blue, 5-Strap
410071 Small Facepiece, Blue, 4-Strap with Nose Cup WARNING
410075 Small Facepiece, Blue, 5-Strap with Nose Cup • The employer is responsible for establishing that this
410079 Small Facepiece, Black, 5-Strap with Nose Cup respirator is suitable for the user’s applications.
410090 Small Facepiece, Black, 5-Strap • This facepiece must be worn and used as specified in
SPERIAN’s instructions.
420010 Standard Facepiece, Blue, 4-Strap
• Your SPERIAN respirator has been constructed of
420015 Standard Facepiece, Blue, 5-Strap materials selected for their performance, safety,
420071 Standard Facepiece, Blue, 4-Strap with Nose Cup and durability. However, all materials have exposure
420075 Standard Facepiece, Blue, 5-Strap with Nose Cup limitations to extremes of heat and cold or to the many
chemicals in use today, and could be degraded by
420079 Standard Facepiece, Black, 5-Strap with Nose Cup
exposure beyond their limitations, creating conditions
420090 Standard Facepiece, Black, 5-Strap in which this SPERIAN equipment would be dangerous
to use.
• Before entering an environment while wearing SPERIAN
II. SAFETY PRECAUTIONS
equipment, you must conduct safe, scientific tests
The Warnings, Cautions, and Notes contained in this to determine if the environment could render the
manual have the following significance: equipment unsafe. Results of this testing should be
well documented. Seek the help of a certified safety
WARNING professional or industrial hygienist. DO NOT USE this
equipment if the user would be endangered in any way
Maintenance or operating procedures
through environmentally induced degradation of the
and techniques that will result in per-
materials
sonal injury or death if not carefully fol-
lowed.

CAUTION
Maintenance or operating procedures and
techniques that will result in damage to
equipment if not carefully followed.

Sperian Respiratory Protection USA, LLC

3001 South Susan St., Santa Ana, CA 92704
©
Copyright Sperian Respiratory Protection USA, LLC AN ISO 9001 Toll-Free 888.APR.SCBA or 714.545.0410
April 2008 All Rights Reserved REGISTERED Fax 714.850.0299
P/N 420094 REV C 03/09 COMPANY www.sperianprotection.com
 WARNING
in the apparatus. SPERIAN cannot be responsible for • Do not use this respirator at temperatures below -30°F
damage to property, personal injury, or death in which (-1°C) or above 130°F (71°C). Do not wear this respirator
environmental exposure is a contributing factor. if a satisfactory fit, as determined by a qualitative or
• Do not use this respirator in environments where the quantitative fit test, cannot be obtained. See ANSI
concentrations of contaminants are unknown, or where Z88.2 1992 and OSHA Standards for Asbestos and
the atmosphere is immediately dangerous to life or Lead. Beards, stubble, or sideburns will prevent a good
health (IDLH). IDLH atmospheres are defined as: facepiece seal. Do not use this respirator unless you
1. Those which the wearer could not breathe for short are clean shaven. Absence of one or both dentures can
periods. seriously affect the fit of the facepiece.
2. Those from which the wearer could not escape • No respirator can provide complete protection from all
without the aide of the respirator. conditions. Use extreme care for emergency operations.
3. Those which have an immediate or delayed adverse Do not use this respirator for applications involving
effect on health. exposure to high heat or direct flame.
