RLX CONTROL HANDLE

O. M. 10574

MC FILE NUMBER: 733-0186

DATE OF ISSUE: 01/86
REVISION: I, 11-09

WARNING
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
© 2009 CLEMCO INDUSTRIES CORP. the immediate vicinity.
One Cable Car Dr.
Washington, MO 63090 *If you are using a Clemco Distributor
Phone (636) 239-4300 Maintenance and Part Guide, refer to
Fax (800) 726-7559
the orange warnings insert preceding
Email: [email protected]
www.clemcoindustries.com the Index before continuing with the
enclosed instructions.
Electronic files include a Preface
containing the same important
information as the orange cover.
 PREFACE

GENERAL INSTRUCTIONS
WARNING Described herein are some, BUT NOT ALL, of the major
requirements for safe and productive use of blast
• Read and follow ALL instructions before using machines, remote control systems, operator respirator
this equipment. assemblies, and related accessories. Completely read ALL
• Failure to comply with ALL instructions can result instruction manuals prior to using equipment.
in serious injury or death.
• In the event that the user, or any assistants of the The user's work environment may include certain
user of this equipment cannot read or cannot HAZARDS related to the abrasive blasting operation.
completely understand the warnings and Proper protection for the blaster, as well as anyone else
information contained in these instructions, the that may be EXPOSED to the hazards generated by the
employer of the user and his assistants must blasting process, is the responsibility of the user and/or
thoroughly educate and train them on the proper the employer. Operators MUST consult with their employer
operation and safety procedures of this about what hazards may be present in the work
equipment. 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,
NOTICE TO PURCHASERS AND USERS OF OUR or materials present in the surface to be blasted such as
PRODUCTS AND THIS INFORMATIONAL MATERIAL lead or heavy metals in coatings. The environment may
also include fumes that may be present from adjacent
The products described in this material, and the information coatings application, contaminated water, engine exhaust,
relating to those products, is intended for knowledgeable, chemicals, and asbestos. The work area may include
experienced users of abrasive blasting equipment. PHYSICAL HAZARDS such as an uneven work surface,
poor visibility, excess noise, and electrical hazards. The
No representation is intended or made as to the suitability of operator MUST consult with his employer on the
the products described herein for any particular purpose or identification of potential hazards, and the appropriate
application. No representations are intended or made as to the measures that MUST be taken to protect the blaster and
efficiency, production rate, or the useful life of the products others that might be exposed to these hazards.
described herein. Any estimate regarding production rates or
production finishes are the responsibility of the user and must ALL machines, components and accessories MUST be
be derived solely from the user’s experience and expertise, installed, tested, operated and maintained only by trained,
and must not be based on information in this material. knowledgeable, experienced users.

The products described in this material may be combined by DO NOT modify or substitute any Clemco parts with other
the user in a variety of ways for purposes determined solely by types or brands of equipment. Unauthorized modification
the user. No representations are intended or made as to the and parts substitution on supplied air respirators is a
suitability or engineering balance of the combination of violation of OSHA regulations and voids the NIOSH
products determined by the user in his selection, nor as to the approval.
compliance with regulations or standard practice of such
combinations of components or products.
OPERATIONAL INSTRUCTIONS
Abrasive Blast Equipment is only a component of the range of
equipment used in an abrasive blasting job. Other products OPERATOR SAFETY EQUIPMENT
may include an air compressor, abrasive, scaffolding, hydraulic
work platforms or booms, paint spray equipment,
dehumidification equipment, air filters and receivers, lights, WARNING
ventilation equipment, parts handling equipment, specialized
respirators, or equipment that while offered by Clemco may
• Blast operators and others working in the vicinity of
have been supplied by others. Each manufacturer and supplier
abrasive blasting must always wear properly-
of the other products used in the abrasive blasting job must be
maintained, NIOSH-approved, respiratory protection
contacted for information, training, instruction and warnings
appropriate for the job site hazards.
with regard to the proper and safe use of their equipment in the
• DO NOT USE abrasives containing more than one
particular application for which the equipment is being used.
percent crystalline (free) silica. Ref. NIOSH Alert
The information provided by Clemco is intended to provide
#92-102
instruction only on Clemco products. All operators must be
trained in the proper, safe, use of this equipment. It is the • Inhalation of toxic dust (crystalline silica, asbestos,
responsibility of the users to familiarize themselves with, and lead paint and other toxins) can lead to serious or
comply with, all appropriate laws, regulations, and safe fatal disease (silicosis, asbestosis, lead or other
practices that apply to the use of these products. Consult with poisoning).
your employer about training programs and materials that are
available.
• ALWAYS wear NIOSH-approved supplied-air respirators
Our company is proud to provide a variety of products to the as required by OSHA, in the presence of any dust including,
abrasive blasting industry, and we have confidence that the but not limited to, handling or loading abrasive; blasting or
professionals in our industry will utilize their knowledge and working in the vicinity of blast jobs; and cleanup of expended
expertise in the safe efficient use of these products. abrasive. Prior to removing respirator, an air monitoring

I
 PREFACE

instrument should be used to determine when surrounding equipment. If controls are altered, involuntary activation, which
atmosphere is clear of dust and safe to breathe. may cause serious injury, can occur.

