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: [email protected] 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 responsibil-
ity. 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: 2.2 Leveling

Your Gilson Test-Master ®, crated for shipping, weighs be- At the operating site, set the Test-Master ® on the floor.
tween 600—700lbs, depending on which model you have The machine will rest on three leveling feet, one at each
and how many trays are packed inside. Use appropriate front corner and one at the center back.
equipment to unload and move it.

Wear safety glasses. Cut the banding and lift the carton off. NOTE: DO NOT connect electric power until you
Save the carton until you have inspected the Test-Master® have leveled the Test-Master ®.
and placed it into service.

Check the machine over, looking for loose screws, indica- Use the following procedure:
tions of a hydraulic leak or any other damage.
1. Open the doors.
If you find concealed shipping damage after you have
signed for the Test-Master ®, call the delivering freight 2. If there are trays and a pan in the Test-Master®, remove
carrier immediately for an inspection. Save all the packing all but the tray in the second position from the top
materials and leave the Test-Master ® just as it is. of the separator. Leave this tray extended about 4in
from the front of the machine. Otherwise, insert a tray
When you're sure your Test-Master ® is in acceptable con- in the second position from the top of the separator,
dition, remove the trays and dustpan from the machine. leaving this tray extended about 4in from the front of
To do this, open the doors. Step on the pump pedal and the machine.
depress it completely, releasing the clamping pressure.
Push down on the lower separator frame to be sure that 3. Pump the foot pedal with short strokes until the tray
the separator is fully extended. Slide the trays and dust- is clamped in position.
pan out of the Test-Master® and set them aside. Close
the doors. 4. Place a carpenter's level across the extended tray,
resting it on the tray's flanges. DO NOT place the
Use proper equipment to lift the Test-Master® off its skid. level on the machine's case.
Save the skid. Keeping the machine as close to the floor
as possible, move it to the site where you intend to oper- 5. Adjust the three leveling feet until the Test-Master® is
ate it. Make sure not to drop the machine. 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 set-up: 6. When you have leveled the Test-Master ® in both

directions, tighten the locking nuts on all three feet.
2.1 Site Selection
7. Release the clamping pressure by pushing the foot
1. Choose a site where there is a solid, rigid, level floor pedal all the way to the floor. Push down on the bot-
with adequate space available for installation, opera- tom of the separator unit to be sure that the separator
tion and maintenance. is fully extended.

2. Make sure your electrical hookup is compatible with 8. Replace the trays and pan which you removed and
the Test-Master® shipped to you and that a grounded, close the doors.
three-pronged receptacle is within reach of the machine
or that other properly-grounded electrical power is
available for connection by an authorized person. NOTE: Whenever you move the Test-Master ®, be
sure to re-level it before you use it. Follow the
3. Choose a site with adequate ventilation. leveling instructions provided.

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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6

2.3 Initial Testing (5) If the timing belt is loose or has slipped off
its pulleys, turn to Maintenance Instruc-
tions and complete Disassembly Instruc-
NOTE: Be sure to read and understand all safety tions 4—6. Then find the Timing Belt
instructions and initial test instructions before pro- information in Section 4.0, Maintenance
ceeding and follow all these instructions during the and follow the instructions for adjusting
testing process. or re-seating the belt.
d. Look for concealed shipping damage, such as
Read and understand the instructions for operating bent, dented or loose parts.
the Test-Master's timer. Be sure you know how to stop
the Test-Master® before you activate the timer. 2.4 Shutdown

Make sure that your Test-Master® is electrically con- Open the doors. Release the clamping pressure by pushing
figured to be compatible with your power supply and the foot pedal all the way to the floor and pushing down
that all wiring is grounded and properly installed. 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.
After leveling the Test-Master ® for the first time, run this
initial test. With trays and pan in the machine and the Unplug or disconnect electric power from the Test-Master®.
doors open: DO NOT reconnect power until you are ready to use the
Test-Master ®.
1. Pump the foot pedal with short strokes until the sepa-
rator is clamped. Close the doors.
NOTE: Whenever you move the Test-Master ®, be
2. Plug in the Test-Master . ®
sure to re-level it before you use it. Follow the
leveling instructions provided.
3. Following the timer instructions, set the timer for 10
seconds.