• Never use this respirator without appropriate SPERIAN • Accessories not offered by SPERIAN may degrade
cartridges/filters identified on the NIOSH approval label performance, and will void NIOSH certification.
securely threaded onto the face piece. • NEVER use this respirator without SPERIAN cartridges
• This respirator does not supply oxygen and must not be or filters securely threaded onto the facepiece. This
used in the atmospheres containing less than 19.5% respirator must be used in conjunction with a written
oxygen by volume. respirator program meeting the requirements of the
• Our engineers cannot predict what will happen to this OSHA Standard for Respiratory Protection, 29 CFR
equipment in every potential environment. Materials 1910.134, available from the U.S. Department of Labor,
can be chemically attacked if exposed to the wrong Occupational Safety and Health Administration. The
environment and may exhibit excessive corrosion or program must include procedures for evaluating air
other forms of damage. Permeation of gases and liquids contaminants and selecting appropriate respirators,
through the materials could be excessive. Extreme of procedures for proper use of respirators, procedures
temperature might cause thermal degradation. Each of for testing the facepiece-to-face fit of respirators,
these things, or a combination of them, could crated procedures for cleaning, disinfecting, inspecting,
conditioning with this SPERIAN equipment would be maintaining, and storing respirators, procedures for
dangerous to use. determining if workers are physically and medically
• All persons using this SPERIAN breathing apparatus capable of wearing respirators, and procedures for
must be amde aware of its limitations. training employees in the use of respirators and in
We cannot be responsible for any damage to property, recognizing the hazards associated with contaminants
personal injury, or dath in which environmental in the work place. When used with a written respirator
exposure is a contributing factor. program, this respirator will reduce, but not eliminate
• Always read cartridge labels prior to use to be certain the inhalation of contaminants.
that you have cartridges and/or filters that will provide • SPERIAN respirators, accessories, and associated
the required protection. Cartridges/filters labeled for equipment should not be used in atmospheres which
protection against particulate only shall not be used may contain contaminant concentrations above the
for gases/vapors, and cartridges/filters labeled for lower explosive level (LEL). Intrinsic safety certification
protection against gases/vapor only shall not be used of electronic components does not eliminate potential
for particulates: danger from ignition in these atmospheres.
• Immediately return to a non-contaminated area if: • FAILURE TO OBSERVE ALL WARNINGS MAY RESULT IN
a. You taste or smell contaminates , or if your eyes, PERSONAL INJURY, SERIOUS ILLNESS, OR DEATH.
nose, or throat become irritated. blasting, underwater
diving, or interior structural fire fighting.
b. Breathing becomes difficult.
c. The air you are breathing becomes uncomfortably
warm.
d. You feel nauseous or dizzy.
• This respirator does not protect exposed areas of the
body. Some contaminates can be absorbed directly
through the skin while other may irritate exposed area.
• This respirator must not be used for abrasive blasting,
underwater diving, or interior structural fire fighting.