• NIOSH-approved, supplied-air respirators are to be worn • Inspect the air control orifice DAILY for cleanliness.
ONLY in atmospheres: NEVER use welding hose in place of twinline control hose. The
• NOT IMMEDIATELY dangerous to life or health and, internal diameter and rubber composition are UNSAFE for
• from which a user can escape WITHOUT using the remote control use.
respirator.
• UNLESS OTHERWISE SPECIFIED, maximum working
• Clemco supplied-air respirators DO NOT REMOVE OR pressure of blast machines and related components MUST
PROTECT AGAINST CARBON MONOXIDE (CO) OR ANY NOT exceed National Board approved 125 psig (8.5 BAR).
OTHER TOXIC GAS. Carbon monoxide and toxic gas removal
and/or monitoring device must be used in conjunction with • NEVER weld on blast machine. Welding may affect
respirator to insure safe breathing air. dimensional integrity of steel wall and WILL VOID National
Board approval.
• Air supplied to respirator MUST BE AT LEAST GRADE D
QUALITY as described in Compressed Gas Association • Point nozzle ONLY at structure being blasted. High
Commodity Specification G-7.1, and as specified by OSHA velocity abrasive particles WILL inflict serious injury. Keep
Regulation 1910.139 (d). unprotected workers OUT of blast area.

• ALWAYS locate compressors to prevent contaminated air • NEVER attempt to manually move blast machine when it
(such as CO from engine exhaust) from entering the air intake contains abrasive. EMPTY machines, up to 6 cu. ft.(270kg)
system. A suitable in-line air purifying sorbent bed and filter or capacity, are designed to be moved:
CO Monitor should be installed to assure breathing air quality. • on flat, smooth surfaces by AT LEAST two people;
• with the Clemco "Mule"; or
• ALWAYS use a NIOSH-approved breathing air hose to • with other specially designed machine moving devices.
connect an appropriate air filter to the respirator. Use of a non-
approved air hose can subject the operator to illness caused • Larger empty blast machines or ANY blast machine
by the release of chemical agents used in the manufacture of containing abrasive MUST be transported by mechanical lifting
non-approved breathing air hose. equipment.

• ALWAYS check to make sure air filter and respirator

system hoses are NOT CONNECTED to in-plant lines that AIR HOSE, BLAST HOSE, COUPLINGS, AND NOZZLE HOLDERS
contain nitrogen, acetylene or any other non-breathable gas.
NEVER use oxygen with air line respirators. NEVER modify air • Air hose, air hose fittings and connectors at compressors
line connections to accommodate air filter/respirator breathing and blast machines MUST be FOUR times the size of the
hose WITHOUT FIRST testing content of the air line. FAILURE nozzle orifice. Air hose lengths MUST be kept as short as
TO TEST THE AIR LINE MAY RESULT IN DEATH TO THE possible AND in a straight line. Inspect DAILY and repair
RESPIRATOR USER. leakage IMMEDIATELY.

• Respirator lenses are designed to protect against • Blast hose inside diameter MUST be THREE to FOUR
rebounding abrasive. They do not protect against flying times the size of the nozzle orifice. AVOID sharp bends that
objects, glare, liquids, radiation or high speed heavy materials. wear out hose rapidly. Use SHORTEST hose lengths possible
Substitute lenses from sources other than the original to reduce pressure loss. Check blast hose DAILY for soft
respirator manufacturer will void NIOSH-approval of this spots. Repair or replace IMMEDIATELY.
respirator.
• 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
BLAST MACHINES AND REMOTE CONTROLS that DO NOT provide a TIGHT fit on hose. ALWAYS use
manufacturers recommended coupling screws.

• Replace coupling gaskets FREQUENTLY to prevent

WARNING 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.
• ALWAYS equip abrasive blast machines with
remote controls.
• Install safety pins at EVERY coupling connection to
• Abrasive blast machine operators must wear NIOSH- prevent accidental disengagement during hose movement.
approved supplied-air respirators (ref: OSHA
regulations 1910.94, 1910.132, 1910.139 and
• ALWAYS attach safety cables at ALL air hose AND blast
1910.244).
hose coupling connections. Cables relieve tension on hose and
control whipping action in the event of a coupling blow-out.
• NEVER modify OR substitute remote control parts. Parts
from different manufacturers are NOT compatible with Clemco

II
 PREFACE

MAINTENANCE of the purchase price, as set forth below:

1. Seller makes no warranty with respect to products used
• ALWAYS shut off compressor and depressurize blast other than in accordance hereunder.
machine BEFORE doing ANY maintenance. 2. On products seller manufactures, seller warrants that all
products are to be free from defects in workmanship and
• Always check and clean ALL filters, screens and alarm materials for a period of one year from date of shipment to
systems when doing any maintenance. buyer, but no warranty is made that the products are fit for a
particular purpose.
• ALWAYS cage springs BEFORE disassembling valves IF 3. On products which seller buys and resells pursuant to this
spring-loaded abrasive control valves are used. order, seller warrants that the products shall carry the then
standard warranties of the manufacturers thereof, a copy of
• ALWAYS completely follow owner's manual instructions which shall be made available to customer upon request.
and maintain equipment at RECOMMENDED intervals. 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
ADDITIONAL ASSISTANCE
model.
5. Seller makes no warranty that the products are delivered
• Training and Educational Programs. free of the rightful claim of any third party by way of patent
Clemco Industries Corp. offers a booklet, Blast-Off 2, infringement or the like.
developed to educate personnel on abrasive blast equipment 6. This warranty is conditioned upon seller’s receipt within ten
function and surface preparation techniques. Readers will learn (10) days after a buyer’s discovery of a defect, of a written
safe and productive use of machines, components and various notice stating in what specific material respects the product
accessories, including selection of abrasive materials for failed to meet this warranty. If such notice is timely given, seller
specific surface profiles and degrees of cleanliness. will, at its option, either modify the product or part to correct the
defect, replace the product or part with complying products or
• The Society for Protective Coatings (SSPC) offers a video parts, or refund the amount paid for the defective product, any
training series on protective coatings including one entitled one of which will constitute the sole liability of seller and a full
"Surface Preparation." For loan or purchase information, settlement of all claims. No allowance will be made for
contact SSPC at the address shown below. alterations or repairs made by other than those authorized by
seller without the prior written consent of seller. Buyer shall
TECHNICAL DATA AND RESEARCH COMMITTEES afford seller prompt and reasonable opportunity to inspect the
products for which any claim is made as above stated.
• The following associations offer information, materials and
videos relating to abrasive blasting and safe operating Except as expressly set forth above, all warranties, express,
practices. implied or statutory, including implied warranty of
The Society for Protective Coatings (SSPC) merchantability, are hereby disclaimed.
40 24th Street, Pittsburgh PA 15222-4643
Phone: (412) 281-2331 • FAX (412) 281-9992 DAILY SET-UP CHECK LIST
Email: [email protected] • Website: www.sspc.org
National Association of Corrosion Engineers (NACE)
1440 South Creek Drive, Houston TX 77084 WARNING
Phone: (281) 228-6200 • FAX (281) 228-6300
Email: [email protected] • Website: www.nace.org • ALL piping, fittings and hoses MUST be checked
American Society for Testing and Materials (ASTM) DAILY for tightness and leakage.
100 Barr Harbor Dr., West Conshohocken, PA 19428 • ALL equipment and components MUST be thoroughly
Phone (610) 832-9500 • FAX (610) 832-9555 checked for wear.
Email: [email protected] • Website: www.astm.org • ALL worn or suspicious parts MUST be replaced.
• ALL blast operators MUST be properly trained to
NOTICE operate equipment.
This equipment is not intended to be used in an area that might • ALL blast operators MUST be properly outfitted with
be considered a hazardous location as described in the abrasive resistant clothing, safety shoes, leather gloves
National Electric Code NFPA 70 1996, article 500. and ear protection.
• BEFORE blasting ALWAYS use the following check list.
WARRANTY
The following is in lieu of all warranties express, implied or
statutory and in no event shall seller or its agents, successors,
□ 1. PROPERLY MAINTAINED AIR COMPRESSOR sized
nominees or assignees, or either, be liable for special or to provide sufficient volume (cfm) for nozzle and other tools
consequential damage arising out of a breach of warranty. This PLUS a 50% reserve to allow for nozzle wear. Use large
warranty does not apply to any damage or defect resulting compressor outlet and large air hose (4 times the nozzle orifice
from negligent or improper assembly or use of any item by the size). FOLLOW MANUFACTURERS MAINTENANCE
buyer or its agent or from alteration or attempted repair by any INSTRUCTIONS.
person other than an authorized agent of seller. All used,
repaired, modified or altered items are purchased “as is” and
□ 2. BREATHING AIR COMPRESSOR (oil-less air pump)
with all faults. In no event shall seller be liable for capable of providing Grade D Quality air located in a dust free,
consequential or incidental damages. The sole and exclusive contaminant free area. If oil-lubricated air compressor is used
remedy of buyer for breach of warranty by seller shall be repair to supply respirator, it should have high temperature monitor
or replacement of defective parts or, at seller’s option, refund and CO monitor or both. If CO monitor is not used, air MUST
be tested FREQUENTLY to ensure proper air quality.
III
 PREFACE

□ 3. Clean, properly maintained NIOSH-APPROVED □ 8. BLAST HOSE with ID 3 to 4 times the nozzle orifice.
SUPPLIED-AIR RESPIRATOR. ALL components should Lines MUST be run AS STRAIGHT AS POSSIBLE from
ALWAYS be present. NEVER operate without inner lens in machine to work area with NO sharp bends. Check DAILY for
place. Thoroughly inspect ALL components DAILY for internal wear and external damage.
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. □ 9. HOSE COUPLINGS, NOZZLE HOLDERS fitted
SNUGLY to hose end and installed using PROPER coupling

□ 4. OSHA required BREATHING AIR FILTER for removal

screws. Coupling lugs MUST be snapped FIRMLY into locking
position. Gasket MUST form positive seal with safety pins
of moisture and particulate matter from breathing air supply. inserted through pin holes. Check gaskets and replace if ANY
THIS DEVICE DOES NOT REMOVE OR DETECT CARBON sign of wear, softness or distortion. ALWAYS install safety
MONOXIDE (CO). ALWAYS USE CO MONITOR ALARM. cables at every connection to prevent disengagement. Check
nozzle holder for worn threads. NEVER MIX DIFFERENT

□ 5. ASME CODED BLAST MACHINE sized to hold 1/2

BRANDS OF COMPONENTS. Check each of these
components DAILY.
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 □ 10. Inspect NOZZLE and GASKET DAILY for wear.
objects and a cover to prevent entry of moisture overnight. Replace nozzle when 1/16" larger than original size or if liner
appears cracked. Check nozzle threads for wear.