4. Activate the timer to start the Test-Master®. 3.0 operating instructions:

5. The Test-Master® should run for 10 seconds and stop. Always review and completely understand all safety, op-
erating, and maintenance instructions before you place
6. If not, check to be sure you have properly connected your Test-Master ® into service.
compatible power to your Test-Master ®.
3.1 General Instructions
7. Repeat steps 3 and 4. Should the Test-Master ® fail
to run, an electrical connection has probably come To clamp trays in place:
loose in shipping. Call Gilson Company, Inc. Techni- 1. First be sure they are inserted fully.
cal Support line at 800.444.1508 (8AM - 5PM EST) 2. Pump the foot pedal, using short strokes until trays
Monday - Friday. are clamped and held in place.
3. Close the doors.
8. If there is excessive noise or vibration during the
test run: To release trays:
1. Open the doors.
a. Re-check to be sure the Test-Master ® is level. 2. Depress the pedal to the floor and hold it in place for
b. Re-check to make sure you have clamped up a moment.
your separator and trays. 3. Push down on the lower separator frame until the
c. Check to see that the timing belt is properly- separator is fully extended.
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.

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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6

3.2 Timer Set-Up & Operation 8. Using both handles on the hopper, lift it to feed the
sample into the machine. When the sample is loaded,
This unit is equipped with an easy-to-operate Gilson interval lower the hopper back into the Test-Master ®.
count-down timer. The timer has a large 0.6in LED display 9. When the Test-Master® stops, open the doors.
and will operate in four different modes. It is powered by line 10. Release the trays.
voltage and will work on power supplies from 100—265 VAC, 11. Remove the trays and continue the procedure
50/60Hz, with up to 20 amps Inductive or Resistive current. specified for your test. MANUAL ON TEST SIEVING
METHODS (BK-447), an ASTM publication available
from Gilson, provides detailed information on test-
Note: The main device controlled by the timer may sizing procedures.
be restricted to operating on a more limited electrical 12. Follow Shutdown procedure in Section 2.4.
supply range. Check the device carefully to insure
compatibility with your electrical supply. 3.3 Test Times

