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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
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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.
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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.
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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.
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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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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
4.2 Disassembly
4.2.1 Outer Case Removal
To access internal parts for maintenance, you must
remove all or part of the outer case. Refer to the flowchart and these instructions to determine how much
disassembly is required for your repair work.
1. ALWAYS unplug the Test-Master® and lock out the
power supply before beginning disassembly.
2. Open the doors, remove the trays, and set them
aside.
3. Remove the Drive Case Cover:
From the front of the machine, reach under the cover
at its center and locate the head of the mounting
screw. Remove the screw, slide the case cover
toward you, and lift it off. Now you have access for
the following procedures:
a. Adjust the setting of the pump pedal.
b. Lubricate bearings.
c. Tighten the setscrew on the drive pulley.
d. Check, adjust, or replace the drive belt.
e. Check tension of the timing belt.
Follow the instructions found later in this manual.
For other procedures, continue disassembly.
4.2.2 Blocking/Unblocking the Separator
For some maintenance procedures, you need to block
the separator to hold it in the clamped position WITHOUT
the use of hydraulics.
1. Find the t wo notched separator holding plates which
are mounted by wing nuts on the guide frame below
the separator, one on each side of the Test-Master
®
They will be in the down position.
2. Pump up the hydraulic system to clamp the separator.
If the hydraulic system is not working, compress the
separator manually. Supporting the separator from
the bottom, lift the separator into its compressed
position so that you can follow step 3.
3. Loosen the wing nuts, rotate the plates upward and
re-tighten.
4. Release the hydraulic pressure (or lower the separator if you compressed it manually) and the bottom
of the separator assembly will come to rest in the
notches of the holding plates.
With the separator BLOCKED, you have access for
the following procedures:
a. Repair or replace guide pin assemblies.
b. Access hydraulic pump.
.
4. Remove the four screws at the corners of the top
cover, and lift off the cover and hopper.
5. To remove right side cover, first disconne ct the timer.
The timer-to-motor connection is fastened to the
front of the drive case. Remove the tape. NOTE
that the green sections plug into each other, so
that later you will know how to reconnect the timer.
Unplug the timer. Support the weight of the right
panel with a two-by-four or other block. Remove
nine mounting screws from the right side cover, and
pull the panel off the machine. Reinstall one of the
screws in the second hole from the top of the back
cover, to hold this panel in place.
6. Remove the left side cover in the same way. The
machine is now accessible for the following procedures:
a. Adjust, re-seat or replace the timing belt.
b. Inspect, repair, or replace the tensioning pulley.
c. Inspect the guide pin assemblies.
When you have finished your maintenance procedure, UNBLOCK the Separator to restore it to
operating condition as follows:
a. Pump up the hydraulic system to re-clamp the
separator.
b. Return the holding plates to the down position.
c. Release the pressure.
4.3 Lubrication of Bearings
1. Using a grease gun with a flexible nozzle, lubricate
the four shaft bearings, two on each side of the drive
case, after about every 360 hours of operation. Apply
a lithium-based or lithium-compatible grease.
2. Lubricate the motor end bearings with a few drops of
oil as needed, about once a year under normal use.
4.4 Belts
Both the drive belt and the timing belt will wear with use
and should be inspected periodically for tension, alignment and condition.
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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
Review and completely understand all safety and maintenance instructions before attempting to inspect or adjust
belts. ALWAYS disconnect and lock out electric power.
4.4.1 Drive Belt & Pulley
The drive belt sometimes stretches when it is first used,
so check its tension after the first day of operation.
1. Follow Disassembly Instructions 1—3 to access
the drive belt for inspection and adjustment.
2. The play in the belt should equal 1/64 of the distance between the centers of the pulleys.
3. If the drive belt is too loose, it will slip and the TestMaster® will run too slowly or else in spurts.
4. If the drive belt is too tight, it will wear out quickly.
To Adjust Drive Belt Tension:
a. Loosen the four motor mounting nuts.
b. Slide the motor forward or back as needed.
c. Re-tighten the four nuts.
d. To prevent excessive wear on the drive belt, be
sure that the motor and drive pulleys are lined up
with each other.
c. To reseat or replace the timing belt, remove the bolts
at the top of the tensioning bracket. This allows the
bracket to pivot toward the front of the machine,
loosening the tension on the timing belt.
d. Remove the screw that secures the tensioning pul-
ley to the bracket.
e. Remove the pulley.
f. Remove the belt. Inspect it for damage and obtain
a replacement if necessary.