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IV. PARTS LIST
ACCESSORIES
ITEM QTY. (Ea.) P/N DESCRIPTION
P/N DESCRIPTION
1 1 941723 Headstrap, 4-Strap, Blue
968424 Headstrap, 5-Strap, 980003 Spectacles Kit
Black 980017 Nose Cup Kit
961094 Headstrap, 5-Strap, Blue 140095 Lens Cover
2 1 420002 Standard Skirt, 4-Strap, 951015 Anti-fog Solution (1 oz.)
Blue 951016 Anti-fog Solution (16 oz.)
420003 Standard Skirt, 5-Strap, 430000 Welding Shield, Standard Weld
Black ing Plate
420081 Standard Skirt, 5-Strap, 430030 Welding Shield, Auto-Dark, Vari
Blue able 9-12 Shade
1 410002 Small Skirt, 4-Strap, 430040 Welding Shield, Auto-Dark, Fixed
Blue 10 Shade
410003 Small Skirt, 5-Strap, 430005 Welding Bib, Lower
Black 430010 Welding Bib, Upper
410081 Small Skirt, 5-Strap,
Blue NOTE
3 2 839102 Screw Use only components with the part numbers listed on the
4 2 941280 Rim NIOSH approval label. Use of any other components will
5 1 941712 Lens void the approval.
6 1 940135 Strap Assy.
7 1 520039 Cover TABLE 1. CARTRIDGES AND FILTERS
8 2 955805 Screw
9 1 420020 Cap MODEL NO. CARTRIDGES
10 1 pkg. of 6 140001 Inhalation Valve 100100 Organic Vapors
11 1 pkg. of 2 140002 Threaded Connector 100200 Acid Gases: Sulfur Dioxide, Chlorine, Hy
drogen Chloride, Formaldehyde
12 1 420008 Grill 100300 Organic Vapors and Acid Gases: Organic
13 Cartridges —See Table 1 Vapors; Sulfur Dioxide, Chlorine, Hydrogen
14 Filters — See Table 1 Chloride, Chlorine Dioxide, Hydrogen Fluo
15 1 140079 Filter Retainer ride, Hydrogen Sulfide (Escape Only)
16 1 941759 Speaking Diaphragm 100400 Ammonia and Methylamine
109100 Combination Organic Vapors; HEPA;
Assy. Dusts, Fumes, and Mists; Pesticides; and
17 1 820031 O-ring Mists of Paint, Lacquer, and Enamel
18 1 980081 Nozzle 109200 Combination Acid Gases; HEPA; and
19 1 pkg. of 4 140003 Exhalation Valve Dusts, Fumes, and Mists: Sulfur Dioxide,
20 1 824014 Leak Check O-ring Chlorine, Hydrogen Chloride; HEPA; Dusts,
Fumes, and Mists
21 1 824014 Cap O-ring 109300 Combination Organic Vapors; Acid Gases;
22 1 981177 Filter Shower Cap HEPA; Dusts, Fumes, and Mists; and
Pesticides: Organic Vapors; Sulfur Dioxide,
Chlorine, Hydrogen Chloride, Chlorine
Dioxide, Hydrogen Fluoride, Hydrogen
Sulfide (Escape Only); HEPA; Dusts,
Fumes, and Mists; Pesticides
109400 Combination Ammonia; Methylamine; HEPA;
and Dusts, Fumes, and Mists
1091 Combination Organic Vapors and P100
1092 Combination Acid Gases and P100: Sulfur Diox
ide, Chlorine, Hydrogen Chloride; and P100
1093 Combination Organic Vapors; Acid Gases;
and P100: Organic Vapors; Sulfur Dioxide,
Chlorine, Hydrogen Chloride, Chlorine Dioxide,
Hydrogen Fluoride, Hydrogen Sulfide (Escape
Only); and P100
1094 Combination Ammonia; Methylamine; and
P100
FILTERS
101000 Dusts and Mists when used with 100100,
100200, 100300, or 100400 cartridge, and
140079 retainer.
102000 Paint, Lacquer, and Enamel Mists, and Dusts
& Mists when used with 100100 cartridge and
140079 retainer.
104000 Pesticides; Paint, Lacquer, and Enamel
Mists; and Dusts, Fumes, and Mists when
used with 100100 cartridge and 140079 retainer.
Dusts, Fumes, and Mists when used with
100300 cartridge and 140079 retainer.
109000 HEPA; and Dusts, Fumes, and Mists
1090 P100
Figure 1. Series 4000 APR 1195 P100 Disk
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 1. Inspect the respirator as described in section VI,
WARNING
paragraph B.
Following is a partial list of mate- 2. Adjust the top facepiece straps until one inch of
rials for which these respirators strap extends through each buckle. Fully loosen
MUST NOT be used. This list is far
the lower straps.
from complete. Contact SPERIAN
for information on other materials. 3. Place the neck strap around the back of your
neck.
4. Place your chin against the chin cup and center
Acroline Hydrogen Selenide the facepiece.
Aniline Isocyanates: TDI, HDI, MDI 5. Grasp the facepiece with your hand, and pull the
Arsine Methanol straps over your head.
Boron Hydrides Methylene Chloride, Methyl 6. Tighten the bottom straps until a good seal is ob-
Bromide, Methyl Chloride tained. Adjust the top straps if required.
Bromine Nitro Compounds: 7. For the 5-strap facepiece, tighten the lower straps,