Times of 5—10 minutes are normal, depending upon ma-

Current timer mode is indicated by the four red LED’s on terial types and sizes. Materials in the fine series range
the timer face: (No. 4 to No. 200) may require more than 15 minutes.
The proper test time results in complete separation and
• A = MMSS (99min:59sec x 1 second) sizing of the sample.
• B = HHMM (99hr:59min x 1 minute)
• C = SSSS (9999sec x 1 second) You can establish standard test times for different types
• D = MMMM (9999min x 1 minute) of samples by looking for complete sample separation.
After a test is finished, run each tray separately with a
(H is for hours, M for minutes, and S for seconds.) To adjust clean pan to see if a significant amount of sample is still
the timer mode, press and hold both <UP> and <DOWN> keys passing. If so, lengthen your test time.
at the same time until the display shows the mode. Once the
mode letters are displayed, press <UP> or <DOWN> to change 3.4 Sample Sizes
modes. Press <START/STOP> to accept new mode.
The sample capacity of the Test-Master ® varies according
To set the run time, press either <UP> or <DOWN>. The to the type and size range of the material being tested.
first digit on the right hand side will flash in half-second Sample size is often established in the test specifications.
intervals. Press either arrow key to adjust to the desired For example, ASTM C 136, specification for "Sieve or
value. To enter the displayed digit and move to the next, Screen Analysis of Fine and Coarse Aggregates," calls
press <START/STOP>. Once the last digit on the left is for minimum weights of test sample of coarse aggregate
entered, the timer is ready to start. (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. ASTM C 136 sample Sizes
When allowed to time-out, the timer beeps and displays Nominal Max. Size of Min. Sample
DONE. Press any key to continue. Setting and Mode values Particle, in (mm) Weight, kg
are saved automatically and restored on power-up.
3/8 (9.5) 1
To operate the Test-Master : ® 1/2 (12.5) 2
1. Make sure your Test-Master ® is level, following the 3/4 (19) 5
procedure provided. 1 (25) 10
2. Fully insert the trays you need. 1-1/2 (37.5) 15
3. Clamp the trays in place. 2 (50) 20
4. Close the doors. 2-1/2 (63) 35
5. Pour your sample into the hopper, making sure not to 3 (75) 60
overload the Test-Master®. The hopper is designed 3-1/2 (90) 100
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 ®. Normally, these minimum sample sizes (and larger in
7. Set the timer and activate it to start the Test-Master®. many cases) can be handled in the Test-Master® in a
Refer to the timer instructions. 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: tenance person for this machine, safety is your respon-
The limiting tray should have no more than one layer of sibility. You are responsible for operating and maintain-
particles over the wire cloth area. Overloading will prevent ing this equipment in compliance with these instructions
complete and proper aggregate separation in your test. 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 Before performing any maintenance, always review this
or pellets may be tested in somewhat larger amounts manual and be sure you understand the safety, operat-
by weight. Many light materials are also soft and require ing and maintenance instructions. If you have any ques-
short test times to avoid degradation of the sample. 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: The Test-Master's electric motor has internal thermal
ASTM C 136 specifies that at the end of the test, the protection. The motor will automatically shut off if
limiting tray should contain no more than four grams/ it is overloaded. If this happens, disconnect the
in2 of sieving surface. For materials similar in density to power. Otherwise, the motor could restart by itself
sand, this converts to about 1,350g (3lb) on the limiting after it cools down.
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 ALWAYS disconnect the Test-Master® and lock out the
than for testing, larger amounts of material may be intro- power supply before performing maintenance or repairs.
duced, though sharpness of separation will decrease as
the load increases. ALWAYS check electrical wiring for loose connections
and for pinched or frayed wires.
3.5 Pan Options
ALWAYS wear safety glasses or goggles wen you are
The standard dustpan tray (TS-112) is used in the bottom working with the Test-Master ®.
slot, where it shakes with the screen trays. This arrange-
ment is adequate for most situations. 4.1 Preparation for Maintenance

The stationary pan with adapter (TSA-116) is recom- Unplug or disconnect Test-Master® and lock out power.
mended if the movement of the standard tray makes it
difficult to handle fine materials. The adapter fits the bottom Read and understand all the safety instructions and the
vibrating slot and provides a dust seal to the stationary maintenance instructions for the parts you plan to repair.
dustpan below.
Use the flowchart in the back of this manual as a guide
For separation of fine aggregates, we recommend the to move through the various disassembly and repair
use of equipment specifically designed for such testing. procedures.
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 NOTE: When ordering parts for your Test-Master®,
on a routine basis. 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 4.2.2 Blocking/Unblocking the Separator

4.2.1 Outer Case Removal For some maintenance procedures, you need to block
the separator to hold it in the clamped position without
To access internal parts for maintenance, you must the use of hydraulics.
remove all or part of the outer case. Refer to the flow-
chart and these instructions to determine how much 1. Find the two notched separator holding plates which
disassembly is required for your repair work. are mounted by wing nuts on the guide frame below
the separator, one on each side of the Test-Master ®.
1. Always unplug the Test-Master ® and lock out the They will be in the down position.
power supply before beginning disassembly.
2. Pump up the hydraulic system to clamp the separator.
2. Open the doors, remove the trays, and set them If the hydraulic system is not working, compress the
aside. separator manually. Supporting the separator from
the bottom, lift the separator into its compressed
3. Remove the Drive Case Cover: position so that you can follow step 3.
From the front of the machine, reach under the cover
at its center and locate the head of the mounting 3. Loosen the wing nuts, rotate the plates upward and
screw. Remove the screw, slide the case cover re-tighten.
toward you, and lift it off. Now you have access for
the following procedures: 4. Release the hydraulic pressure (or lower the separa-
tor if you compressed it manually) and the bottom
a. Adjust the setting of the pump pedal. of the separator assembly will come to rest in the
b. Lubricate bearings. notches of the holding plates.
c. Tighten the setscrew on the drive pulley.
d. Check, adjust, or replace the drive belt. With the separator BLOCKED, you have access for
e. Check tension of the timing belt. the following procedures:

Follow the instructions found later in this manual. a. Repair or replace guide pin assemblies.
For other procedures, continue disassembly. b. Access hydraulic pump.

4. Remove the four screws at the corners of the top When you have finished your maintenance pro-
cover, and lift off the cover and hopper. cedure, UNBLOCK the Separator to restore it to
operating condition as follows:
5. To remove right side cover, first disconnect the timer.
The timer-to-motor connection is fastened to the a. Pump up the hydraulic system to re-clamp the
front of the drive case. Remove the tape. NOTE separator.
that the green sections plug into each other, so b. Return the holding plates to the down position.
that later you will know how to reconnect the timer. c. Release the pressure.
Unplug the timer. Support the weight of the right
panel with a two-by-four or other block. Remove 4.3 Lubrication of Bearings
nine mounting screws from the right side cover, and
pull the panel off the machine. Reinstall one of the 1. Using a grease gun with a flexible nozzle, lubricate
screws in the second hole from the top of the back the four shaft bearings, two on each side of the drive
cover, to hold this panel in place. case, after about every 360 hours of operation. Apply
a lithium-based or lithium-compatible grease.
6. Remove the left side cover in the same way. The
machine is now accessible for the following pro- 2. Lubricate the motor end bearings with a few drops of
cedures: oil as needed, about once a year under normal use.

a. Adjust, re-seat or replace the timing belt. 4.4 Belts

b. Inspect, repair, or replace the tensioning pulley.
c. Inspect the guide pin assemblies. Both the drive belt and the timing belt will wear with use
and should be inspected periodically for tension, align-
ment 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 mainte- c. To reseat or replace the timing belt, remove the bolts
nance instructions before attempting to inspect or adjust at the top of the tensioning bracket. This allows the
belts. ALWAYS disconnect and lock out electric power. bracket to pivot toward the front of the machine,
loosening the tension on the timing belt.
4.4.1 Drive Belt & Pulley d. Remove the screw that secures the tensioning pul-
ley to the bracket.
The drive belt sometimes stretches when it is first used, e. Remove the pulley.
so check its tension after the first day of operation. f. Remove the belt. Inspect it for damage and obtain
a replacement if necessary.
1. Follow Disassembly Instructions 1—3 to access
the drive belt for inspection and adjustment. Tensioning Pulley Inspection:
Take this chance to check the condition of the tensioning
2. The play in the belt should equal 1/64 of the dis- pulley and its bearings. Spin the pulley on its bearings.
tance between the centers of the pulleys. If it does not turn smoothly, replace the bearings.

3. If the drive belt is too loose, it will slip and the Test- a. Drive out both bearings from one side of the pulley.
Master® will run too slowly or else in spurts. b. Press new bearings into place.

4. If the drive belt is too tight, it will wear out quickly. Counterweight Alignment:
a. Rotate the drive shaft by hand, looking for a mark
To Adjust Drive Belt Tension: that indicates the thick part of the eccentric. Turn
a. Loosen the four motor mounting nuts. the shaft until this mark is at the top of the shaft.
b. Slide the motor forward or back as needed. The connecting rod is now at its highest position
c. Re-tighten the four nuts. and the counterweights are flat-side-up.
d. To prevent excessive wear on the drive belt, be b. Rotate the counterweight shaft until its counter-
sure that the motor and drive pulleys are lined up weights are flat-side up and parallel to the coun-
with each other. terweights on the drive shaft.

