Gilson Testing Screen
Contents
1. TS 1 amp TS 2 Testing Screens B Release the clamping force of the separator TS 1 Pull the hydraulic pump handle all the way toward the front of the machine or TS 2 Turn clamp rods counterclockwise C Load your desired sequence of screen trays into your Testing Screen being careful not to pinch your fingers with already inserted screen trays Wear gloves during this process D Apply clamping force on the trays TS 1 Apply short strokes to the hydraulic pump handle The hydraulic system will apply ten sion on both sides of the separator or TS 2 Turn the two clamp rods clockwise si multaneously and as equally as possible using your sense of touch to determine when the trays are firmly clamped DO NOT overtighten this can cause damage and wear to parts Itis better to under tighten though this will cause noisy operation To reduce noise increase clamping pressure by turning the clamp rods simultaneously clockwise Do not wear loose clothing which can get caught on the clamp rods while making this final adjustment E Load the Testing Screen The Testing Screen will work more efficiently if the machine is started first Choose your loading method by considering the nature and characteristics of your sample and the type of dust it will release into the atmosphere There are two types of tests 1 Agitation of the sample until separation is complete 2 Agitation of the sample for a predetermined2. Operating 8 Service Manual Gilson Testing Screen Models TS 1 8 TS 2 Copyright 2004 Gilson Company Inc Table of Contents Safety Instructions l Uncrating Instructions ll Installation Instructions Ill Operating Instructions IV Sample Capacity V Maintenance A Lubrication B Removal of Covers C Drive Assembly D TS 2 Clamp Rod Assembly E TS 1 Hydraulic Clamping System F Wire Cloth and Screen Trays VI Operating Problems Vil Repair Parts amp Diagrams VIII Customer Registration Form Page 1 TS 1 amp TS 2 Testing Screens 14 14 15 20 Gilson Company Inc TS 1 amp TS 2 Testing Screens 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 You should always review and completely understand these safety and operating instructions before using this machine DANGER This machine operates on electrical current Improper use could result in electric shock electrocution injury by explosion or even death ALWAYS make sure the motor and other electrical components are appropriate and properly configured for your intended use and your available power source Testing Screens are nor mally wired for 115V 60Hz and come with a 1 2 HP motor The standard motor is not explo sion proo
3. ROD ASSEMBLY Clamp rod Upper guide bearing screw S Collar amp Pin wN Hard steel wearing plate w gt Lower threaded block Lower threaded block screw Lower guide bearing assy lM E TS 1 HYDRAULIC SYSTEM The TS 1 hydraulic clamping system consists of a low pressure hydraulic pump two hydraulic cyl inders and two hydraulic clamp rod assemblies The system uses a medium viscosity hydraulic oil such as Shell Tellus 25 or Mobil AW 32 WARNING Disconnect the Testing Screen from its power source and lock out the connection prior to performing maintenance and or repairs Page 9 Gilson Company Inc 1 Checking the oil To determine the level and quality of the hydraulic oil a Unplug or otherwise disconnect the Testing Screen from its power source and lock out the connection Release the pressure in the system by pull ing the pump handle all the way toward the front of the machine Remove the 5screws that secure the external pump cover to the top and lift the cover off Observe the position of the internal pump cover its vent is slightly closer to the front handle end of the pump than to the back Remove the internal pump cover and set it aside carefully so that you will know how to reinstall it later The reservoir should be filled to a quarter inch from the top and the oil should appear clean If oil is clean but low fill tank to correc
4. to protect the threads while leveling Use lock nuts unless you plan to otherwise lock the nuts in position INITIALLY levelthe Testing Screen s outercase both front to back and side to side Do this by placing and or removing metal shims under the feet until the top of the machine is level along all four edges The Testing Screen must be level for proper test results and best operation of the machine Keep shimming to a minimum If you cannot level the Testing Screen without excessive shimming either relocate the machine to a level foundation or otherwise provide a more level foundation so that shimming can be reduced Page 4 TS 1 amp TS 2 Testing Screens F Draw mounting nuts down equally on all four feet G H of the machine making sure the machine case remains level Finally level the internal separator unit 1 Insert a screen tray into the third screen tray position from thetop of separator leaving one third of its length extended out of the front of the machine If there are already trays in the Testing Screen TS 1 Pull handle on hydraulic pump all the way toward the front of the machine to release hydraulic clamping force Remove top two screen trays fully and the third screen tray one third of the way or TS 2 Turn the manual screw type clamp rods counterclockwise to release clamping force and remove the top two screen trays fully and the third screen tray one third of the way 2 Ap
5. vvasher Corner spring cup vvasher 2 TS 2 STANDARD CLAMP ROD ASSEMBLY V belt Drive pulley Driving Parts Drive pulley main shaft 5 or 5 3 4 O D Drive pulley special 8 O D Motor pulley 2 O D Motor pulley special V belt 29 30 35 On Off Overload switch Motor 1 2 HP 115V 60Hz single phase Motor mounting bolt washers Lower threaded block Lower threaded block screw Lower guide Motor pulley bearing assy Pulleys originally supplied with Serial No 2287 amp lower are currently listed as special Several sizes of pulleys amp V belts are currently in use Replacement orders should specify belt lengths amp pulley O D s Page 16 Gilson Company Inc TS 1 amp TS 2 Testing Screens VII Repair Parts 8 Diagrams Continued Screen Tray complete vvith vvire cloth 4 to No 4 inclusive steel vvire No 5 to No 14 inclusive No 16 to No 100 vvith support bars No 200 vvith support bars Special cloth over 4 openings steel Punched steel plates with round openings see list of stock sizes below Tyler Standard Coarse Series Dust pan tray Replacement Wire Cloth Sections 4 to No 4 steel No 5 to No 14 No 16 to No 100 No 200 Special cloth over 4 openings steel Punched steel plates with round openings Tyler Standard Coarse Series stainless steel Supporting backup cloth optional Screen Tray Parts Screen tr
