OPERATING MANUAL
Gilson Test-Master® Testing Screens
TM-5 & TM-6
Rev: 04/12/2013
PHONE: 800-444-1508 P.O. Box 200, Lewis Center, Ohio 43035-0200 FAX: 800 -255-5314
740-548-7298 E-mail: customerservice@gilsonco.com Website: www.globalgilson.com 740-548-5314
Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
SAFETY INSTRUCTIONS
Whether you are the owner, employer, operator, or maintenance person for this machine, safety is your responsibility. You are responsible for operating and maintaining this equipment in compliance with these instructions and for
using common sense. Review and completely understand the operating and safety instructions before using this
machine.
WARNING!
This machine operates on electric current. Improper operation could result in electric shock, electrocution,
or an explosion!
1. ALWAYS make sure the motor and other electrical components are appropriate and properly configured for
your intended use and available power source. The standard Test-Master® comes with a 1/3hp motor wired for
115V/60Hz. Motors are NOT explosion-proof.
2. ALWAYS check electrical wiring for loose connections and for pinched or frayed wiring.
3. ALWAYS use a properly-wired, three-pronged plug, or otherwise ground the machine. Connect the machine to
a properly-wired, three-pronged receptacle. Make sure the cord is located where no one will trip or get tangled
in it.
4. ALWAYS disconnect and lock out power supply before performing maintenance and repairs.
WARNING!
WARNING: DO NOT operate the machine without having all doors, covers and guards in place.
WARNING: DO NOT bypass or tamper with the safety interlock switch.
WARNING: USE CAUTION when loading and unloading trays or aggregate from the machine. Pinch points
between the trays are necessary for proper operation.
WARNING: ALWAYS level the machine prior to operation.
WARNING: ALWAYS unplug or disconnect machine from the power source when the unit is not in operation.
WARNING: Keep all parts of your body, clothing, tools and other objects away from the separator, drive belts,
drive pulleys, connecting rods, counterweights and all other moving parts of the machine while it is
operating.
WARNING: ALWAYS wear safety glasses when operating, maintaining, or repairing this machine.
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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
TABLE OF CONTENTS
Page
Safety Instructions 2
Table of Contents 3
1.0 Unpacking 4
2.0 Set-Up 4
2.1 Site Selection 4
2.2 Leveling 4
2.3 Initial Test 5
2.4 Shutdown 5
3.0 Operating Instructions 5
3.1 General Instructions 5
3.2 Timer Set-Up & Operation 6
3.3 Test Times 6
3.4 Sample Sizes 6
3.5 Pan Options 7
4.0 Maintenance 7
4.1 Preparation for Maintenance 7
4.2 Disassembly 8
4.2.1 Outer Case Removal 8
4.2.2 Blocking/Unblocking the Separator 8
4.3 Lubrication of Bearings 8
4.4 Belts 8
4.4.1 Drive Belt & Pulley 9
4.4.2 Timing Belt & Tensioning Pulley 9
4.5 Guide Pin Assembly 9
4.6 Drive Assembly 10
4.7 Hydraulic System 10
4.8 Wire Cloth & Screen Trays 13
5.0 Parts Lists & Diagrams 14
5.1 Replacement Parts List 14
5.2 Parts List for Diagram 1 15
5.3 Diagram 1 16
5.4 Parts List for Diagram 2 17
5.5 Diagram 2 18
5.6 Parts List for Diagram 3 19
5.7 Diagram 3 20
6.0 Maintenance Flow Chart 21
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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
1.0 UNPACKING:
Your Gilson Test-Master®, crated for shipping, weighs between 600—700lbs, depending on which model you have
and how many trays are packed inside. Use appropriate
equipment to unload and move it.
Wear safety glasses. Cut the banding and lift the carton off.
Save the carton until you have inspected the Test-Master®
and placed it into service.
Check the machine over, looking for loose screws, indications of a hydraulic leak or any other damage.
If you find concealed shipping damage after you have
signed for the Test-Master®, call the delivering freight
carrier immediately for an inspection. Save all the packing
materials and leave the Test-Master® just as it is.