To Replace the Drive Belt: Timing Belt Installation:

a. Loosen the motor mounting nuts as for adjustment. Reinstall the timing belt along with the tensioning pulley:
b. Slide the motor toward the center of the machine a. Fit the belt around the front timing pulley and over
to relieve tension on the belt. the top of the middle timing pulley, taking care not
c. Slip the belt off the pulleys. to change the rotation of the shafts and counter-
d. Slip the new belt around the pulleys. Adjust the weights.
tension as described above before you re-tighten b. Insert the tensioning pulley into the loop of the belt.
the mounting nuts. c. Holding the belt and pulley together, bolt the pulley
to the tensioning bracket.
Drive Pulley: d. Reinstall the upper bolts and adjust them to create
If the drive pulley is loose on the drive shaft, use an the proper tension on the timing belt.
allen wrench to tighten its setscrew. e. Check to be sure that all the counterweights are
flat-side-up and parallel to each other and to the
4.4.2 Timing Belt & Tensioning Pulley top of the drive case.

The timing belt should fit tightly. 4.5 Guide Pin Assembly

1. A worn or loose timing belt may slip teeth on the The separator assembly of the Test-Master® vibrates inde-
pulleys and cause the machine to be out of balance, pendently from the frame. Alignment of these components
vibrate excessively and walk. is maintained by four guide pin assemblies; two on each
2. If the timing belt has slipped out of position, inspect side, one upper and one lower. Each assembly consists of
it and replace or reseat as required. a guide pin, a guide block, a fiber guide bushing, a guide
seal, and nuts, bolts, and washers. Shims are used for
Timing Belt Adjustment or Replacement: alignment when a Test-Master ® is being assembled. For
a. Follow disassembly procedures 1—6. the system to work properly, all four guide pins must be
b. Tighten the belt by adjusting the bolts at the top of parallel, and the upper and lower guide pins on each side
the tensioning bracket. 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 assem- b. If you are installing new assemblies, place the
blies immediately after the Test-Master® has been running. shims so that the block is square with the separa-
If the guide pins feel hot or are loose, the bushings have tor guide frame so that the upper and lower guide
worn. At this point you have the option of replacing only the pins line up with each other.
bushings and seals. If the bushings wear out completely, the
guide pins will get out of line and cause the Test-Master® 5. Place a carpenter's level across the top and sides
to make a loud, hammering noise. You will need to replace of the separator guide frame and position the guide
the guide pin assemblies in this instance. block so that its top is level.