6. amp rod can be moved more than 1 32 in any direction you should replace parts in the hydraulic clamp rod assembly To replace hydraulic clamp rods and parts 1 Unplug or otherwise disconnect the Testing Screen from its power source and lock out the connection 2 If you have not done so drain the system and disassemble and remove the cylinder following the procedure in Section 4 3 Working through the access hole near the base of the machine drive the roll pin out of the clamp rod collar Slide the clamp rod collar down to rest on the lower guide bearing 4 Loosen the upper and lower guide bear ing screws 5 Pull the clamp rod up and out of the separator 6 Replace the worn parts as needed 7 To reassemble reverse the procedure except do not re tighten the guide bearing screws Follow hydraulic cylinder reassem bly instructions Now finger tighten upper and lower guide bearing screws then give each an additional 360 tightening with a wrench Front and rear screws on each bearing need to be equally tight If screws repeatedly loosen during operation use a little Loctite 8 After fully reassembling the unit with cov ers installed run it empty for a few minutes It should run freely and quietly Gilson Company Inc F VVIRE CLOTH AND SCREEN TRAYS Check condition of wire cloth and screen trays both before and after each operation 1 WIRE CLOTH Testing grade wire cloth is a precision made mat
7. ar safety glasses protective clothing and hearing protection Wear approved NIOSH MSHA respirator as required by the sample to prevent inhaling any dust which may be considered hazardous Page 2 Gilson Company Inc TS 1 8 TS 2 Testing Screens Gilson Testing Screen The Gilson Testing Screen is the industry standard for quality control of construction materials testing a necessity for busy testing laboratories Il Uncrating Instructions IMPORTANT Check your Testing Screen for damage immediately upon receipt Examine the shipping carton before uncrating then inspect the machine and trays prior to removal from the skid Pay particular attention to the covers on top of the Testing Screen If any damage is noted STOP HERE and notify the freight carrier to request an inspection This inspection must include a check for internal damageto motor drive andclamping mechanisms Follow the procedures in Section V Maintenance to remove and reinstall covers Save all packing materials until inspection is complete The Testing Screen will weigh between 360 Ib 163kg without trays and 600 Ib 272kg with trays when you receive it Use equipment adequate to handle this weight safely since you will be lifting it to remove it from its skids and to shim it during installation A Lift the carton off the Testing Screen Set it aside in case you need to return the machine because of shipping damage Locate the volt ag
8. ate with your fingers or needle nose pliers and pull it up through the hole If the plate is worn replace it 1 Drop the plate through the large clamp rod hole 2 Use a screwdriver to position wearing plate so that the holes line up g If you are replacing only the clamp rod remove parts from the old clamp rod 1 With a 3 16 drift punch drive the roll pin out of the collar 2 Remove collar and upper guide bearing from the clamp rod 3 Install parts on new clamp rod h Ifyou are replacing the lower guide bearing do so now leaving the screws loose i Ifthe threads on the lower end of clamp rod are stripped replace lower threaded block Leave the screws loose j Reinsertthe clamp rod and turn it clockwise until the upper guide bearing rests on the top ofthe machine Install upper guide bearings leaving screws loose Crescent washer goes between the head of the screw and the top of the bearing Tighten lower threaded block screws Finger tighten upper and lower guide bearing screws then give each a 360 tight ening with a wrench Front and rear screws on each bearing need to be equally tight If screws repeatedly loosen during operation use a little Loctite k Reassemble in reverse order Do not plug in or try to operate the Testing Screen without all covers installed Run empty for a few minutes to be sure the machine runs freely and quietly TS 1 amp TS 2 Testing Screens TS 2 STANDARD CLAMP
9. ave scoredthe cast aluminum plunger bore This wear condition can not be re paired and the pump must be replaced To remove the plunger and replace O rings a Remove the pump handle retainer pin and the two plunger guide screws b Pull and removethe plunger and O ring assembly c Replace the O rings Dip the O ring end of the plunger in hydraulic oil and reinsert it into pump body Reassemble the Testing Screen by re versing the disassembly process Reinstall all covers Do not plug in or try to operate the Testing Screen without all covers in stalled 4 Hydraulic cylinder inspection and repair The hydraulic cylinders apply force to the clamp rods which draw the separator parts together If your machine losesclamping pressure during operation and or if you frequently need to add hydraulic oil inspect the hydraulic cylinders for wear Page 12 TS 1 amp TS 2 Testing Screens CAUTION When working with the hydraulic cylinders take care not to score surfaces where seals must be maintained WARNING Disconnect the Testing Screen from its power source and lock out the connection prior to performing maintenance and or repairs a To inspect the cylinders for wear 1 NOTE Unplug or othervvise disconnect the Testing Screen from its povver source and loch out the connection Drain the hydraulic system follovving the instructions in Section 2 Refertothe hydraulic cylinder diagram The s