Tensioning Pulley Inspection:
Take this chance to check the condition of the tensioning
pulley and its bearings. Spin the pulley on its bearings.
If it does not turn smoothly, replace the bearings.
a. Drive out both bearings from one side of the pulley.
b. Press new bearings into place.
Counterweight Alignment:
a. Rotate the drive shaft by hand, looking for a mark
that indicates the thick part of the eccentric. Turn
the shaft until this mark is at the top of the shaft.
The connecting rod is now at its highest position
and the counterweights are flat-side-up.
b. Rotate the counterweight shaft until its counter-
weights are flat-side up and parallel to the coun-
terweights on the drive shaft.
To Replace the Drive Belt:
a. Loosen the motor mounting nuts as for adjustment.
b. Slide the motor toward the center of the machine
to relieve tension on the belt.
c. Slip the belt off the pulleys.
d. Slip the new belt around the pulleys. Adjust the
tension as described above before you re-tighten
the mounting nuts.
Drive Pulley:
If the drive pulley is loose on the drive shaft, use an
allen wrench to tighten its setscrew.
4.4.2 Timing Belt & Tensioning Pulley
The timing belt should fit tightly.
1. A worn or loose timing belt may slip teeth on the
pulleys and cause the machine to be out of balance,
vibrate excessively and walk.
2. If the timing belt has slipped out of position, inspect
it and replace or reseat as required.
Timing Belt Adjustment or Replacement:
a. Follow disassembly procedures 1—6.
b. Tighten the belt by adjusting the bolts at the top of
the tensioning bracket.
Timing Belt Installation:
Reinstall the timing belt along with the tensioning pulley:
a. Fit the belt around the front timing pulley and over
the top of the middle timing pulley, taking care not
to change the rotation of the shafts and counter-
weights.
b. Insert the tensioning pulley into the loop of the belt.
c. Holding the belt and pulley together, bolt the pulley
to the tensioning bracket.
d. Reinstall the upper bolts and adjust them to create
the proper tension on the timing belt.
e. Check to be sure that all the counterweights are
flat-side-up and parallel to each other and to the
top of the drive case.
4.5 Guide Pin Assembly
The separator assembly of the Test-Master® vibrates independently from the frame. Alignment of these components
is maintained by four guide pin assemblies; two on each
side, one upper and one lower. Each assembly consists of
a guide pin, a guide block, a fiber guide bushing, a guide
seal, and nuts, bolts, and washers. Shims are used for
alignment when a Test-Master® is being assembled. For
the system to work properly, all four guide pins must be
parallel, and the upper and lower guide pins on each side
must be in line.
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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
We recommend periodic inspection of the guide pin assemblies immediately after the Test-Ma ster® has been running.
If the guide pins feel hot or are loose, the bushings have
worn. At this point you have the option of replacing only the
bushings and seals. If the bushings wear out completely, the
guide pins will get out of line and cause the Test-Master®
to make a loud, hammering noise. You will need to replace
the guide pin assemblies in this instance.
Inspection of the bushings and pins requires some disassembly as described below.
Access:
1. READ AND UNDERSTAND SAFETY AND DISASSEMBLY INSTRUCTIONS AT THE BEGINNING OF
THE MAINTENANCE SECTION AND THE GUIDE
PIN REPLACEMENT INSTRUCTIONS.
2. UNPLUG the Test-Master® and LOCK OUT the
POWER.
3. LEVEL THE MACHINE, following the instructions in
the installation section. You will not be able to complete the guide pin replacement unless the machine
frame is level to begin with.
4. Follow Disassembly Instructions 2—6.
5. BLOCK THE SEPARATOR, following disassembly
instructions 7—10.
6. CHECK ALL FOUR GUIDE PINS: Try to move each
one by hand. If a pin feels hot or if it is loose or wobbly,
the bushing inside the guide block has worn out.