Inspection of the bushings and pins requires some disas- 6. Use the play in guide bolt holes and shims to make
sembly as described below. fine adjustments to position the guide block. Then
tighten the bolts completely.
Access:
1. READ AND UNDERSTAND SAFETY AND DISAS- 7. Reinstall the guide pin. COMPLETE THIS INSTAL-
SEMBLY INSTRUCTIONS AT THE BEGINNING OF LATION BEFORE PROCEEDING TO REPAIR AN-
THE MAINTENANCE SECTION AND THE GUIDE OTHER GUIDE PIN ASSEMBLY.
PIN REPLACEMENT INSTRUCTIONS.
8. When you have finished with all the guide pin assemblies
2. UNPLUG the Test-Master ® and LOCK OUT the you plan to work on, run a final alignment check:
POWER.
a. Unblock the separator using the procedure in
3. LEVEL THE MACHINE, following the instructions in DISASSEMBLY INSTRUCTION 10.
the installation section. You will not be able to com- b. Place several trays in position as though you were
plete the guide pin replacement unless the machine preparing to run a test.
frame is level to begin with. c. Clamp the separator and close the doors.
d. Run the Test-Master ® for ten minutes.
4. Follow Disassembly Instructions 2—6. WARNING! THE TEST-MASTER® IS NOT DE-
SIGNED TO BE OPERATED WITHOUT GUARDS
5. BLOCK THE SEPARATOR, following disassembly AND COVERS IN PLACE. STAND BACK. KEEP
instructions 7—10. YOURSELF, YOUR CLOTHING AND ALL OTHER
OBJECTS AWAY FROM THE MACHINE.
6. CHECK ALL FOUR GUIDE PINS: Try to move each e. After the Test-Master ® stops, touch the tops of the
one by hand. If a pin feels hot or if it is loose or wobbly, guide pins. They may be warm, which is normal.
the bushing inside the guide block has worn out. If one or more guide pins are hot to the touch, the
guide pins are out of alignment. Return to steps
Procedure: 4 and 5 and make adjustments as necessary.
WORK ON GUIDE PIN ASSEMBLIES ONE AT A TIME. BE-
FORE WORKING ON A LOWER GUIDE PIN ASSEMBLY, REASSEMBLE THE TEST-MASTER® IN REVERSE
lift the corresponding hydraulic cylinder assembly about ORDER. Make sure all bolts are secure.
3/8in and move it toward the center of the machine.
BE SURE THE TEST-MASTER® IS LEVEL before placing
1. Loosen guide pin setscrew, and remove the guide it into service. DO NOT connect electric power until you
pin. Observe the position of the shims that determine are ready to operate the Test-Master®.
the vertical alignment of the guide block.
4.6 Drive Assembly
2. Remove guide bolts, guide block and shims, KEEP-
ING THE SHIMS for reassembly. The drive belt and timing belt and their pulleys have been
described earlier.
3. If you are repairing the guide pin assembly, press out
old seal and bushing and press in new ones. Maintenance to other parts of the drive assembly require
removal of the drive case. Please call Gilson to request
4. Reinstall guide block, including the shims, leaving the instructions for these procedures.
guide bolts loose.
4.7 Hydraulic System
a. If you are installing old guide blocks with new
bushings, position the shims as they were. 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 cylin- 2. Follow Disassembly Procedures 1—4.
ders apply force to the separator, compressing it into the
clamped position. The system is pressurized by applying 3. Follow Disassembly Procedures 7—10.
short strokes to the foot pedal. Pressure is released by
depressing the foot pedal all the way to the floor and push- Now you have access to the hydraulic pump.
ing down on the lower frame of the separator. Always
leave the separator in the released position when the Hydraulic Oil:
Test-Master ® is not in use. The Test-Master ® uses a medium-viscosity, non-foaming
hydraulic oil.
WHETHER YOU ARE THE OWNER, EMPLOYER,
OPERATOR, OR MAINTENANCE PERSON, YOU ARE To check the level and quality of the hydraulic oil, follow
RESPONSIBLE FOR CONDUCTING MAINTENANCE the above access procedures to disassemble the Test-
PROCEDURES ON THE TEST-MASTER® IN COMPLI- Master® and to block the separator in the closed position.
ANCE WITH THE SAFETY PRECAUTIONS AND OTHER Then proceed:
INSTRUCTIONS IN THE MANUAL. BEFORE YOU BEGIN
TO WORK ON THE HYDRAULIC SYSTEM, ALWAYS 1. Release pressure and remove the pump cover. The
RE-READ THE MANUAL AND BE SURE YOU UNDER- oil level should be 1/4in from the top of the reservoir
STAND BOTH THE SAFETY AND MAINTENANCE IN- and the oil should appear clear.
STRUCTIONS. IF YOU HAVE ANY QUESTIONS, PLEASE
CALL Call Gilson Company, Inc. Technical a. Some discoloration of the oil is acceptable; visible
Support line at 800.444.1508 (8AM - 5PM EST) dirt is not acceptable.
Monday - Friday. b. Fine aluminum flakes which disintegrate between
your fingers are acceptable; aluminum chips are
ALWAYS DISCONNECT THE TEST-MASTER® AND not acceptable.
LOCK OUT THE POWER SUPPLY BEFORE PERFORM- c. If oil is not in acceptable condition, proceed to
ING MAINTENANCE OR REPAIRS. next section, "To Change Hydraulic Oil."