10. ay complete for flat wire cloth no wire cloth Screen tray complete for hook wire cloth no wire cloth Tray side clamps flat wire cloth 2 Tray side clamps hook edge wire cloth 2 Tray end clamps 2 Tray rubber corner gaskets 4 Tray bolts with nuts amp washers 10 Front tray baffle Wire cloth support strip insert 5 max per tray Wire cloth and punched plates are Testing Grade and conform to applicable ASTM amp AASHTO speci fication standards Sizes of round openings in punched steel plates regularly carried in stock 4 3 1 2 3 2 1 2 2 1 4 1 3 4 1 1 2 1 3 8 1 1 4 1 7 8 3 4 5 8 1 2 3 8 5 16 1 4 3 16 1 8 All have non perforated border amp no partial openings Page 17 Gilson Company Inc TS 1 8 TS 2 Testing Screens VII Repair Parts 8 Diagrams Continued Hydraulic Cylinder Assembly complete NI NOOR WD 8 9 10 11 12 13 14 15 Page 18 S Hydraulic Cylinder Cap Hydraulic Cylinder Spring Clamp Rod Hex Jam Nut Hydraulic Cylinder Piston NI Hydraulic Cylinder Quad Ring Set Cylinder Cap Screw Cylinder and Base Sub Assembly Cylinder O Ring Hydraulic Clamp Rod Assembly complete Hydraulic Upper Guide Bearing Screw Hydraulic Upper Guide Bearing Hydraulic Upper Guide Bearing Sleeve Hydraulic Clamp Rod with Collar amp Pin Lower Frame Plate Lower Frame Plate Screw Hydraulic Lower Guide Bearing Hydraulic Lower Guide Bear
11. d bearings or the wrist pin assembly Refer to section on drive assembly maintenance B TESTING SCREEN SHUTS OFF If either the Testing Screen or its motor is over loaded a circuit breaker in the switch could dis Page 14 TS 1 amp TS 2 Testing Screens connect If the machine stops during a test check the switch If the red button extends halfway out the circuit breaker has tripped Check to see that you have sufficient voltage to the machine Ifso check to see if your sample is too large To reset push the red button all the way in and push the green button to restart SHIFTING OF MATERIALS An imbalance or out of level vibration can cause shifting of material to the sides or corners of trays decreasing screening efficiency Such shifting is likely to be intermittent especially on a new screen Run the machine empty for half an hour before making drastic changes the problem may disappear of its own accord If shifting persists check the foundation to be sure that all mounting bolts are equally tight Check also the bottom to case bolts Tighten mounting bolts on the side to which material is moving Loosen the opposite side slightly Look for bent tray edges and material trapped between vibrating sections Worn guide bearings wristpins and or connecting rods also cause shift ing of material Refer to sections on maintenance of those parts Sample material will also shift if the unit is not properly l
12. dard Testing Screens are driven by a 115V 60Hz 1 2 HP electric motor requiring 12 to 15 Amps to operate A dedicated 20 Amp circuit is recommended Machines with model numbers ending in F are configured to operate on 230V 50Hz 1 Locate the voltage label on the back of the Testing Screen and check to be sure that the machine is wired as ordered 2 Make sure your electrical power source is of a like configuration 3 Make sure the Testing Screen and your electrical power source are properly grounded 4 Makesure the switch located on right vertical surface of the top cover is in the OFF posi tion GREEN button OUT RED button IN lll Operating Instructions Read and understand all of the safety and operating instructions and sample capacity information in this manual before operating the Testing Screen These instructions cover operation of the Testing Screen not performance of any test Your Testing Screen operates on electric current Follow appropriate safety precautions A Locate the Testing Screen s power switch which is found on the right vertical surface of the top cover The machine is turned ON by pushing the GREEN button and turned OFF by pushing the RED but ton Make sure that the switch is in the OFF position GREEN button OUT RED button IN Plug your Testing Screen sthree pronged plug into a properly grounded power source or otherwise properly ground your Testing Screen Page 5
13. e and Coarse Aggregates calls for maximum screen loadings for 14 3 4 x 22 3 4 375x578mm clear screen areas as follows Nominal Maximum Maximum Screen Loadings Size of Particle Ib kg No 4 4 75mm 5 7 2 6 3 8 9 5 mm 11 2 5 1 1 2 12 5 mm 14 8 6 7 3 4 19 0 mm 22 5 10 2 1 0 25 0 mm 29 8 13 5 1 5 37 5 mm 44 5 20 2 2 0 50 0 mm 59 5 27 0 2 5 63 0 mm 75 0 34 0 3 0 75 0 mm 89 3 40 5 3 5 90 0 mm 106 9 48 5 4 0 100 0 mm 118 8 53 9 5 0 125 0 mm 148 6 67 4 Maximum screen loading for materials denser than limestone aggregates should be adjusted accordingly Samples can be run in two or more batches if necessary The capacity of the screen for a given sample is determined by the sample in the tray with the maximum load Acoarse series size tray at completion of sieving should carry a load limit equal to the amount of material needed for one layer of particles over the wire cloth area If all tray slots are not required for a test an in termediate tray may be used to relieve loading Page 6 TS 1 amp TS 2 Testing Screens on a critical tray and allow the use of a larger test sample Capacity is a function of volume Materials such as lightweight aggregate or coal must be tested in somewhat larger amounts by weight Many light materials are also soft Their test times should be limited to avoid degradation of the sample If you get poor separation or loss of material from th
14. e label on the back of the Testing Screen and check to be sure that the machine is wired as ordered B If you have a TS 1 Hydraulic Testing Screen remove the 5 screws that secure the external pump cover to the top Lift the cover off and look for oil leaks Report any leaks found to Gilson If none reinstall cover and proceed C Release clamping pressure on the screen trays 1 If you have a TS 1 Hydraulic Testing Screen pull the hydraulic pump handle all the way toward the front of the machine 2 If you have a TS 2 Standard Testing Screen turn the clamp rods counterclockwise D Remove screen trays by sliding them out the front of the machine Be prepared to handle the weight of the trays Removing the trays will reduce the weight of the machine to about 360 Ib 163kg E Use proper equipmentto liftthe machine about six inches off the floor Securely block up machine so that you can safely remove skids After removing the skids setthe machine onto the floor Set aside skids nuts and bolts in case you need them G Check all screws nuts and bolts to make sure they are not loose ll Installation Instructions IMPORTANT Read and understand all safety and installation instructions in this manual BEFORE you begin installing the Testing Screen CAUTION DO NOT connect the Testing Screen to an electrical power source until you have mounted the machine to its intended foundation verified that the machine is wi