Procedure:
WORK ON GUIDE PIN ASSEMBLIES ONE AT A TIME. BEFORE WORKING ON A LOWER GUIDE PIN ASSEMBLY,
lift the corresponding hydraulic cylinder assembly about
3/8in and move it toward the center of the machine.
1. Loosen guide pin setscrew, and remove the guide
pin. Observe the position of the shims that determine
the vertical alignment of the guide block.
2. Remove guide bolts, guide block and shims, KEEPING THE SHIMS for reassembly.
3. If you are repairing the guide pin assembly, press out
old seal and bushing and press in new ones.
4. Reinstall guide block, including the shims, leaving the
guide bolts loose.
a. If you are installing old guide blocks with new
bushings, position the shims as they were.
b. If you are installing new assemblies, place the
shims so that the block is square with the separator guide frame so that the upper and lower guide
pins line up with each other.
5. Place a carpenter's level across the top and sides
of the separator guide frame and position the guide
block so that its top is level.
6. Use the play in guide bolt holes and shims to make
fine adjustments to position the guide block. Then
tighten the bolts completely.
7. Reinstall the guide pin. COMPLETE THIS INSTALLATION BEFORE PROCEEDING TO REPAIR ANOTHER GUIDE PIN ASSEMBLY.
8. When you have finished with all the guide pin assemblies
you plan to work on, run a final alignment check:
a. Unblock the separator using the procedure in
DISASSEMBLY INSTRUCTION 10.
b. Place several trays in position as though you were
preparing to run a test.
c. Clamp the separator and close the doors.
d. Run the Test-Master® for ten minutes.
WARNING! THE TEST-MASTER® IS NOT DE-
SIGNED TO BE OPERATED WITHOUT GUARDS
AND COVERS IN PLACE. STAND BACK. KEEP
YOURSELF, YOUR CLOTHING AND ALL OTHER
OBJECTS AWAY FROM THE MACHINE.
e. After the Test-Master® stops, touch the tops of the
guide pins. They may be warm, which is normal.
If one or more guide pins are hot to the touch, the
guide pins are out of alignment. Return to steps
4 and 5 and make adjustments as necessary.
REASSEMBLE THE TEST-MASTER® IN REVERSE
ORDER. Make sure all bolts are secure.
BE SURE THE TEST-MASTER® IS LEVEL before placing
it into service. DO NOT connect electric power until you
are ready to operate the Test-Master®.
4.6 Drive Assembly
The drive belt and timing belt and their pulleys have been
described earlier.
Maintenance to other parts of the drive assembly require
removal of the drive case. Please call Gilson to request
instructions for these procedures.
4.7 Hydraulic System
The Test-Master's clamping system consists of a hydraulic
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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
pump and two hydraulic cylinder assemblies. The cylinders apply force to the separator, compressing it into the
clamped position. The system is pressurized by applying
short strokes to the foot pedal. Pressure is released by
depressing the foot pedal all the way to the floor and pushing down on the lower frame of the separator. ALWAYS
leave the separator in the released position when the
Test-Master® is not in use.
WHETHER YOU ARE THE OWNER, EMPLOYER,
OPERATOR, OR MAINTENANCE PERSON, YOU ARE
RESPONSIBLE FOR CONDUCTING MAINTENANCE
PROCEDURES ON THE TEST-MASTER® IN COMPLIANCE WITH THE SAFETY PRECAUTIONS AND OTHER
INSTRUCTIONS IN THE MANUAL. BEFORE YOU BEGIN
TO WORK ON THE HYDRAULIC SYSTEM, ALWAYS
RE-READ THE MANUAL AND BE SURE YOU UNDERSTAND BOTH THE SAFETY AND MAINTENANCE INSTRUCTIONS. IF YOU HAVE ANY QUESTIONS, PLEASE
CALL CALL GILSON COMPANY, INC. TECHNICAL
SUPPORT LINE AT 800.444.1508 (8AM - 5PM EST)
MONDAY - FRIDAY.
ALWAYS DISCONNECT THE TEST-MASTER® AND
LOCK OUT THE POWER SUPPLY BEFORE PERFORMING MAINTENANCE OR REPAIRS.