□ 6. AIR LINE FILTER installed AS CLOSE AS POSSIBLE

to machine inlet. Sized to match inlet piping or larger air supply □ 11. Use abrasive that is properly sized and free of harmful
line. Clean filter DAILY. Drain OFTEN. substances; such as, free silica, cyanide, arsenic or lead.
Check material data sheet for presence of toxic or harmful

□ 7. REMOTE CONTROLS MUST be in PERFECT

substances.

operating condition. ONLY use APPROVED spare parts,

including twin- line hose. DAILY: test system operation and □ 12. Test surface to be blasted for toxic substances. Take
check button bumper and spring action of lever and lever lock. appropriate, and NIOSH required, protective measures for
DO NOT USE WELDING HOSE. operator and bystanders which pertain to substances found on
the surface to be blasted.

1 Air Compressor

11. Silica-free Abrasive 5. ASME Coded

Blast Machine

7. Remote
Controls
3. NIOSH
2. Breathing Air Compressor Approved 6. Air Line
(or) Supplied-Air Filter
2. Ambient Air Pump Respirator
for low pressure
respirator

10. Appropriately
4. CPF Air-Filter Sized Nozzle

8. Blast Hose
9. Hose Couplings and
Safety Cables

IV
 RLX PNEUMATIC AND RLX ELECTRIC CONTROL HANDLE Page 1

1.0 INTRODUCTION
CAUTION
1.1 Scope Caution indicates a potentially hazardous
situation which, if not avoided, may result in
1.1.1 This Owner's Manual covers the installation,
operation, maintenance, troubleshooting, and replacement
minor or moderate injury.
parts for the following models of Clemco RLX pneumatic
and electric control handles.
WARNING
Description Stock no.
Warning indicates a potentially hazardous
RLX Pneumatic ............................................................10565 situation which, if not avoided, could result in
RLX Pneumatic with ACS Toggle Switch....................07625 death or serious injury.
RLX Electric w/Lo-Profile Connector ...........................10840
RLX Electric w/Twist-Lock Connector .........................05801

1.1.2 This manual contains instructions common to both

DANGER
the pneumatic and electric control handle. Read the Danger indicates an imminently hazardous
common instructions before proceeding to the section situation which, if not avoided, will result in
relating specifically to pneumatic or electric model. death or serious injury.

1.1.3 This manual covers the RLX Remote Control

Handle only. The operator must be trained in the safe 1.3 General Description
operation of remote control system, blast machine, and all
other equipment used. They must know about the hazards 1.3.1 The principal components of the control handle
associated with abrasive blasting. To ensure safe blasting, are shown in Figure 1. The control handle is the main
before using the control handle, read the manuals for the activator of Clemco remote control systems. When the
specific blast machine, remote controls and accessories control handle lever is up, it is in the non-blast position.
used. Pressing the control handle lever down activates the
remote controls.
1.1.4 The current RLX and the earlier RLX and Recova-
Loks are interchangeable when used as complete units. Handle Lever Lever Lock

1.2 Safety Alerts

Rubber Button Nylon Tie
1.2.1 Clemco uses safety alert signal words, based
on ANSI Z535.4-1998, to alert the user of a potentially Adaptor
Fittings
hazardous situation that may be encountered while
operating this equipment. ANSI's definitions of the signal Pneumatic RLX
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. Switch
Obey all safety messages that follow this symbol to
avoid possible injury or death. Lo-Profile Connector
For use with 10840
only Electric RLX
CAUTION
Caution used without the safety alert symbol
indicates a potentially hazardous situation
which, if not avoided, may result in property Twist-Lock Connector
damage. For use with 05801
only
Figure 1

© 2009 CLEMCO INDUSTRIES CORP. • www.clemcoindustries.com • Manual No. 10574

 RLX PNEUMATIC AND RLX ELECTRIC CONTROL HANDLE Page 2

1.3.2 A remote control system is an OSHA-required 1.3.5 ACS Option

safety device. Pressing the control handle lever down
activates the remote controls. When the operator 1.3.5.1 The ACS is a separate control that is usually used
intentionally or unintentionally removes hand-held to operate an air-actuated abrasive metering valve. The
pressure from the remote control handle, the machine ACS closes the metering valve independently of the
deactivates, stopping air and abrasive flow through the blasting, so air without abrasive exits the nozzle. The
nozzle. The remote control system “fails to safe”, which operator uses this feature for blow-down. If an application
means any interruption in the control-air circuit for requires frequent choking of the blast machine, the line
reasons such as a break in the line, the compressor could control a valve to remotely choke the machine.
stops running, or the operator drops the blast hose, the
remote controls deactivate the blast machine. 1.3.5.2 Pneumatic control: The pneumatic ACS switch
is mounted on the control handle. A separate air line
connects to the ACS switch to operate the valve. Refer to
the remote control systems manual for instructions.
WARNING
Never modify or substitute remote control 1.3.5.3 Electric control: The electric ACS cut off switch
parts. Parts from different manufacturers are is an integral part of the control cord, not the control
not compatible with Clemco equipment. If ANY handle. The system utilizes a standard electric RLX. Refer
part of the remote control system is altered, to the remote control systems manual for instructions.
involuntary activation, which may cause
serious injury, can occur.