15. e trays should first check the amount of sample onthe individual screen tray and adjustthe sample size accordingly Diagnosis should then proceed to checking for proper leveling and looking for worn broken or out of adjustment components as described in Section V Maintenance Remember that the ASTM minimum sample weights are for representative samples Initial sampling should always be done by taking a much larger amount from several areas in a storage bin or stockpile then combining and reducing the amount to a manageable size by splitting Gilson Sample Splitters are ideal for this purpose FINE AGGREGATES The Testing Screen is designed primarily for operation in the coarse size range of 4 to No 4 Separation of finer materials is less efficient and fine particles may become trapped behind side liners of trays causing test errors For separations of fine aggregates from No 8 through No 200 loading at completion of sieving should be limited to the ASTM C 136 level of 4 grams per square inch of sieving surface assuming a material about the density of sand This is equivalent to loading 1350 grams 3 Ib per tray and will result in ma chine capacity in the fine aggregate range of under 20 Ib per test unless sizes are evenly distributed among the trays Somewhat larger amounts of material may be loaded if the Testing Screen is used for mass separation rather than for testing Sharpness of separation will decrease as loading is
16. erial and should be treated with care 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 the wire cloth to be out of specification to a considerable de gree before it appears so Check the wire cloth periodically for conformance to specifications Wire cloth may eventually sag reducing its effective screening area Wire with 1 4 and coarser openings is rigid and self support ing No 5 and finer sizes have hooked edges which interlock with the tray s side clamps to provide tension adjustment Trays with No 16 and finer wire cloth have wire cloth support strips to minimize wear and distortion Backup wire cloth can be furnished as an option at extra cost if additional support is desired Tray side clamps for hooked edge wire and flat wire are not interchangeable 2 SCREEN TRAYS The life of yourscreentrayscan 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 VI Operating Problems WARNING Disconnect the machine from its power source and lock out the connection prior to performing maintenance and or repairs A NOISY OPERATION Loud knocking during operation often indicates worn connecting rods ro
17. ervoir Oil is taken in here when the pump plunger is pulled outward from the pump casting If oil leaks from this intake hole when the pump plunger moves back into the pump casting then the intake check ball is not seating prop 0 qe De Gilson Company Inc erly Remove the intake check ball Clean it and its seat in the pump casting Also check the ball for nicks or other damage and replace it if necessary 3 Ifthe pump handle creeps back toward the pump casting after you have pumped oil into the cylinders oil is probably leaking back into the pump through the pressure check thrust pin and O ring assembly Dirt or other foreign material can prevent the O ring from seating properly Remove and clean thrust pin O ring and cavity in pump to remove foreign matter Also check O ring for nicks or other damage and replace the O ring if necessary If the pump handle actually flies toward the pump casting then O ring is usually torn and you should replace the assembly 4 The pressure release hole is in the bot tom of the well directly behind the center post Oil normally returns to the reser voir through this hole when the handle is pulled all the way back to release clamp ing pressure If oil returns through this hole during pump up the problem is with the pressure release pin or the pressure release thrust pin and O ring If the Plunger O rings have been allowed to wear excessively the hard steel plunger may h
18. esting Screen from its power source and lock out the connection Remove top and side back covers following Maintenance Procedure B c Loosen the motor mounting bolts To adjust tension in the V belt check first to see that the pulleys are aligned Then position the motor to obtain the proper tension in the V belt Tighten the motor mounting bolts To replace the V belt loosen the motor mounting bolts and slide the motor to ward the front of the machine which will disengage the belt from the motor pulley Before removing the shoulder bolt from the lower end of the connecting rod on the belt side of the Testing Screen insert a pry bar under the front of the case top and over the top ofthe separator Shiftthe separator until the holes in the separator and in connecting rod align Now remove the shoulder bolt Afterremoving the shoulder bolt rotate con necting rod upward until you can remove the belt Place the new V belt around the connecting rod in the reverse manner Replace the shoulder bolt Place the V belt around the pulleys Make sure the pulleys are aligned Move the motor toward the rear of machine until the proper tension exists in the V belt Tighten motor mounting bolts Reassemble in reverse order Do not plug in or try to operate the Testing Screen without all covers installed 2 CONNECTING ROD ASSEMBLY Gilson recom mends replacing entire connecting rod a