When you're sure your Test-Master® is in acceptable condition, remove the trays and dustpan from the machine.
To do this, open the doors. Step on the pump pedal and
depress it completely, releasing the clamping pressure.
Push down on the lower separator frame to be sure that
the separator is fully extended. Slide the trays and dustpan out of the Test-Master® and set them aside. Close
the doors.
Use proper equipment to lift the Test-Master® off its skid.
Save the skid. Keeping the machine as close to the floor
as possible, move it to the site where you intend to operate it. Make sure not to drop the machine.
2. 2 Leveling
At the operating site, set the Test-Master® on the floor.
The machine will rest on three leveling feet, one at each
front corner and one at the center back.
NOTE: DO NOT connect electric power until you
have leveled the Test-Master®.
Use the following procedure:
1. Open the doors.
2. If there are trays and a pan in the Test-Master®, remove
all but the tray in the second position from the top
of the separator. Leave this tray extended about 4in
from the front of the machine. Otherwise, insert a tray
in the second position from the top of the separator,
leaving this tray extended about 4in from the front of
the machine.
3. Pump the foot pedal with short strokes until the tray
is clamped in position.
4. Place a carpenter's level across the extended tray,
resting it on the tray's flanges. DO NOT place the
level on the machine's case.
5. Adjust the three leveling feet until the Test-Master® is
level both side-to-side and front-to-back. Whenever
possible, adjust by lowering the highest foot so that the
Test-Master® stays as close to the floor as possible.
2.0 SETUP:
2.1 Site Selection
1. Choose a site where there is a solid, rigid, level floor
with adequate space available for installation, operation and maintenance.
2. Make sure your electrical hookup is compatible with
the Test-Master® shipped to you and that a grounded,
three-pronged receptacle is within reach of the machine
or that other properly-grounded electrical power is
available for connection by an authorized person.
3. Choose a site with adequate ventilation.
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6. When you have leveled the Test-Master® in both
directions, tighten the locking nuts on all three feet.
7. Release the clamping pressure by pushing the foot
pedal all the way to the floor. Push down on the bottom of the separator unit to be sure that the separator
is fully extended.
8. Replace the trays and pan which you removed and
close the doors.
NOTE: Whenever you move the Test-Master®, be
sure to re-level it before you use it. Follow the
leveling instructions provided.
Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
2.3 Initial Testing
NOTE: Be sure to read and understand all safety
instructions and initial test instructions before proceeding and follow all these instructions during the
testing process.
Read and understand the instructions for operating
the Test-Master's timer. Be sure you know how to stop
the Test-Master
®
before you activate the timer.
Make sure that your Test-Master® is electrically configured to be compatible with your power supply and
that all wiring is grounded and properly installed.
After leveling the Test-Master® for the first time, run this
initial test. With trays and pan in the machine and the
doors open:
1. Pump the foot pedal with short strokes until the separator is clamped. Close the doors.
2. Plug in the Test-Master®.
3. Following the timer instructions, set the timer for 10
seconds.
(5) If the timing belt is loose or has slipped off
its pulleys, turn to Maintenance Instructions and complete Disassembly Instructions 4—6. Then find the Timing Belt
information in Section 4.0, Maintenance
and follow the instructions for adjusting
or re-seating the belt.
d. Look for concealed shipping damage, such as
bent, dented or loose parts.
2.4 Shutdown
Open the doors. Release the clamping pressure by pushing
the foot pedal all the way to the floor and pushing down
on the lower separator frame until the separator is fully
extended. ALWAYS leave the trays unclamped and the
doors closed when the Test-Master® is not in use.
Unplug or disconnect electric power from the Test-Master®.
DO NOT reconnect power until you are ready to use the
Test-Master®.
NOTE: Whenever you move the Test-Master®, be
sure to re-level it before you use it. Follow the
leveling instructions provided.
4. Activate the timer to start the Test-Master®.
5. The Test-Master® should run for 10 seconds and stop.
6. If not, check to be sure you have properly connected
compatible power to your Test-Master®.