2.0 INSTALLATION
1.3.3 Pneumatic control

1.3.3.1 Pneumatic remote controls operate on the return-

WARNING
air or completed-circuit principle. When the control handle Use the RLX Remote Control Handle only with
lever is up, control air from the blast machine travels along Clemco Remote Control Systems. This control
the outbound twinline hose, and escapes through a vent handle was designed to operate only Clemco
opening located under the control handle lever. As long as Remote Controls that include the use of an air
air escapes through the vent, the remote control system flow restricting orifice in the air inlet valve or air
remains inactive. When the control handle lever is inlet piping. Using this control handle on other
pressed, the opening is sealed, and air in the outbound brands of remote controls may cause involuntary
line returns through the inbound line to activate the remote activation of the blast machine or some other
control valves, which start the blasting. When the handle malfunction which could result in serious injury
lever is released, air exhausts from the return line, the
or death.
remote control system deactivates and blasting stops.

1.3.4 Electric control

WARNING
1.3.4.1 Electric remote controls are electro-pneumatic.
When the control handle lever is up, control air from the Moist air that freezes could cause blockage at
blast machine travels to the control box and stops. As long the control handle or in the control lines.
as air does not pass through the box, the remote control Blockage could cause involuntary activation of
system remains inactive. From the box, a 12-volt electrical the remote controls, or prevent the controls
current is sent through the control cord to a switch from deactivating upon release of the control
mounted under the control handle lever. When the control handle. This situation could result in serious
handle lever is pressed, it makes contact with the switch, injury or death. If remote controls are operated
engages solenoids in the control box to permit air to pass in freezing or near freezing weather, install a
through the box to activate the pneumatic remote controls, Clemco Anti-Freeze Injector, stock no. 05537,
which starts the blasting. When the handle lever is on the remote control air supply line. Clemco
released, it immediately disengages the control box, cuts Electric Remote Controls have anti-freeze
off incoming control air, and simultaneously opens the
injectors mounted on the control box.
control box exhaust port so blasting stops.

© 2009 CLEMCO INDUSTRIES CORP. • www.clemcoindustries.com • Manual No. 10574

 RLX PNEUMATIC AND RLX ELECTRIC CONTROL HANDLE Page 3

2.1 Band the control handle to the blast hose close

to the nozzle holder, using the two nylon ties provided.
Once the control is firmly attached, clip the tie ends so
they will not snag the operator's clothing or interfere with
the operation of the control handle.

2.2 Pneumatic Controls

WARNING
Electric remote controls (electro-pneumatic) are Wrap the cord once, loosely
recommended when the nozzle and remote around the hose and band
both sides of each connection.
control handle are farther than 100 feet from the
blast machine. Pressure loss of pneumatic
systems over longer distances increases
actuation time, which prevents fast, safe Band
operation. Contact your Clemco Distributor for
information on converting to electric controls.
Figure 2
2.2.1 Attach the 50-foot twinline hose to the two
adaptor fittings on the control handle. Either side of the
hose can be attached to either fitting. 2.3.2 Working from the control handle back, band the
cord to the blast hose every 4 to 6 feet, and on both sides
2.2.2 Working from the control handle back, band or of each cord connection.
tape the twinline hose to the blast hose every four to six
feet, and as close to the couplings as possible.

2.3 Electric Controls

3.0 OPERATION

WARNING 3.1 Set-Up

The maximum recommended total length of
control cord is 300 feet. Distances greater than 3.1.1 Set up the blast machine and remote controls as
300 feet will offer too much electrical instructed in the corresponding manuals.
resistance, and may cause the controls to
malfunction. If an application requires greater
distance, we suggest that appropriate cord with WARNING
larger gauge wire be provided by the user. Do not operate this equipment before reading
the instruction manuals for all equipment.
2.3.1 Wrap the whip cord from the electric control
handle loosely around the blast hose as shown in Figure 3.2 Daily Check
2, and then connect it to the control cord. The cord must
have ample slack and wrapped as described. Too little 3.2.1 With the air off, before beginning blasting
slack will cause excessive strain on the cord and may
pull the wires out of the connectors or switch when the 3.2.1.1 Make sure that the handle lever will not seal the
hose is curved, or pulled. vent on pneumatic controls, or will not engage the switch
on electric controls, unless the safety lever lock is pulled
down.
CAUTION
Provide enough slack at all cord connections to 3.2.1.2 Make sure that the control handle lever and
prevent the cord from pulling out of the lever lock return to the "up" position when the handle is
connectors when the blast hose is pulled or released.
dragged. Band the cord to the blast hose on both
sides of all connections. 3.2.1.3 Both the handle lever and safety lever lock must
move freely with no drag or binding.