19. evelled The internal vibrating assembly will not work properly in a machine that is out of level Levelling procedure is explained in the section on installation If the case is seriously out of level compared to the vibrating assembly look for worn or misaligned parts SLUGGISH START UP OR OPERATION Check loads on sample trays and total sample weights Review Section IV Sample Capacity Inspect V belts for wear tension and alignment Check pulleys for alignment Review Section V Maintenance Item C Drive Assembly Gilson Company Inc TS 1 8 TS 2 Testing Screens VII Repair Parts 8 Diagrams Always provide us with the serial number of your Testing Screen when you order repair parts Main Drive Housing Assembly Main shaft bearing Main shaft housing Main shaft o a a P Main shaft bearing Main Drive Housing Assembl Main shaft housing Housing bracket bolts 1 2 x1 3 Main shaft Main shaft special low amplitude Main shaft key Les di Main shaft bearings 2 Rod bearing i and inner race b Va Connecting rod r h Rod bearing and inner race Housing bracket bolts 4 o Cap screws and N lock washers Rod bearing Rod I h Cap screws and cap lock washers Connecting Rod Assembly including rod bearing cap screws amp washers Connecting rod 1 each r h amp I h Connecting rod bearings 2 Connecting rod bearing caps 2 Connecting Rods am
20. f ALWAYS check electrical wiring for loose connections and for pinched or frayed wires ALWAYS ground the Testing Screen Connect the three pronged plug to a properly wired three pronged grounded receptacle with appropriate electrical current for the machine or otherwise properly ground your Testing Screen and connect it to a properly grounded power source ALWAYS disconnect and lock out the power supply before performing maintenance or repairs on your Testing Screen DANGER Do not use the Testing Screen in an explosive or hazardous atmosphere It is NOT ex plosion proof or approved for operation in hazardous locations Before using a Testing Screen in your operation make sure it is appropriately designed for your application WARNINGS 1 Operate only in properly ventilated area 2 Your Testing Screen is not counterbalanced It must be adequately mounted to a substantial rigid foundation preferably a poured concrete floor Otherwise the machine will vibrate excessively and move around Level the Testing Screen following the procedure outlined in the installation instructions prior to operation Stop the Testing Screen immediately if excessive vibration or machine movement occurs Do not operate the Testing Screen without all guards and covers in place Keep all parts of your body away from moving parts of the machine while it is operating Do not wear loose clothing which might be caught in moving parts of the machine We
21. increased and overloads can cause damage to valuable wire cloth For applications where test materials are limited to fine series sizes or where special screening problems exist because of softness or density the Testing Screen may be factory equipped with a Speed Variation Accessory A low amplitude ec centric shaft is also available and recommended when working exclusively with friable materials Since most test specifications require no more than several hundred grams of sample for fine aggregates using 8 round sieves is sufficient A Gilson Sand Attachment Accessory for round Gilson Company Inc TS 1 amp TS 2 Testing Screens sieves is available for the Testing Screen It pro vides an inexpensive method when occasional tests in the fine series range are required If fine series tests are made on a routine basis use equipment that is specifically designed for fine a materials Gilson offers a complete line of sieve shakers for this purpose 3 Lubricate the following parts on a regular basis but not as often as the wrist pin as semblies Upper connecting rod bearings Access holes in front of top cover b Lower threaded blocks TS 2 Thecapacity of the Gilson Testing Screenis suitable Access panels on sides of machine case for most laboratory test sizing work For field labo ratories where mobility is important Gilson offers a Porta Screen For large scale mass separation jobs involving hundreds of pound
22. ing Screw Hydraulic Lower Guide Bearing Stop Nut Set of Hydraulic Hoses amp Fittings complete S N 13824 and lower Hydraulic Hose 20 for motor side Hydraulic Hose 10 Hose Clip amp Screw for motor side Hose Fitting Only 13825 and higher Hydraulic Hose 20 Hose Clip and Screw Hose Fitting Gilson Company Inc VII Repair Parts 8 Diagrams Continued Hydraulic Pump complete 17 18 19 20 21 22 23 24 25 26 27 Pump Handle Knob Pump Handle Pump Handle Connecting Link Stroke Limiting Spring Stroke Limiting Washer Plunger Guide amp Seal Plunger Guide Screw Plunger Plunger O Ring Pump Handle Spring Retainer Pin Pump Handle Hinge Pin with Cotter Pump Cover Assembly Pump Cover Screw Pump Cover Gasket Pressure Release Plug 3 8 Pressure Release Spring TS 1 amp TS 2 Testing Screens 37 Pressure Release Thrust Pin w O ring 38 Pressure Release Pin 39 Port Plug 1 8 in Pump Body 40 Pressure Check Plug 1 8 in Pump Body 41 Pressure Check Spring 42 Intake Check Plug 1 8 In Pump Body 43 Intake Check Spring 44 Intake Check Ball 45 Pressure Check Thrust Pin with O Ring Not Shown Pump Mounting Screw With Nut and Washer Hydraulic Oil 1 2 pint can Hydraulic Pump Repair Kit No 1 includes part numbers 25 37 39 40 42 45 Hydraulic Pump Repair Kit No 2 includes part numbers 22 25 35 45 Gilson Company Inc TS 1 8 TS 2 Testing Screens VII Repa
23. ir Parts 8 Diagrams Continued Corner Spring Assembly 4 required Cup washer Cup washer Spring Flat washer
24. ling with oil h Ifrepairsareto be made continue disassembly as described below in Section 3 Step C If youare only replacing hydraulic oil continue to the next step i Reconnect the hose to the cylinder j Fillthe pumpreservoirto within 1 4 ofthe top Replace the pump cover in the same direction as it was before you moved it Pump up pres sure with short strokes on the pump handle Release pressure by pulling the handle all the way toward the front of the machine k Remove the pump cover and add hydraulic oil to fill pump reservoir to within 1 4 of the top again Replace cover again in the proper position and tighten down the mounting screws m Bleed the air out of the hydraulic system 1 Loosenthe connections between the hoses andthe cylinders by unscrewing the swivel connections slightly 2 Pump up the hydraulic system just until oil appears at the loosened connections 3 Retighten the swivel connections n If the fittings leak use hydraulic joint com pound to create a seal between each leaky fitting and the pump or cylinder to which it is attached o Reinstall covers Do not plug in or try to operate the Testing Screen without all cov ers installed 3 Hydraulic pump The hydraulic pump is a low pressure pump with acast aluminum body If your pump leaks or malfunctions especially if the machine is old or heavily used we strongly recommend that you return it to the factory for repair a