2. Follow Disassembly Procedures 1—4.
3. Follow Disassembly Procedures 7—10.
Now you have access to the hydraulic pump.
Hydraulic Oil:
The Test-Master® uses a medium-viscosity, non-foaming
hydraulic oil.
To check the level and quality of the hydraulic oil, follow
the above access procedures to disassemble the TestMaster® and to block the separator in the closed position.
Then proceed:
1. Release pressure and remove the pump cover. The
oil level should be 1/4in from the top of the reservoir
and the oil should appear clear.
a. Some discoloration of the oil is acceptable; visible
dirt is not acceptable.
b. Fine aluminum flakes which disintegrate between
your fingers are acceptable; aluminum chips are
not acceptable.
c. If oil is not in acceptable condition, proceed to
next section, "To Change Hydraulic Oil."
Pump Pedal Adjustment:
If depressing the foot pedal and pushing down on the lower
frame of the separator does not completely release hydraulic pressure, adjust the setting of the pump pedal.
1. Follow Disassembly Procedures 1—3.
2. Find the two hex-head cap screws toward the rear of
the pedal.
3. Loosen the front screw a quarter turn, and tighten the
rear screw a quarter turn.
4. Repeat this adjustment until a complete depression of
the foot pedal causes a complete release of pressure
in the system.
5. Reinstall front panels, but DO NOT reconnect electri-
cal power until you are ready to run a test.
Access to Hydraulic Pump:
To check or replace hydraulic oil, return to the disassembly procedure found at the beginning of Section 4.0,
Maintenance.
2.
If the oil is clean but the level is low, fill to the correct level.
3. Replace the cover and tighten down the screws.
4. Pump up and release the pressure several times to
remove air from the system.
5.
Reopen the pump and again add oil to 1/4in from the top.
6. Reinstall cover and tighten the screws.
7. Unblock the separator:
a. Pump up the system to re-clamp the separator
and take the pressure off the holding plates.
b. Return the plates to the down position.
c. Release the pressure by depressing the foot
pedal and pushing down on the lower frame of
the separator.
8. Reassemble the Test-Master® in reverse order.
9. Check to be sure the Test-Master® is level before
you use it.
1. READ AND UNDERSTAND SAFETY INSTRUCTIONS,
DISASSEMBLY INSTRUCTIONS AND THE PUMP
MAINTENANCE INSTRUCTIONS WHICH FOLLOW.
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10. DO NOT connect electrical power until you are ready
to operate the machine.
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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
To Change Hydraulic Oil:
If the oil is dirty, or if you need to work on the pump, first
drain the oil from the system. You will need a clean place
to work and a pan to receive the drained oil.
If you have disassembled the Test-Master® to check the
hydraulic oil, return to the Disassembly Instructions at the
beginning of Section 4.0, Maintenance and follow procedure 5 to remove the right (timer side) panel. Otherwise,
read, understand and follow Preparation For Maintenance
and Disassembly instructions 1—5 and 7—10.
Then proceed:
1. Release pump pressure.
2. Disconnect pump-to-cylinder hose at the pump end
and drain the oil from the hose into the pan.
3. Disconnect the cylinder end of the hose and reconnect the pump end.
4. Apply a few strokes to the pump pedal to drain the
oil from the pump into the pan.
5. Remove the pump cover and inspect the inside of the
reservoir. If you find sludge in the bottom of the reser voir,
clean it out with solvent before refilling with oil.
6. If repairs are to be made, continue disassembly as
described below. If you are only replacing hydraulic
oil, continue to the next step.
7. Reconnect hose, cylinder end first.
8. Fill the pump with oil to a 1/4in from the top.
9. Replace the cover and tighten the screws.
15.
Check to be sure the Test-Master® is level before you use it.
16. DO NOT connect electrical power until you are ready
to operate the machine.
Hydraulic Pump:
The hydraulic pump is a low-pressure pump with a cast
aluminum body. If your pump leaks or malfunctions, we
recommend that you return it to the factory for repair (a
three to five day process) or purchase a new pump. Call
Gilson Company for instructions.
It is sometimes possible to repair pumps in the field by
replacing parts. Refer to instructions, diagrams and parts
price list. The various springs are NOT interchangeable.