© 2009 CLEMCO INDUSTRIES CORP. • www.clemcoindustries.com • Manual No. 10574

 RLX PNEUMATIC AND RLX ELECTRIC CONTROL HANDLE Page 4

3.2.1.4 Before applying air be certain the handle lever

and lever lock are in the up (no-blast) position WARNING
OSHA requires the use of remote controls on
WARNING all blast machines when an operator controls
Malfunctioning control handles could cause the nozzle. To comply with OSHA regulations,
unintentional actuation of a blast machine, or the control handle, must be held down
prevent a machine from deactivating upon manually. Do not tie down the control handle
release. Malfunctioning control handles must be lever or attempt to bypass any part of the
taken out of service immediately and repaired or remote control system. Doing so will defeat the
replaced. Serious injury or death can result from purpose of the fail-to-safe feature of the remote
unintentional blasting. control. Serious injury or death could result
from uncontrolled blasting. Ref. 29 CFR
1910.244 (b).
3.2.2 With the air on and while blasting, check the
pneumatic control handle for leaks.

3.3 Blasting 3.4 Stop Blasting

3.3.1 Operators must wear appropriate protective 3.4.1 To stop blasting, release the handle lever.
gear, including: abrasive-resistant clothing, leather
gloves, eye and hearing protection, and a NIOSH- 3.4.2 When the control handle lever is released, the
approved Type CE Supplied-Air Respirator. safety lever lock will flip up to lock the handle lever in
the up (open) position.
WARNING 3.4.3 Make sure that the control handle safety lever
Failure to wear approved respirators could lock is up, and that it prevents the handle lever from
result in serious lung disease or death. engaging.
Abrasive blasting produces harmful dust. Do
not blast without the use of a properly fitted 3.4.4 Always open the safety petcock during work
and maintained NIOSH-approved, type CE breaks and before filling the blast machine. Opening the
Supplied-Air Respirator that is approved for petcock prevents unintentional blasting. Refer to the
abrasive blasting. Everyone in the blasting area remote control owner’s manual for the location of the
safety petcock.
must wear an approved respirator.
Abrasive blasting could cause abrasive
particles around the blast machine and blast
nozzle to become airborne. The loud sounds of
WARNING
air released at the blast machine and nozzle When approaching an idle blast machine, and
could cause hearing damage. Anyone in the before loading the blast machine with abrasive,
blasting area must wear an approved respirator, always check to make sure the safety petcock
eye protection and hearing protection. is open. This step is especially important if one
worker (a machine tender) loads the machine
3.3.2 Hold the blast hose securely and point the with abrasive while another worker (the blast
nozzle only at objects intended to be blast cleaned. operator) controls the blasting. The blast
operator could pressurize the machine before
3.3.3 Pull back the safety lever lock and depress the the machine tender has moved away from the
remote control handle. Within a few seconds the remote machine. During pressurization abrasive could
controls will respond and blasting will begin. be forced out of the top of the machine, and
cause injury.
WARNING
Be prepared for the recoil from the blast hose.
Blasting will begin within a few seconds after
pressing the control handle lever.

© 2009 CLEMCO INDUSTRIES CORP. • www.clemcoindustries.com • Manual No. 10574

 RLX PNEUMATIC AND RLX ELECTRIC CONTROL HANDLE Page 5

4.0 MAINTENANCE 4.4.2 Install a new lever lock and spring, and
reassemble in reverse order.
4.1 Inspection
4.4.3 Check to make sure the lever lock moves freely,
4.1.1 The RLX Control Handle is a safety device. raises to full up position, and that the handle lever will not
Inspect it before and after each use to make sure it engage unless the lever lock is pulled down.
functions properly.

• The handle lever must not engage unless the lever 4.5 Handle Lever Replacement, Figure 4
lock is pulled down.
• The handle lever must return to the full up position 4.5.1 Remove the lock nut from the shoulder screw.
when released. Before removing the screw, note the positions of the
• The lever lock must return to the up position when the spacers and spring as shown in Figure 4. The bent end of
handle lever is released. the spring is against the handle lever and facing up. The
• Both the handle lever and lever lock must move freely straight end is against the body and facing down. The
with no drag or binding. spring and spacers must be placed correctly when
reinstalling the handle.
4.2 Cleaning

4.2.1 Periodically clean around the springs, handle

lever, and lever lock to make sure the unit is free of
Spring
abrasive and debris that could cause the handle lever or
lever lock to bind.
Lock Nut
4.3 Spring Replacement

4.3.1 Follow the instructions in Section 4.4 to replace

the lever lock spring, and Section 4.5 to replace the handle
lever spring.
Spacers Shoulder Screw
4.4 Lever Lock Replacement, Figure 3

4.4.1 Remove the lock nut from the shoulder screw. Figure 4
Before removing the screw, note the positions of the
spacers and spring, as shown in Figure 3. The bent end of
the spring is toward the inside and forcing the lever lock 4.5.2 Install a new handle lever and spring, and
up. The straight end is toward the outside facing down and reassemble in reverse order.
against the tab.
4.5.3 Check to make sure that the handle lever moves
freely, that it rises to full up position, and does not engage
unless the lever lock is pulled down.
Lever Lock

4.6 Pneumatic Control Handle

Lock Nut
4.6.1 Rubber button replacement
Spacers
4.6.1.1 Remove the old button.
Spring
4.6.1.2 Install the new button, stem first, by pushing it
from the bottom side of the handle lever. Pull the stem
Shoulder Screw to seat the button.

Tab 4.6.1.3 Trim the button stem flush with the top of the
Figure 3 handle lever.