25. p Bearings Connecting rod bearing cap screws amp lock washers 3 per cap Sold separately Wristpin shoulder bolt 5 8 x2 2 Wristpin sleeve retaining washer 2 Wristpin sleeve 2 Rod bearing ba Rod bearing and inner race Main shaft bearing and inner race Wristpin shoulder bolt cox l Wristpin Nevvristpin sleeve Wristpin Wristpin sleeve shoulder bolt retaining washer sleeve retaining washer Wristpin sleeve DA A These parts not included with Connecting Rods or Connecting Rod Assemblies Gilson Company Inc TS 1 amp TS 2 Testing Screens Vil Repair Parts amp Diagrams Continued Always provide us with the serial number of your Testing Screen when you order repair parts Clamp Rod Assembly for Model TS 2 2 required Clamp rod with upper guide bearing collar amp pin Clamp rod with collar amp pin Collar amp pin only Upper guide bearing Upper guide bearing screws 3 8 x3 4 2 Lower threaded block Lower threaded block screws 3 8 x5 8 2 Clamp rod Lower guide bearing Lower guide bearing screws 3 8 x1 1 4 2 Upper guide bearing Lower guide bearing stop nut 3 8 2 screw Hard steel wearing plate Lower guide bearing dust guard standard NS Corner Spring Assembly 4 required not pictured c i Collar amp Pin orner spring I Corner spring bolt 1 2 x6 1 2 wN Hard steel wearing plate BD Corner spring stop nut 1 2 Corner spring flat
26. period of time Your choice will depend on the nature and characteristics of your sample and on the requirements of your test If yourtest requires complete separation watch the test progress through the top of the Testing Screen To determine whether material is still passing through a fine mesh screen insert the clean dust pan tray directly below the screen tray in question Separation is complete when no particles fall into the tray Ifthe Testing Screen or the motor is overloaded a circuit breaker in the switch could disconnect the power If the machine stops in the middle Gilson Company Inc of a test check the switch If the RED button is halfway out the circuit breaker has tripped Determine the cause of the overload andcorrect it To restart push the RED button all the way in and then push the GREEN button G Turn off machine by pushing the RED button and unload the various screentrays and dust pan Loaded screen trays are not as light as they may appear Use common sense and proper equipment Unless you plan to continue operating the Test ing Screen unplug or disconnect it as this will eliminate a tripping hazard and reduce electrical hazards IV Sample Capacity A COARSE AGGREGATES The quantity of sample to be loadedis established by test specifications and depends greatly on the type of material and its particle size range The ASTM C 136 specification for Sieve or Screen Analysis of Fin
27. plug or otherwise disconnect the Testing Screen from its power source and lock out the connection Remove top and side back covers following Maintenance Procedure B b Check forworn guide bearings and orthreaded blocks by pushing the clamp rods back to front and side to side If the clamp rods move more than 1 32 in any direction the guide bearings need to be replaced c Remove screen trays and from inside the machine examine the threaded sections of the clamp rods If the threads are stripped replace the lower threaded blocks as well as the clamp rods 2 Allparts ofthe TS 2 mechanical clamping sys tem are available for replacement as individual items or as assemblies e g Clamp Rod with Upper Guide Bearing Collar and Pin They are pre assembled for easy installation Gilson Company Inc To replace clamp rod or clamp rod assembly a Unplug or otherwise disconnect the Testing Screen from its power source and lock out the connection Remove top and side back covers following Maintenance Procedure B b Remove upper guide bearing screws c Loosen the screws in lower guide bearing d Loosen the screws in the lower threaded block e Turn the clamp rod counterclockwise until you can pull it up and out of the machine f Remove and inspect the hardened steel wearing plate which rests on the upper separator frame Use a magnet to lift one end of the wear plate to the large clamp rod hole Grip the wear pl
28. plyclamping forceto hold remaining screen trays including the screen tray that extends from the front of the Testing Screen TS 1 Apply short strokes to the hydraulic pump handle or TS 2 Turn the tvvo clamp rods simultaneously and as equally as possible using your sense oftouch to determine when the trays are firmly clamped 3 Using a level on the protruding screen tray re level Testing Screen by adding or removing shims until the separator and screen tray are level side to side and front to back Give mounting nuts a final tightening 4 Release clamping pressure and put desired screen trays into the machine If you have a TS 1 Hydraulic Testing Screen examine and test the hydraulic system for leaks Remove the 5 screvvs that secure the external pump cover to the top and lift the cover off Observe the position of the internal pump cover its vent is slightly closer to the front handle end of the pump than to the back With hydraulic clamping pressure released remove the internal pump cover setting it aside carefully so that you will know how to reinstall it later Check the oil level Gilson Company Inc in the pump It should be 1 4 from the top of the reservoir If not refer to instructions for replacing hydraulic oil When you are finished reinstall the external pump cover I Check electrical wiring of your Testing Screen to make sure it is wired as ordered and is appropriate for your power source Stan