Pump Removal:
1. READ AND UNDERSTAND SAFETY INSTRUCTIONS, DISASSEMBLY INSTRUCTIONS AND THE
FOLLOWING PUMP REMOVAL AND MAINTENANCE INSTRUCTIONS.
2. Follow Disassembly Procedures 1—5.
3. Follow Disassembly Procedures 7—10.
4. Drain the oil from the hydraulic system according to
the instructions given.
5. Disconnect hose from pump.
6. Remove pump mounting screws.
7. Disconnect the pump pedal connecting link.
8. Lift pump out of Test-Master®.
10. Pump up and release the pressure several times to
remove air from the system.
11. With the pressure released, remove the cover and
add oil to a 1/4in from the top.
12. Replace the cover and tighten the screws.
13. Unblock the separator:
a. Pump up the system to re-clamp the separator
and take the pressure off the holding plates.
b. Return the plates to the down position.
c. Release the pressure by depressing the foot
pedal and pushing down on the lower frame of
the separator.
14. Reassemble the Test-Master® in reverse order.
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NOTE: When working on the hydraulic pump, take
care NOT to score surfaces where seals must be
maintained.
IMPORTANT! DO NOT REMOVE OR ADJUST THE
BYPASS ASSEMBLY.
These parts are assembled and preset at the factory.
Any change in the by-pass pressure could damage the
vibrating assembly of the Test-Master®.
1. Remove parts carefully, so as not to damage the pump
casting or any parts to be reinstalled. Balls must NOT
be nicked or scratched.
2. To reinstall, tap balls gently into their seated position
with a soft metal, blunt-ended rod.
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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
3. Use commercial plumber's pipe dope on port plugs.
To Remove Plunger & Replace O-Rings:
1. Remove the 2 plunger guide screws.
2. Slide out plunger and O-Ring assembly.
3. Replace O-Rings.
4. Dip O-Ring end of plunger into hydraulic oil and
reinsert it into the pump body.
5. Reinstall the pump in reverse order, using pipe dope
on hose fittings.
6. Unblock the separator:
a. Pump up the system to re-clamp the separator
and take the pressure off the holding plates.
b. Return the plates to the down position.
c. Release the pressure by depressing the foot
pedal and pushing down on the lower frame of
the separator.
7. Reassemble the Test-Master® in reverse order.
8. Check to be sure the Test-Master® is level before you
use it.
9. DO NOT connect electrical power until you are ready
to operate the machine.
Hydraulic Cylinders:
Maintenance to the hydraulic cylinders requires their removal from the Test-Master®. Please call Gilson to request
instructions for this procedure.
4.8 Wire Cloth & Screen Trays
Check condition of wire cloth and screen trays both before
and after operation.
Wire Cloth:
Testing grade wire cloth is a precision instrument and
should be treated as such. The ASTM E 11 specification
permits only very slight variations in average opening and
wire diameter of testing grade wire cloth. Abrasion due to
normal use and/or improper cleaning and handling can
cause wire to be out of specification to a considerable
degree before it appears to be worn. Check wire cloth
periodically for conformance to specs. Wire cloth may
eventually sag, reducing its effective screening area.
Wire with 1/4in and coarser openings is rigid and selfsupporting. No. 5 and finer sizes have hooked edges
which interlock with tray side clamps to provide tension
adjustment. Trays with No. 16 and finer wire cloth have
support strip inserts to minimize wear and distortion. Tray
backup cloth is available as an option at extra cost if additional support is desired. Tray side clamps for hooked
edge wire and flat wire are not interchangeable.
Screen Trays:
The life of your screen trays can be prolonged by establishing good procedures for handling and storing trays.
Avoid bumping or bending the corners of the tray flanges.
Bent flanges "work" during operation of the machine and
will eventually break.
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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
5.0 PARTS LISTS & DIAGRAMS:
5.1 Replacement Parts List
To aid in parts identification, refer to the figures indicated. When ordering, please specify the Model No. and Serial
No. which are found on the nameplate of your machine.