© 2009 CLEMCO INDUSTRIES CORP. • www.clemcoindustries.com • Manual No. 10574

 RLX PNEUMATIC AND RLX ELECTRIC CONTROL HANDLE Page 6

4.6.2 Gasket replacement 4.7.2.4 Install a new switch and cord assembly using
Terminals No. 1 and 3. Provide slack in the wires between
4.6.2.1 Remove the handle lever per Section 4.5. the cable clamp and connector; if the cord is pulled the
wire will not pull from the connector.
4.6.2.2 Remove the six screws holding the pneumatic
adaptor to the body. 4.7.2.5 Reassemble in reverse order. Make sure that the
springs are in place, the handle lever and lever lock move
4.6.2.3 Install a new gasket. freely, and the handle lever will not engage unless the
lever lock is down.
4.6.2.4 Place the pneumatic adaptor on the gasket and
hand tighten all screws before tightening them with a 4.7.3 Twist-Lock Connector
screwdriver to uniformly compress the gasket.
4.7.3.1 Loosen the screws clamping the cord, and the
front of the connector.
4.6.2.5 Reassemble the handle lever, making sure the
spacers and spring are in place.
4.7.3.2 Pull the shell off the plug, and remove the two
leads from the screw terminals.
4.6.2.6 Check to make sure that the handle lever moves
freely, that it rises to full up position, and will not engage 4.7.3.3 Install a new switch and cord assembly. Either
unless the lever lock is pulled down. lead can go on either terminal.

4.7 Electric Control Handle 4.7.3.4 Reassemble in reverse order. Make sure that the
springs are in place, the handle lever and lever lock move
4.7.1 Switch replacement freely, and the handle lever will not engage unless the
lever lock is down.
4.7.1.1 Remove the handle lever per Section 4.5.

4.7.1.2 Remove screws holding the switch and cord

clamp.
5.0 TROUBLESHOOTING
4.7.1.3 Follow instructions in Section 4.8.2 for replacing Section 5.1 troubleshoots common symptoms for both the
the switch with Lo-Profile connector, or Section 4.8.3 for pneumatic and electric control handles. Section 5.2 covers
Twist-Lock connector. the pneumatic control handle, Section 5.3 is for the electric
control handle. Section 5.4 pertains to the optional ACS
4.7.2 Lo-Profile Connector: Ref. Figure 5 feature. Refer to the appropriate remote control manual for
malfunctions in the remote control system.
4.7.2.1 Remove the compression nut, thrust washer, and
gasket from the connector shell. 5.1 Common Symptoms, Pneumatic & Electric

5.1.1 Handle Lever Fails To Return To The Non-

Insert Assembly Blast Position (Up) When Released.

Shell 5.1.1.1 Inspect the handle lever for damage or abrasive

that may cause binding against the body.
Gasket Set Screws
5.1.1.2 Inspect the spring for damage or fatigue.
Nut Cable Clamp
5.1.1.3 Replace the handle lever or spring as necessary.

Washer 5.1.2 Lever Lock Fails To Pop Up When the Handle

Figure 5 Is Released

5.1.2.1 Inspect the lever lock for damage or build up of

4.7.2.2 Unscrew the shell from the coupling insert debris or abrasive that could cause binding.
assembly.
5.1.2.2 Inspect the spring for damage or fatigue.
4.7.2.3 Loosen the cable clamp and set screws holding
the cord, and remove the cord from the assembly. 5.1.2.3 Replace lever lock or spring as necessary.

© 2009 CLEMCO INDUSTRIES CORP. • www.clemcoindustries.com • Manual No. 10574

 RLX PNEUMATIC AND RLX ELECTRIC CONTROL HANDLE Page 7

5.2 Pneumatic Control Handle 5.3.2.3 Refer to the appropriate remote control manual for
malfunctions in the remote control system.
5.2.1 Remote Controls Do Not Activate When The
Handle Lever Is Pressed. 5.4 Optional ACS Feature

5.2.1.1 Inspect the rubber button for wear or damage, 5.4.1 No Abrasive Flow When the ACS Toggle Is
and make sure it seals the vent opening in the pneumatic Turned On.
adaptor when the handle is pressed.
5.4.1.1 Pneumatic
5.2.1.2 Press the handle lever and feel and listen for air
leaks anyplace on the handle. When the handle lever is • Make sure the metering valve is not closed.
pressed, no air should escape. If there is a leak, it must be • Check for leak or blockage in the single line hose or
located and repaired. If no air escapes when the handle fittings from the control handle to the metering valve.
lever is down, the problem is not in the control handle; • Obstruction in abrasive metering valve, or valve
refer to the appropriate remote control manual for requires service. Refer to the metering valve manual
malfunctions in the remote control system. for operation of the valve.
• Make sure the machine contains abrasive.
5.2.2 Remote Controls Do Not Deactivate When The
Handle Lever Is Released. 5.4.1.2 Electric