29. pring is compressed inside the cylinder by thecap so caution is required Keep pressure on the cap with your hand as you remove the three screws Release the pressure of your hand slowly so that the compressed spring does not pop out suddenly Remove cap and spring Remove the side access panel near machine s base Grasp lower section of hydraulic clamp rod with vice grips and hold it steady while unscrewing the clamp rod hex jam nut Now pull the rest of the cylinder up and off the clamp rod Examine the piston and the two quad rings one fits in a groove on the piston flange and the other fits inside the piston Replace quad rings if you find hydraulic oil above the flange on the piston It should not be necessary to disassemble the cylinder from its base only very rarely will a cylinder O ring need replacement In this case use a 3 16 drift punch to drive each of the roll pins through to the center hole until they fall out Remove the old O ring Apply a little hydraulic oil to the new O ring and install it Reassemble If you plan to work on the hydraulic clamp rod assembly do so now using the instruc tions in the next section To reassemble the unit Slide the cylinder and base assembly onto the upper end of the hydraulic clamp rod Dip the piston in hydraulic oil to lubricate the quad rings Insert the piston into the cylinder Gilson Company Inc 4 Install the jam n
30. red as ordered and is appropriate for your power source The Gilson Testing Screen is a ruggedly con structed machine that will provide years of service if installed correctly and maintained properly Most cases of poor operation are caused by faulty instal lation You can avoid problems by careful planning prior to placing your new unit into service A In locating the machine for operation you should consider the following 1 Noise and dust caused by the Testing Screen 2 Adequate ventilation and a nonexplosive atmo sphere 3 Adequate space around all sides of the machine for operation and maintenance 4 Location and accessibility of your power sup ply 5 A level substantial rigid foundation for instal lation Gilson recommends installation on a level poured concrete floor 6 Desired elevation you may want an elevated foundation for the machine for easier tray han dling However this also elevates the loading area Page 3 Gilson Company Inc B Provide 0 5 diameter anchor bolts or other mounting bolts set on centers of 20 5 and 32 as shovvn on Foundation Plan Leave about 1 5 of thread to allovv for the foot and leveling shims FOUNDATION PLAN FOR GILSON TESTING SCREEN Using proper and adequate equipment safely and securely place the Testing Screen onto the fouranchor bolts so thatthethreaded ends extend through the holes in the feet Place mounting nuts on the anchor bolts
31. s of material and for automated testing use the Gilso Matic See a Gilson Catalog for further information B REMOVAL OF TOP AND SIDE BACK COVERS Use this procedure whenever you need to re move the covers for repair or maintenance of your Testing Screen WARNING Disconnect the machine from its power source and lock out the connection prior to performing maintenance and or repairs V Maintenance 1 TS 1 Hydraulic Testing Screen Unscrew the knob on the pump handle Remove the 13 screws that secure the top cover and lift IMPORTANT The person performing maintenance and or repairs on the Testing Screen is responsible for safety and is required to read and understand the safety instructions in this manual prior to commencing work All shields guards and other safety devices must be properly replaced and secured upon completion of work Only parts supplied and or approved by Gilson are acceptable this cover off Reinstall the knob 2 TS 2 Standard Testing Screen Turntheclamp rodhandles so they point sideways and away from the machine Remove the 13 screws that secure the top cover and lift this cover off for use on the machine 3 Loosen or remove the 5 screws that secure the side back cover and pivot that section toward the back of the machine allowing it to be supported by the motor wire Most sample dusts are abrasive by nature Daily lubri cation and cleaning of the Testing Screen takes onl
32. ssem blies to avoid fit and tolerance problems during installation Use the following procedure a b Unplug or otherwise disconnect the Testing Screen fromits power source and lock outthe connection Remove top and side back cov ers following Maintenance ProcedureB If you are working on a TS 1 first remove the Page 8 TS 1 8 TS 2 Testing Screens hydraulic cylinder Follovvthe instructionsin the section on hydraulic cylinder inspection and repair c Insert a pry bar under the front of the case top and on top of the separator front and shift the separator until the holes in the separator and in connecting rod align d Remove the wristpin shoulder bolt and remove the connecting rod e Reverse this procedure to reinstall the assembly Do not take apart or remove the main shaft housing assembly which is installed using factory fixtures Ifthis assembly is moved out of its position the Testing Screen s internal vibrating assembly will go out of level You will not get proper test results The main shaft bearings are sealed and do not require lubrication D TS 2 CLAMP ROD ASSEMBLY The TS 2 has a threaded mechanical clamping system Continuous overtightening of the clamp rods can cause premature wearing Maintenance procedures for TS 1 Clamping Assemblies are noted under TS 1 Hydraulic Sys tem Section E 1 Periodically check your clamp rod assemblies for wear by following these steps a Un
33. t level and reassemble If oil appears dirty first replace the internal pump cover Then drain and refillthe system following the procedure in Section 2 below beginning with Step C 2 To drain and refill the hydraulic system a Unplug or otherwise disconnect the Testing Screen from its power source and lock out the connection Cleanthe top ofthe TS 1 so you have a clean environment to prevent foreign materials from contaminating the oil Release the system pressure by pulling the pump handle all the vvay tovvard the front of the machine If you are continuing from checking the oil and have removed the ex ternal pump cover leave it off Remove top and side back covers following Maintenance Procedure B Disconnect the hose from one of the hy draulic cylinders leaving the other end of the hose connected to the pump Place the free end of the hose into a clean container at a level that will allow gravity to empty the system Pump the handle carefully to drain the hydraulic oil from the system Page 10 TS 1 amp TS 2 Testing Screens f Observe the position of the pump cover its vent is slightly closer to the front handle end of the pump than to the back Remove pump cover and set it aside carefully so that you will know how to reinstall it later g If there is sludge in the bottom of the pump reservoir remove the pump from the ma chine and clean it out with solvent before refil