Part No. Description
REPLACEMENT TRAYS & WIRE CLOTH
TSA-100 Screen Tray, complete with Wire Cloth 4in (100mm) to No.4 (4.75mm)
TSA-101 No.5 (4mm) to No.14 (1.4mm)
TSA-102 No.16 (1.8mm) to No.100 (150µm)
TSA-106 No.200 (75µm)
TSA-99 Special Sizes, Over 4in Openings
TSA-115 Punched Plates with Round Openings
TSA-110 "Tyler Standard" Brass, Coarse Series
TSA-113 Standard Dustpan Tray
TSA-116 Stationary Dustpan with Adapter (3in deep)
TSA-117 Inclined Chute Pan (6in high)
REPLACEMENT WIRE CLOTH ONLY
TSA-125 4in (100mm) to No.4 (4.75mm)
TSA-126A No.5 (4mm) to No.14 (1.4mm)
TSA-126B No.16 (1.8mm) to No.100 (150µm)
TSA-127 No.200 (75µm)
TSA-124 Special Sizes, Over 4in Openings
TSA-130 Punched Plates with Round Openings
TSA-132 "Tyler Standard" Brass, Coarse Series
TSA-135 Supporting Back-up Cloth
TSA-136 Screen Tray Only, Complete, for Flat Wire Cloth, Coarser than No.4
TSA-137 Screen Tray Only, Complete, for Hooked Wire Cloth, No.5 & Finer
—
—
—
—
—
—
EXTERIOR PARTS
—
—
—
—
Tray Side Clamp, for Flat Wire Cloth
Tray Side Clamp, for Hooked Wire Cloth
Tray End Clamp
Tray Rubber Corner Gasket
Tray Bolt with Nut & Washer
Tray Front Baffle
Outer Case - Right (Timer) Side Panel with Door
Outer Case - Left Panel with Door
Outer Case - Back Panel
Top Cover & Hopper Assembly
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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
5.2 Parts List for Diagram 1
Part or Key No. Description No. Req'd
BASE FRAME & GUIDE PIN ASSEMBLY PARTS
RPTM-BFGPA1 Base Frame 1 1
RPTM-BFGPA2 Leveling Foot with Jam Nut 3 1
RPTM-MTRMOUNT
RPTM-BFGPA4
Motor Mount with Cap Screws (2) & Lock Washers (2) 1 1
Guide Pin Assembly, including Guide Block, Guide Pin, Guide Bushing,
Seal, Bolts (2), and Washers (2)
4 1
RPTM-BFGPA5 Guide Pin Only 4
RPTM-BFGPA6 Guide Bushing Only 4
RPTM-BFGPA7 Guide Bolt & Washer Only 8
RPTM-BFGPA8 Guide Seal Only 4
SEPARATOR & GUIDE FRAME PARTS
RPTM-SAGF1 Separator Assembly, complete for Model TM-5 1 1
RPTM-SAGF2 Separator Assembly, complete for Model TM-6 1
RPTM-SEP-FRAME
RPTM-SEPGDRAME
Separator Assembly-to-Guide-Frame Bolts, Nuts & Lock Washers 4
Separator Guide Frame 1 1
RPTM-SAGF5 Separator Pull-Down Spring 2 1
RPTM-3SHPWN Separator Holding Plate, with Wing Nut & Lock Washer 2 1
S1 Separator Guide Pin 2 1
S2 Separator Guide Pin Bracket 2 1
S3 Separator Guide Pin Bracket Bushing 4 1
ELECTRIC & DRIVING PARTS
Diagram
—
—
—
—
—
—
RPTM-MOTOR Motor, 1/3hp, 115/230V, 1,725rpm, Totally Enclosed 1 1
RPTM-MMNW Motor Mounting Nut with Lock & Flat Washers 4 1
RPTM-3EDP3 Motor Pulley with Set Screws (2) & Key 1 1
RPTM-EDP8 Drive Belt 1 1
—
—
—
—
Timer 1
Timer Mounting Plate with Screws (4), & Lock Washers (4) 1
Electrical Harness - Motor to Timer Switch 1
Electrical Harness - Motor to Receptacle Plug 1
RPTM-EDP14 Plug-in Cord 1
HYDRAULIC SYSTEM PARTS
200 Hydraulic Cylinder Assembly, including Piston, O-Ring & Cap 2 1
—
Hydraulic Cylinder O-Ring Only 2 1
204 Tee & Nipple 1 1
205 Pump-to-Cylinder Hose 1 1
206 Cylnder-to-Cylinder Hose 1 1
207 90° Swivel Fitting 3 1
—
—
—
—
—
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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