Carbon Dioxide Nitrogen Oxides the temple straps, then the top strap, until all the
Carbon Monoxide Nitroglycerin headstraps lie flat on your head.
Carbonyls Nitrobenzene
NOTE
Cyanogen Nitromethane When properly adjusted, the headstrap hub should
Dimethylaniline Ozone be centered on the back of your head, and the lower
straps should be below your ears.
Dimethyl Sulfate Phosgene
Ethyl Cyanide Phosphine C. Facepiece Fit Check
Fluorine Phosphorous Trichloride
Hydrogen Cyanide Stibine WARNING
Sulfur Chloride Vinyl Chloride If a leak-tight seal is not obtained during the
following fit checks, do not wear the respi-
V. USE INSTRUCTIONS rator. Ask your supervisor or safety profes-
sional for assistance.
A. Filter/Cartridge Installation
1. Ensure that you have the correct filter and/or
chemical cartridge for the specific contaminants in 1. Positive Pressure Fit Check
your work area. If you are not sure, consult your a. Hold your palm over the exhalation valve grill.
supervisor or safety professional. b. Exhale gently to create a positive pressure
2. Thread the P100 or HEPA filters or correct chemi- inside the facepiece.
cal cartridges onto the facepiece connectors. c. If leakage occurs, readjust facepiece and
3. Carefully hand-tighten, ensuring a good seal straps until leak-tight. If you are unable
against the facepiece. Do not over tighten. to obtain a proper fit, consult your safety
4. To install filter pads, insert the correct filter pad professional.
into the filter retainer with the side stamped with 2. Negative Pressure Fit Check
the part number facing the wearer. a. Remove the filters and cover the filter inlets
5. Snap the filter retainer onto the chemical car- with your hands and inhale gently. Hold your
tridge. breath for a few seconds. The facepiece
6. When using the transparent filter retainer, P/N should collapse on your face without leaking.
140079, inspect the assembly through the re- b. If the facepiece leaks, reposition, check straps,
tainer and ensure that: and repeat the leak check.
a. The edge of the filter makes contact with the c. If a good fit was achieved, reinstall the filters.
entire retainer wall.
b. The filter is not bunched or folded. D. Using the Respirator
c. The filter completely covers the top of the
cartridge. To receive the maximum protection available from your
respirator, you must follow your employer’s instructions
B. Donning on the use and maintenance of the respirator. Read and
understand the following warnings prior to using the
WARNING respirator.
Always read cartridge labels prior to use to
be certain that you have cartridges and/or WARNING
filters that will provide the required protec- ● Never remove your respirator for any rea-
tion. Cartridges/filters labeled for protection son while you are in the work area.
against particulates only shall not be used ● You must leave the work area immediately
for gases/vapors, and cartridges/filters la- if the face piece seal is disturbed for any
beled for protection against gases/vapors reason, such as:
only shall not be used for particulates. Both
cartridges/filters must be of the same type.
4
 G. Cartridge Replacement
Warning­—Continued
The cartridges must be replaced whenever you smell
a. Slipping due to excessive sweating or or taste contaminants, or if your eyes, nose, or throat
excessive head movement. become irritated. Cartridges must also be replaced
b. The facepiece becomes dislodged as a result if they show any sign of damage. Dispose of used
of being knocked.
cartridges in accordance with applicable local, state,
c. You sneeze or cough while wearing the
facepiece.
and federal guidelines.
d. You need to blow your nose, scratch covered 1. Return to an area with clean air.
areas of your face, or need to adjust your 2. Unscrew the used cartridges from the facepiece
spectacles kit.
e. For any other reason that would cause the
connectors and discard.
facepiece seal to be disturbed. 3. Securely install new cartridges onto threaded
You must restore the facepiece seal and perform facepiece connectors as described in section V,
a fit check before reentering the work area. paragraph A.