7. Repeat steps 3 and 4. Should the Test-Master® fail
to run, an electrical connection has probably come
loose in shipping. Call Gilson Company, Inc. Technical Support line at 800.444.1508 (8AM - 5PM EST)
Monday - Friday.
8. If there is excessive noise or vibration during the
test run:
a. Re-check to be sure the Test-Master® is level.
b. Re-check to make sure you have clamped up
your separator and trays.
c. Check to see that the timing belt is properly-
seated and tight.
(1) Turn to Section 4.0, Maintenance.
(2) Read and understand the SAFETY
INSTRUCTIONS and Disassembly
Instructions.
(3) Complete disassembly steps 1—3.
(4) Inspect the timing belt. If the belt is
in place, check to see that it fits tightly.
3.0 OPERATING INSTRUCTIONS:
Always review and completely understand all safety, operating, and maintenance instructions before you place
your Test-Master® into service.
3.1 General Instructions
To clamp trays in place:
1. First be sure they are inserted fully.
2. Pump the foot pedal, using short strokes until trays
are clamped and held in place.
3. Close the doors.
To release trays:
1. Open the doors.
2. Depress the pedal to the floor and hold it in place for
a moment.
3. Push down on the lower separator frame until the
separator is fully extended.
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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
3.2 Timer Set-Up & Operation
This unit is equipped with an easy-to-operate Gilson interval
count-down timer. The timer has a large 0.6in LED display
and will operate in four different modes. It is powered by line
voltage and will work on power supplies from 100—265 VAC,
50/60Hz, with up to 20 amps Inductive or Resistive current.
NOTE: The main device controlled by the timer may
be restricted to operating on a more limited electrical
supply range. Check the device carefully to insure
compatibility with your electrical supply.
Current timer mode is indicated by the four red LED’s on
the timer face:
• A=MMSS (99min:59secx1second)
• B=HHMM (99hr:59minx1minute)
• C=SSSS (9999secx1second)
• D=MMMM (9999minx1minute)
(H is for hours, M for minutes, and S for seconds.) To adjust
the timer mode, press and hold both <UP> and <DOWN> keys
at the same time until the display shows the mode. Once the
mode letters are displayed, press <UP> or <DOWN> to change
modes. Press <START/STOP> to accept new mode.
To set the run time, press either <UP> or <DOWN>. The
first digit on the right hand side will flash in half-second
intervals. Press either arrow key to adjust to the desired
value. To enter the displayed digit and move to the next,
press <START/STOP>. Once the last digit on the left is
entered, the timer is ready to start.
8. Using both handles on the hopper, lift it to feed the
sample into the machine. When the sample is loaded,
lower the hopper back into the Test-Master®.
9. When the Test-Master® stops, open the doors.
10. Release the trays.
11. Remove the trays and continue the procedure
specified for your test. MANUAL ON TEST SIEVING
METHODS (BK-447), an ASTM publication available
from Gilson, provides detailed information on testsizing procedures.
12. Follow Shutdown procedure in Section 2.4.
3.3 Test Times
Times of 5—10 minutes are normal, depending upon material types and sizes. Materials in the fine series range
(No. 4 to No. 200) may require more than 15 minutes.
The proper test time results in complete separation and
sizing of the sample.
You can establish standard test times for different types
of samples by looking for complete sample separation.
After a test is finished, run each tray separately with a
clean pan to see if a significant amount of sample is still
passing. If so, lengthen your test time.
3.4 Sample Sizes
The sample capacity of the Test-Master® varies according
to the type and size range of the material being tested.
Sample size is often established in the test specifications.
For example, ASTM C 136, specification for "Sieve or
Screen Analysis of Fine and Coarse Aggregates," calls
for minimum weights of test sample of coarse aggregate
(density such as gravel or limestone) as follows:
Press <START/STOP> to initiate the current run program.
Once running, pressing <START/STOP> again will pause
the timer with the current amount of time remaining on screen.
When allowed to time-out, the timer beeps and displays
DONE. Press any key to continue. Setting and Mode values
are saved automatically and restored on power-up.
To operate the Test-Master®:
1. Make sure your Test-Master® is level, following the
procedure provided.