34. three to five day process or purchase a new pump Call for instructions Gilson Company Inc It is sometimes possible to repair pumps in the field by replacing parts We do not recommend field repair unless you have experience in work ing with hydraulics Refer to the guidelines d below and the diagrams and parts list at the back of this manual The various springs in the pumpare NOT interchangeable When working with the hydraulic pump take care not to score TS 1 amp TS 2 Testing Screens reinstalled Balls must NOT be nicked or scratched Clean pump and parts and dry thoroughly before reassembly To reinstall balls tap them gently into their seated positions with a soft metal blunt ended rod surfaces where seals must be maintained IMPORTANT Do not remove or adjust the bypass assembly These parts are assembled and preset WARNING Disconnect the Testing Screen from its power source and lock out the connection prior to performing maintenance and or repairs FOLLOW THESE GENERAL INSTRUCTIONS when repairing the pump yourself a Unplug or otherwise disconnect the Testing Screen from its power source and lock out the connection b Drain the pump following the instructions set forth in Section 2 ALWAYS observe the position of the internal pump cover before you remove it Its vent is slightly closer to the front handle end of the pump than to the back When you remove the cover set it aside carefull
35. ut and tighten it 5 Insertspring place cap on spring and apply downward pressure on the cap 6 Insert screws and tighten them 7 Reattach hoses 8 Follow the pump refilling procedure de scribed in Section 2 Reinstall covers Do not plug in or try to op erate the Testing Screen without all covers installed HYDRAULIC CLAMP ROD ASSEMBLY Cylinder cap Spring nt Clamp rod hex jam nut lt gt Hydraulic cylinder piston 5 i Quad ring set anal LU Cylinder cap screws ___ Cylinder and base sub assembly Upper guide bearing screws P Upper guide bearing sleeve Lower frame plate Lower frame plate screw 8 Hydraulic clamp rod vvith collar 8 pin Lovver guide bearing screw Lower guide bearing SL ue mb Lower guide bearing nut Al Page 13 TS 1 amp TS 2 Testing Screens 5 Hydraulic clamp rod assembly Hydraulic clamp rods fit through a series of guide bearings and draw separator parts together to clamp trays in place for operation WARNING Disconnect the Testing Screen from its power source and lock out the connection prior to performing maintenance and or repairs To check for wear in the guide bearings apply pressure to the hydraulic cylinders with your hand front to back and side to side If you have removed a cylinder perform this test on the upper end of the hydraulic clamp rod If a cylinder or cl
36. y a few minutes and will greatly extend its service life and reduce down time C DRIVE ASSEMBLY WARNING Always unplug or disconnect the Testing WARNING Disconnect the machine from its power source and lock out the connection prior Screen fromits power supply and loc outthe connection before performing any maintenance or repairs to performing maintenance and or repairs A LUBRICATION Each Testing Screen is fully lubricated andtest run by the manufacturer before it is shipped However periodic lubrication is required 1 V BELT Periodically checkthe Testing Screen s V belt for wear tension and alignment The belt should be snug neither too tight nor too 1 Use a high quality grease to lubricate parts see dene cheneun ii listed below Wipe away excess grease and dirt from around parts after lubrication 2 Atleast daily lubricate the wrist pin assemblies at the lower ends of the connecting rods Access slot under front of top cover Aworn loose tight or misaligned V belt can adversely affect the operation of the Testing Screen A good fit assures longer life less bearing wear and quieter operation than a belt which istoo tight Aloose belt may cause the unit to run too slowly or to slip Page 7 Gilson Company Inc Reep the pulleys aligned to avoid excessive vvear on the belt To adjust or replace the V belt follovv this dis assembly procedure a Unplug or othervvise disconnect the T
37. y so that you will know how to reinstall It c Remove parts carefully so as not to dam age the pump casting or any parts to be HYDRAULIC PUMP ASSEMBLY Bypass Screw a sana D Renova or Adjust Ball O os fey y mn i Pressure Release Check Pressure Page 11 at the factory Any change in the bypass pressure can damage the TS 1 s vibrating assembly If the system fails to maintain clamping pres sure and if you find no oil leaking from the cylinder the failure may be caused by foreign material or dirt in the hydraulic pump There are often aluminum flecks in the hydraulic oil fromthe pumpcasting These are normally of little consequence in pump malfunctions To diagnose problems in the pump re move the internal pump cover and reduce the level of hydraulic oil Place a piece of clear plexiglas completely overthe reservoir opening and screw itin place Pump up the clamping pressure and observe where the oil is returning to the reservoir Here are four possibilities to look for when diagnosing hydraulic pump problems 1 Observe the holes on either side of the base of the center post Ifthe oil is return ing here there is a bypass problem DO NOT attempt to adjust or repair the pump in the field Return it to Gilson for repair or replacement 2 Viewing the pump from above and at the plunger end you will see the intake hole located on araised shelf onthe bottom left side of the res
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