5.2.2.1 Inspect the pneumatic adaptor gasket for swelling, • Make sure the metering valve is not closed.
which restricts air flow through the handle vent opening. • Check for leaks or blockage in the hose or fittings from
the control panel to the metering valve.
5.2.2.2 Inspect the vent opening on the pneumatic • Inspect the solenoid operating the metering valve per
adaptor; make sure it is clear of flashing or obstruction that instructions in the electric remote control system
inhibits air from escaping from the opening. manual.
• Inspect the ACS switch per instructions in the electric
5.2.2.3 Refer to the appropriate remote control manual for remote control system manual.
malfunctions in the remote control system. • Obstruction in abrasive metering valve, or the valve
requires service. Refer to the metering valve manual
5.3 Electric Control Handle for operation of the valve.
• Make sure the machine contains abrasive.
5.3.1 Remote controls do not activate when the
handle lever is pressed. 5.4.2 Abrasive Flow Does Not Stop When ACS
Switch Is Off.
5.3.1.1 Faulty switch: The easiest method to check the
switch is to substitute the control handle with one that is 5.4.2.1 Pneumatic
functioning properly. If this isn't possible; turn off the
compressed air supply. Disconnect the control handle at • Brass filter on ACS switch clogged.
the control cord. With the handle lever down, check • Metering valve requires service. Refer to the metering
continuity across pins No. 1 and 3 in the Lo-Profile valve manual for operation of the valve.
connector, or the two prongs if Twist-Lock connectors are
used. Another method is to listen to the control box and 5.4.2.2 Electric
short across socket No. 1 and 3 on the extension cord. If
the box clicks, the fault is in the switch. Remove the old • Check the exhaust port on the bottom of the panel, air
switch and install a replacement. should momentarily exhaust from the port when the
ACS switch is turned off. If it does not, check the
5.3.2 Remote Controls Do Not Deactivate When The following:
Handle Lever Is Released. • Obstruction in the line between the metering valve
and the ″GRIT VALVE″ connection on the panel.
5.3.2.1 Make sure the handle lever disengages the switch • Faulty ACS switch.
when it is released.
• Faulty solenoid.
• Metering valve requires service. Refer to the metering
5.3.2.2 Make sure the return spring raises the handle
valve manual for operation of the valve.
lever fully up.

© 2009 CLEMCO INDUSTRIES CORP. • www.clemcoindustries.com • Manual No. 10574

 RLX PNEUMATIC AND RLX ELECTRIC CONTROL HANDLE Page 8

6.0 REPLACEMENT PARTS

22859 SERVICE KIT
6.1 RLX Pneumatic, Figure 6 RLX PNEUMATIC CONTROL HANDLE

Item Description Stock No. Item Qty Description

(-) RLX Pneumatic Control Handle Assembly ... 10565 1. 1 Lever lock
* Service kit, Pneumatic RLX (Fig. 6a) ........... 22859 2. 2 Spring
1. Handle lever ................................................... 10573 3. 2 Nut, 8-32 lock, ss
2. Body ................................................................ 10568 4. 4 Spacer washer, stainless steel
3. Pneumatic adaptor ......................................... 10562 5. 2 Screw, 3/16" x 1-1/4" shoulder
4. Adaptor, 1/8" NPT (2 required) ...................... 01940 6. 2 Screw, 8-32 x 1"
5. Tie, nylon wire ............................................... 02195 7. 2 Screw, 4-40 x 3/8"
8. 3 Rubber button
9. 1 Gasket, pneumatic adaptor
10. 2 Screw, 8-32 x 3/8"

1
*
* *

2
* 3
* 8
*
* *
5
3 * 4
7 10
*
4 * 6 2
**
3 1
*
5
4
5 9
2

Figure 6

Figure 6a

© 2009 CLEMCO INDUSTRIES CORP. • www.clemcoindustries.com • Manual No. 10574

 RLX PNEUMATIC AND RLX ELECTRIC CONTROL HANDLE Page 9

6.2 RLX Pneumatic Handle with ACS, Figure 7 6.3 RLX Electric, Figure 8
Note: See Section 6.1 for RLX replacement parts
Item Description Stock No.
Item Description Stock No.
(-) RLX Electric Control Handle
(-) RLX Control Handle Assembly w/ ACS ........07625 w/ Lo-Profile connector ............................... 10840
1. RLX Control Handle (Standard).....................10565 (-) RLX Electric Control Handle
2. Switch assembly, ACS pneumatic ................07654 w/ Twist-Lock connector ............................. 05801
3. Elbow, 1/8" NPT male ...................................03085 1. Handle lever.................................................... 10573
4. Tee, 1/8" NPT brass .......................................02171 2. Body ................................................................ 10568
5. Adaptor, 1/8" NPT ..........................................01940 3. Lever lock ....................................................... 10564
6. Guard, ACS pneumatic switch ......................07655 4. Clamp, switch cord ........................................ 05810
7. Breather muffler, 1/8" NPT .............................07657 5. Spring, lever (2 required) ............................... 05823
8. Switch only, ACS ...........................................07658 6. Switch with cord.............................................. 24842
9. Connector, 1/8" NPT brass ...........................01962 7. Screw, 8-32 X 3/8" rd. hd. (4 required) ........... 05814
8. Nut, 8-32 lock, ss (2 required) ...................... 05815
9. Spacer washer, stainless steel (4 required ... 05434
10. Screw, 3/16" X 1-1/4" shoulder (2 required) ..... 05817
11. Ties, nylon wire............................................... 02195
12. Connector, Lo-Profile male
(for 10840 only) ........................................... 10828
13. Connector, Twist-Lock male
(for 05801 only) ........................................... 02899
4 1

5 1
9
8
8
10 5
3
5 5
7 3
9
10
8
7 9
6
4

6
11

2
2

Figure 7

12

13

Figure 8

© 2009 CLEMCO INDUSTRIES CORP. • www.clemcoindustries.com • Manual No. 10574