Gilson Gilson Test-Master TM-6 User manual

OPERATING MANUAL
Gilson Test-Master®Testing Screens
TM-5 & TM-6
Rev: 04/12/2013
PHONE: [phone] P.O. Box 200, Lewis Center, Ohio 43035-0200 FAX: [phone]
740-548-7298 E-mail: [e-mail] Website: www.globalgilson.com 740-548-5314

Gilson Company, Inc. Gilson Test-Master®Testing Screen: TM-5 & TM-6
Page 2
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.

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

Gilson Company, Inc. Gilson Test-Master®Testing Screen: TM-5 & TM-6
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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.
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 bot-
tom 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.
1.0 UNPACKING:
Your Gilson Test-Master®, crated for shipping, weighs be-
tween 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, indica-
tions 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 con-
dition, 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 dust-
pan 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 oper-
ate it. Make sure not to drop the machine.
2.0 SETUP:
2.1 Site Selection
1. Choose a site where there is a solid, rigid, level floor
with adequate space available for installation, opera-
tion 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.

Gilson Company, Inc. Gilson Test-Master®Testing Screen: TM-5 & TM-6
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(5) If the timing belt is loose or has slipped off
its pulleys, turn to Maintenance Instruc-
tions and complete Disassembly Instruc-
tions 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.
3.0 OPERATING INSTRUCTIONS:
Always review and completely understand all safety, op-
erating, 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.
2.3 Initial Testing
NOTE: Be sure to read and understand all safety
instructions and initial test instructions before pro-
ceeding 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 con-
figured 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 sepa-
rator is clamped. Close the doors.
2. Plug in the Test-Master®.
3. Following the timer instructions, set the timer for 10
seconds.
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. Techni-
cal 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.