VI. MAINTENANCE
E. Doffing
NOTE
CAUTION Inspect this respirator for defects before and after
Always loosen the two lower headstraps com- each use, and at least once monthly if not used.
pletely prior to removing the facepiece. Repair as necessary, clean and disinfect after each
use, and store properly to assure that the respirator is
1. Loosen the two lower headstraps completely. maintained in satisfactory working condition. Keep a
record of inspection and repair dates and results. Refer
to the inspection table in the back of this manual.
CAUTION
Do not twist the nozzle when removing the facepiece A. Cleaning
2. Grasp the nozzle firmly and pull the facepiece upward
over your head. WARNING
3. Remove the neck strap from around your neck. Specialized processes are required to dis-
infect and decontaminate a respirator. You
F. Filter Replacement MUST follow the instructions of the manu-
SPERIAN recommends that the filters be changed at facturer who supplies the disinfecting or de-
least daily, and more often if necessary. The filters must contamination equipment or chemicals.
be replaced whenever they become contaminated with
dust or water; if you smell or taste contaminants; if your NOTE
eyes, nose, or throat become irritated; or if breathing Silicone and rubber parts of the facepiece may be
becomes difficult. Filters must also be replaced if they cleaned between washings with SPERIAN Mask
show any sign of damage. Dispose of used filters in Wipes, P/N 140096.
accordance with applicable local, state, and federal
guidelines. 1. Make a cleaning solution of warm water and a mild
1. Return to an area with clean air. detergent.
2. Remove the cartridges/filters from the facepiece.
2. Remove the filter retainer from the chemical 3. Immerse the facepiece top first in the solution until
cartridge. If using a P100 or HEPA filter, unscrew the exhalation valve is covered.
the used filters from the facepiece connectors 4. Agitate the facepiece and gently clean with a soft
and discard them. brush.
3. Remove and discard the filter pad. 5. Thoroughly rinse the facepiece in fresh water,
paying particular attention to removal of all soap
4. Clean the filter retainer if required.
residue from the exhalation valve. If possible, direct
5. Insert the correct filter pad into the filter retainer running water onto the exhalation valve.
with the side stamped with the part number 6. Disinfect the facepiece in a warm (48°C or 120°F
facing up. maximum) suitable sanitizing solution such as
6. Snap the filter retainer onto the chemical cartridge. a “hypochlorite solution” for 2 to 3 minutes. A
If using a P100 or HEPA filter, securely install new hypochlorite solution can be made by mixing two
filters onto the threaded facepiece connectors as (2) tablespoons of chlorine bleach per each gallon
described in section V, paragraph A. of water. Rinse thoroughly with fresh warm (48°C
or 120°F maximum) water.
7. Perform a fit check.
7. Allow the facepiece to drip dry. Warm air may be
used to speed up drying.
5
 NOTE E. Shipment
Cleaning solutions containing ammonia or repeated All products returned to SPERIAN’s factory, distribu-
washing will remove the lens anti-fog coating. Recoat tors, or repair centers must be decontaminated prior
with SPERIAN Anti-Fog Solution, P/N 951015 (1 oz.), to shipment.
or 951016 (16 oz.).
F. Overhaul Frequency
8. After cleaning, apply three drops of anti-fog This SPERIAN respirator does not have an overhaul
solution as required to the inner surface of the requirement other than that required in Section VI,
lens and spread with a lint-free cloth. Allow to dry Maintenance.
for 15 minutes.
9. Hold the facepiece firmly against your face and G. Additional Information
exhale several times to ensure that the exhalation If you need assistance or additional information on
valve functions smoothly. any SPERIAN product, consult your local distributor
or contact:
B. Inspection (See the Inspection Table in the Back
of this Manual) SPERIAN
3001 South Susan Street
WARNING Santa Ana, CA 92704
Ensure that the o-ring, P/N 824014, is in the cap plug, (714) 545-0410 or toll free 888-APR-SCBA
P/N 420020, and that the cap plug is securely seated
FAX (714) 850-0299
on the nozzle. Using the APR without the cap plug o-
ring or without the cap plug securely seated could al-
low contaminants to leak into the facepiece, resulting
in illness or death. ALL RETURNED PRODUCTS MUST BE
DECONTAMINATED PRIOR TO SHIP-
NOTE MENT. PRODUCTS CONTAMINATED
The leak check o-ring, item 20 of Figure 1, located WITH DANGEROUS SUBSTANCES WILL
between the cap plug (item 9) and the cover (item 7) BE REFUSED AND RETURNED FREIGHT
is to allow the positive pressure fit check only. COLLECT.