2. Fully insert the trays you need.
3. Clamp the trays in place.
4. Close the doors.
5. Pour your sample into the hopper, making sure not to
overload the Test-Master®. The hopper is designed
to hold about one cubic foot of sample, but this still
could exceed the sample size allowed. Refer to the
following section on Sample Sizes.
6. Plug in the Test-Master®.
7. Set the timer and activate it to start the Test-Master®.
Refer to the timer instructions.
Page 6
ASTM C 136 SAMPLE SIZES
Nominal Max. Size of Min. Sample
Particle, in (mm)
W
eight, kg
3/8 (9.5) 1
1/2 (12.5) 2
3/4 (19) 5
1 (25) 10
1-1/2 (37.5) 15
2 (50) 20
2-1/2 (63) 35
3 (75) 60
3-1/2 (90) 100
Normally, these minimum sample sizes (and larger in
many cases) can be handled in the Test-Master® in a
single batch without difficulty.
Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
Capacity of the Test-Master® for a given sample is based
on the amount of material in the tray which has the largest
4.0 MAINTENANCE:
load at the end of the test. This is the limiting tray.
Whether you are the owner, employer, operator, or main-
Coarse Materials:
The limiting tray should have no more than one layer of
particles over the wire cloth area. Overloading will prevent
complete and proper aggregate separation in your test.
tenance person for this machine, safety is your responsibility. You are responsible for operating and maintaining this equipment in compliance with these instructions
and for using common sense. Review and completely
understand the operating and safety instructions before
Capacity is a function of volume, so light materials
using this machine.
(lightweight aggregate, coal, wood chips, etc.) must be
tested in smaller amounts by weight. High-density ores
or pellets may be tested in somewhat larger amounts
by weight. Many light materials are also soft and require
short test times to avoid degradation of the sample.
Before performing any maintenance, always review this
manual and be sure you understand the safety, operat-
ing and maintenance instructions. If you have any ques-
tions, please call the Gilson Company, Inc. Technical
Support line at 800.444.1508 (8am - 5pm EST) Monday
If you are running a test which does not require all six trays
thru Friday.
(seven in Model TM-6), you can use an intermediate tray
to relieve loading on a critical tray, which would allow a
larger overall test sample to be run at one time.
WARNING!
Fine Materials:
ASTM C 136 specifies that at the end of the test, the
limiting tray should contain no more than four grams/
2
in
of sieving surface. For materials similar in density to
sand, this converts to about 1,350g (3lb) on the limiting
tray, or a total sample weight of less than 20lb, unless
the sizes are evenly distributed among the trays. If the
Test-Master® is being used for mass separation rather
than for testing, larger amounts of material may be introduced, though sharpness of separation will decrease as
the load increases.
3.5 Pan Options
The standard dustpan tray (TS-112) is used in the bottom
slot, where it shakes with the screen trays. This arrangement is adequate for most situations.
The stationary pan with adapter (TSA-116) is recommended if the movement of the standard tray makes it
difficult to handle fine materials. The adapter fits the bottom
vibrating slot and provides a dust seal to the stationary
dustpan below.
For separation of fine aggregates, we recommend the
use of equipment specifically designed for such testing.
Shakers for 8in and 12in round sieves are described in
the Gilson catalog. These specially-designed machines
will give you an excellent separation of fine aggregates
on a routine basis.
The Test-Master's electric motor has internal thermal
protection. The motor will automatically shut off if
it is overloaded. If this happens, disconnect the
power. Otherwise, the motor could restart by itself
after it cools down.
®
ALWAY S disconnect the Test-Master
and lock out the
power supply before performing maintenance or repairs.
ALWAY S check electrical wiring for loose connections
and for pinched or frayed wires.
ALWAY S wear safety glasses or goggles wen you are
working with the Test-Master®.
4.1 Preparation for Maintenance
Unplug or disconnect Test-Master® and lock out power.
Read and understand all the safety instructions and the
maintenance instructions for the parts you plan to repair.
Use the flowchart in the back of this manual as a guide
to move through the various disassembly and repair
procedures.
NOTE: When ordering parts for your Test-Master®,
you will need to specify the serial number.
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