TM-5 & TM-6
Parts Diagram #1
(With External Parts Removed)
5.3 Diagram 1
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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
5.4 Parts List for Diagram 2
Part or Key No. Description No. Req'd
DRIVE ASSEMBLY PARTS
D1 Drive Case 1 2
D2 Drive Case Mounting Cap Screws & Washers 4 2
D3 Drive Case Cover & Mounting Bolt 1
D4 Drive Shaft 1 2
D5 Counterweight Shaft 1 2
D6 Shaft Bearing with Mounting Bolts (2) & Washers 4 2
D7 Connecting Rod 1 2
D8 Connecting Rod Bearing 1 2
D9 Bearing Retaining Clip & Cap Screw 3 2
D10 Eccentric with Set Screws (2) & Key 1 2
D11 Eccentric Retaining Snap Ring 1 2
D12 Wrist Pin Sleeve Bushing (Non-Metallic) 1 2
D13 Wrist Pin Sleeve (Steel) with Seals 1 2
D14 Wrist Pin Cap Screw with Nut & Lock Washer 1 2
D15 Counterweight, with Clamp, Screws (2) & Lock Washers 4 2
D16 Eccentric Locating Snap Ring 2 2
D17 Drive Shaft Locating Snap Ring 2 2
D18 Timing Pulley with Bushing & Cap Screws (2) & Key 2 2
D19 Timing Belt 1 2
D20 Tensioning Bracket 1 2
D21 Tensioning Pulley 1 2
D22 Tensioning Pulley Bearing 2 2
D23 Tensioning Pulley Mounting Cap Screw & Washers 1 2
D24 Drive Pulley with Set Screws (2) & Key 1 2
Diagram
—
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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
TM-5 & TM-6
(Drive Assembly)
Parts Diagram #2
5.5 Diagram 2
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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
5.6 Parts List for Diagram 3
Part or Key No. Description No. Req'd
HYDRAULIC SYSTEM PARTS
208
Pump Pedal with Arm, Cap Screws (2), Lock Nuts (2), & Key with Set Screw
1 3
209 Pump Pedal Spring 1 3
210—212
Pedal-to-Pump Linkage, complete with Thru Swivel Shaft, Bushings
(2), Lock Washers (2), and Link Arm
3 3
211 Bushing Only 2 3
212 Screw & Lock Washer Only 2 3
—
—
TM Hydraulic Pump, Complete 1 3
Hydraulic Oil, 1/2 Pint Can
— —
219 Pump Pedal Connecting Link 1 3
220 Stroke Limiting Spring 1 3
221 Stroke Limiting Washer 2 3
222 Plunger Guide & Guide Seal 1 3
227 Guide Seal Only 1 3
223 Plunger Guide Screw 2 3
224 Plunger Only 1 3
225 Plunger O-Ring 2 3
228 Pump Cover with Vent 1 3
229 Pump Cover Screw 4 3
230 Pump Cover Gasket 1 3
235 Pressure Release Plug, 3/8in 1 3
236 Pressure Release Spring 1 3
237 Pressure Release Thrust Pin with O-Ring 1 3
237-1 Pressure Release O-Ring Only 1 3
238 Pressure Release Pin 1 3
239 Port Plug, 1/8in, in Pump Body 3 3
240 Pressure Check Plug, 1/8in, in Pump Body 1 3
242 Intake Check Plug, 1/8in, in Pump Body 1 3
241 Pressure Check Spring 1 3
243 Intake Check Spring 1 3
244 Intake Check Ball 1 3
245 Pressure Check Thrust Pin with O-Ring 1 3
245-1 Pump Mounting Screw with Lock Washer 3 3
Diagram
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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
TM-5 & TM-6
Parts Diagram #3
(Hydraulic Pump & Pedal Parts)
5.7 Diagram 3
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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6
6.0 MAINTENANCE FLOW CHART:
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