C. Repair (See the Repair Table in the Back of this

Manual)
Repair by the user is limited to replacement of
components as listed on the NIOSH approval label.
Disassembly should be performed only to the extent
necessary to replace the components. To protect your
warranty and the NIOSH certification of the equipment,
all other repairs must be done only by authorized
SPERIAN technicians and repair centers. Consult your
SPERIAN distributor for the one nearest you.

D. Storage

WARNING
This SPERIAN respirator does not have
a defined storage life. Carefully inspect it
before each use.

CAUTION
The maximum storage temperature for this de-
vice is 140°F (60°C). Long term exposure to el-
evated storage temperatures could cause pre-
mature deterioration.

After inspection and cleaning, store your SPERIAN

APR to protect it against dust, sunlight, extreme heat
and cold, excessive moisture, or damaging chemicals.

6
VII. INSPECTION TABLE

IF ANY OF THE DEFECTS LISTED BELOW ARE FOUND, HAVE THE RESPIRATOR REPAIRED BEFORE USE.
COMPONENT LOOK FOR
FACEPIECE LENS 1. Nicks, scratches, or abrasions which could impair visibility.
2. Deep gouges or cracks which could reduce impact resistance.
3. Anti-fog coating in need of replacement.
FACEPIECE RIMS 1. Deformed, cracked, or broken.
2. Loose screws. Do not overtighten.
FACEPIECE SKIRT 1. Cuts, gouges, or punctures.
2. Tears or nicks in the sealing area.
3. Deterioration from age, heat, or contamination.
FACEPIECE HEADSTRAP 1. Abrasions or nicks.
2. Deterioration from age, heat, or contamination.
FACEPIECE BUCKLES 1. Crushed, bent, or corroded.
2. Damaged or loose rivets.
FACEPIECE INLET NOZZLE 1. Loose cover screws.
2. Heat or impact damage.
3. Nicks, cracks, or dents in the exhalation valve seat.
4. Nicks, cracks, tears, or creases in the exhalation valve.
5. Sticking exhalation valve. Exhale a few times to test. The valve must close after
each exhalation. Valves that fail to close must be replaced.
SPEAKING DIAPHRAGM Holes or tears. Do not remove to inspect.

VIII. REPAIR TABLE

COMPONENT INSTRUCTIONS
HEADSTRAP REPLACEMENT 1. Remove the old headstrap from the facepiece, noting the routing of the straps.
2. Install new headstrap.
NOSE CUP 1. Unscrew the speaking diaphragm ring counterclockwise and remove it, along with
the o-ring from the nozzle. NOTE: If the speaking diaphragm ring is too tight to
remove by hand, use the Speaking Diaphragm Tool, P/N 980019.
2. Discard the old nose cup.
3. If removed, reinstall the o-ring on the speaking diaphragm ring.
4. Fit the speaking diaphragm ring into the nose cup.
5. Position the nose cup inside the facepiece with the locating pins seated in the
exhalation valve hole.
6. Tighten the speaking diaphragm ring.
7. Perform a facepiece fit check as described in section V, paragraph C.
FACEPIECE LENS REPLACEMENT 1. Use a 5/32 inch Allen wrench to remove the two rim screws.
2. Gently sepearte the rims from the facepiece.
3. Pull the facepiece skirt away from the lens.
4. Remove the old lens.
5. Match one corner of the new olens with the corner of the skirt.
6. Place the edge of the lens inside the lens channel fo the skirt.
7. Knead the skirt until it fits evenly around the edge of the lends, and the corners of
the skirt match the corners of the lens.
8. Install the two rims. Start both scrws but do not tighten. CAUTION-Do not pinch
the skirt between the rims.
9. Alternatley tighten each screw until firmly tightened.
NOTE ─ The corners of the skirt should be centered between each rim when instal-
lation is complete.
10. Perform a facepiece fit check as described in section V, paragraph C.
EXHALATION VALVE 1. Remove the valve grill cover form the nozzle.
2. Remove and discard teh old exhalation valve.
3. Insert a new valve and pull the valve stem until it snaps into place.
4. Replace teh valve grill cover.
5. Perform a facepiece fit check as described in section V, paragraph C.
ACCESSORIES Each modification kit and acessory purchased from SPERIAN has installation
instructions. Use these instructions for removing and replacing any accessory.

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