Pump Pedal Adjustment: 2. If the oil is clean but the level is low, fill to the correct level.
If depressing the foot pedal and pushing down on the lower
frame of the separator does not completely release hy- 3. Replace the cover and tighten down the screws.
draulic pressure, adjust the setting of the pump pedal.
4. Pump up and release the pressure several times to
1. Follow Disassembly Procedures 1—3. remove air from the system.

2. Find the two hex-head cap screws toward the rear of 5. Reopen the pump and again add oil to 1/4in from the top.
the pedal.
6. Reinstall cover and tighten the screws.
3. Loosen the front screw a quarter turn, and tighten the
rear screw a quarter turn. 7. Unblock the separator:

4. Repeat this adjustment until a complete depression of a. Pump up the system to re-clamp the separator
the foot pedal causes a complete release of pressure and take the pressure off the holding plates.
in the system. b. Return the plates to the down position.
c. Release the pressure by depressing the foot
5. Reinstall front panels, but do not reconnect electri- pedal and pushing down on the lower frame of
cal power until you are ready to run a test. the separator.

Access to Hydraulic Pump: 8. Reassemble the Test-Master ® in reverse order.

To check or replace hydraulic oil, return to the disas-
sembly procedure found at the beginning of Section 4.0, 9. Check to be sure the Test-Master ® is level before
Maintenance. you use it.

1. READ AND UNDERSTAND SAFETY INSTRUCTIONS, 10. Do not connect electrical power until you are ready
DISASSEMBLY INSTRUCTIONS AND THE PUMP to operate the machine.
MAINTENANCE INSTRUCTIONS WHICH FOLLOW.

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Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6

To Change Hydraulic Oil: 15. Check to be sure the Test-Master® is level before you use it.
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 16. Do not connect electrical power until you are ready
to work and a pan to receive the drained oil. to operate the machine.

If you have disassembled the Test-Master ® to check the Hydraulic Pump:

hydraulic oil, return to the Disassembly Instructions at the The hydraulic pump is a low-pressure pump with a cast
beginning of Section 4.0, Maintenance and follow proce- aluminum body. If your pump leaks or malfunctions, we
dure 5 to remove the right (timer side) panel. Otherwise, recommend that you return it to the factory for repair (a
read, understand and follow Preparation For Maintenance three to five day process) or purchase a new pump. Call
and Disassembly instructions 1—5 and 7—10. Gilson Company for instructions.

Then proceed: It is sometimes possible to repair pumps in the field by

1. Release pump pressure. replacing parts. Refer to instructions, diagrams and parts
price list. The various springs are not interchangeable.
2. Disconnect pump-to-cylinder hose at the pump end
and drain the oil from the hose into the pan. Pump Removal:
1. READ AND UNDERSTAND SAFETY INSTRUC-
3. Disconnect the cylinder end of the hose and recon- TIONS, DISASSEMBLY INSTRUCTIONS AND THE
nect the pump end. FOLLOWING PUMP REMOVAL AND MAINTE-
NANCE INSTRUCTIONS.
4. Apply a few strokes to the pump pedal to drain the
oil from the pump into the pan. 2. Follow Disassembly Procedures 1—5.

5. Remove the pump cover and inspect the inside of the 3. Follow Disassembly Procedures 7—10.
reservoir. If you find sludge in the bottom of the reservoir,
clean it out with solvent before refilling with oil. 4. Drain the oil from the hydraulic system according to
the instructions given.
6. If repairs are to be made, continue disassembly as
described below. If you are only replacing hydraulic 5. Disconnect hose from pump.
oil, continue to the next step.
6. Remove pump mounting screws.
7. Reconnect hose, cylinder end first.
7. Disconnect the pump pedal connecting link.
8. Fill the pump with oil to a 1/4in from the top.
8. Lift pump out of Test-Master ®.
9. Replace the cover and tighten the screws.

10. Pump up and release the pressure several times to NOTE: When working on the hydraulic pump, take
remove air from the system. care NOT to score surfaces where seals must be
maintained.
11. With the pressure released, remove the cover and
add oil to a 1/4in from the top.
IMPORTANT! DO NOT REMOVE OR ADJUST THE
12. Replace the cover and tighten the screws. BYPASS ASSEMBLY.

13. Unblock the separator: These parts are assembled and preset at the factory.
a. Pump up the system to re-clamp the separator Any change in the by-pass pressure could damage the
and take the pressure off the holding plates. vibrating assembly of the Test-Master ®.
b. Return the plates to the down position.
c. Release the pressure by depressing the foot 1. Remove parts carefully, so as not to damage the pump
pedal and pushing down on the lower frame of casting or any parts to be reinstalled. Balls must not
the separator. be nicked or scratched.

14. Reassemble the Test-Master ® in reverse order. 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. Hydraulic Cylinders:

Maintenance to the hydraulic cylinders requires their re-
To Remove Plunger & Replace O-Rings: moval from the Test-Master ®. Please call Gilson to request
1. Remove the 2 plunger guide screws. instructions for this procedure.

2. Slide out plunger and O-Ring assembly. 4.8 Wire Cloth & Screen Trays

3. Replace O-Rings. Check condition of wire cloth and screen trays both before
and after operation.
4. Dip O-Ring end of plunger into hydraulic oil and
reinsert it into the pump body. Wire Cloth:
Testing grade wire cloth is a precision instrument and
5. Reinstall the pump in reverse order, using pipe dope should be treated as such. The ASTM E 11 specification
on hose fittings. permits only very slight variations in average opening and
wire diameter of testing grade wire cloth. Abrasion due to
6. Unblock the separator: normal use and/or improper cleaning and handling can
a. Pump up the system to re-clamp the separator cause wire to be out of specification to a considerable
and take the pressure off the holding plates. degree before it appears to be worn. Check wire cloth
b. Return the plates to the down position. periodically for conformance to specs. Wire cloth may
c. Release the pressure by depressing the foot eventually sag, reducing its effective screening area.
pedal and pushing down on the lower frame of Wire with 1/4in and coarser openings is rigid and self-
the separator. supporting. No. 5 and finer sizes have hooked edges
which interlock with tray side clamps to provide tension
7. Reassemble the Test-Master ® in reverse order. adjustment. Trays with No. 16 and finer wire cloth have
support strip inserts to minimize wear and distortion. Tray
8. Check to be sure the Test-Master ® is level before you backup cloth is available as an option at extra cost if ad-
use it. ditional support is desired. Tray side clamps for hooked
edge wire and flat wire are not interchangeable.
9. Do not connect electrical power until you are ready
to operate the machine. Screen Trays:
The life of your screen trays can be prolonged by estab-
lishing 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
— 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
exterior parts

— 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 Diagram

base frame & guide pin assembly parts

RPTM-BFGPA1 Base Frame 1 1
RPTM-BFGPA2 Leveling Foot with Jam Nut 3 1
RPTM-MTRMOUNT Motor Mount with Cap Screws (2) & Lock Washers (2) 1 1
Guide Pin Assembly, including Guide Block, Guide Pin, Guide Bushing,
RPTM-BFGPA4 4 1
Seal, Bolts (2), and Washers (2)
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 Separator Assembly-to-Guide-Frame Bolts, Nuts & Lock Washers 4 —
RPTM-SEPGDRAME 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

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

(With External Parts Removed)

Parts Diagram #1
TM-5 & TM-6
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 Diagram

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

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 Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6

Parts Diagram #2
(Drive Assembly)
TM-5 & TM-6
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 Diagram

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
Pedal-to-Pump Linkage, complete with Thru Swivel Shaft, Bushings
210—212 3 3
(2), Lock Washers (2), and Link Arm
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

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 Gilson Company, Inc. Gilson Test-Master® Testing Screen: TM-5 & TM-6

(Hydraulic Pump & Pedal Parts)

Parts Diagram #3
TM-5 & TM-6
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:

Page 21