CASTLE TSM-21 User manual

CASTLE INC PO BOX 750236 PETALUMA CA 94975
WWW.CASTLEUSA.COM
Diagnostic Manual
TSM-21 Pocket Hole Machine with Parker or Humphrey Solenoids
Serial numbers 61076 and above
CASTLE
,
INC.

Table of Contents
1 .............................................................................................................................4 INTRODUCTION
1.1 ........................................................................................................5 HOW TO USE THIS MANUAL
2 ...................................................................................................6 DRY CYCLE TESTING 21.95
2.1 ..................................................................................................................................6 PURPOSE
2.2 DRY TEST TSM-21...................................................................................................................6
3 DEFINITIONS .................................................................................................................................9
4 DIAGNOSTIC DESCRIPTIONS....................................................................................................11
4.1 CLAMP OPERATION..................................................................................................................11
4.2 ROUTER OPERATION................................................................................................................13
4.3 DRILL OPERATION....................................................................................................................15
4.4 OVERALL MACHINE OPERATION AND POCKET ADJUSTMENT.......................................................16
5 PROCEDURES.............................................................................................................................18
5.1 CLAMP FOOT PAD OR CYLINDER REPLACEMENT 21.01 ...........................................................18
5.2 UNCLOGGING THE CLAMP SOLENOID 21.10 ..........................................................................19
5.3 CLAMP SOLENOID CHECK 21.11 ........................................................................................21
5.4 CLAMP CYLINDER CHECK 21.12 .........................................................................................23
5.5 CLAMP EXHAUST CHECK 21.13............................................................................................24
5.7 ROUTER MOTOR OPERATION 21.20 ...................................................................................26
5.8 ADJUSTING THE WEB, ROUTER STOP PLATE 21.21 ...............................................................28
5.9 ROUTER STOP SWITCH (NC) 21.22 ....................................................................................29
5.10 UNCLOGGING THE ROUTER SOLENOID 21.30 ........................................................................31
5.11 ROUTER CHECK SOLENOID 21.31.......................................................................................32
5.12 ROUTER FEED RATE ADJUSTMENT 21.32 .............................................................................33
5.13 DRILL MOTOR OPERATION 21.40 .......................................................................................35
5.14 DRILL SETTINGS AND BIT DEPTH 21.41...............................................................................36
5.15 DRILL SINGLE COIL BAR SPRING 21.42...............................................................................38
2.3 MANUAL OVERRIDE OF SOLENIOIDS............................................................................................8
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5.21 PILOT HOLE ALIGNMENT 21.72...........................................................................................49
5.22 FOOT SWITCH (NO) 21.80................................................................................................50
5.23 RESETTING THE MACHINE 21.81........................................................................................52
5.24 SAFETY SWITCH/SAFETY BUTTONS (NO) 21.82.....................................................................52
5.25 TOOLING CHECK AND REPLACEMENT 21.83 .........................................................................54
5.26 AIR PRESSURE REGULATOR SETTING 21.90 ........................................................................56
5.27 REPLACING SOLENOID VALVES 21.91 .................................................................................57
5.28 ATTACHING AIR SUPPLY 21.92 ..........................................................................................60
6 APPENDIX A – MACHINE SAFETY 21.96.................................................................................61
6.1 GENERAL SAFETY RULES FOR MACHINE OPERATORS................................................................61
7 APPENDIX B – WIRING DIAGRAM 21.84 ................................................................................63
8 APPENDIX C – CONTROL BOX WORKS 21.93 .......................................................................64
9 APPENDIX D – SOLENOID, PNEUMATIC DIAGRAM 21.94 ......................................................65
10 APPENDIX E – INDEX .................................................................................................................66
5.16 21.43 .......................................................................................39
DRILL STOP SWITCH (NC)
5.17 UNCLOGGING THE DRILL SOLENOID 21.50 ...........................................................................41
5.18 21.51..........................................................................................43
DRILL SOLENOID CHECK
5.19 21.60..........................................................................................45
DRIVE CYLINDER CHECK
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5.20 21.61..........................................................48
EXHAUST MUFFLERS ON SOLENOID VALVES

1Introduction
Thank you for making the Castle TSM-21 Screw Pocket Machine a vital part of your shop. The
TSM-21 is designed for use on a wide variety of materials including hardwoods, softwoods,
melamine, particleboard and MDF.
This manual is intended for anyone working with, or performing maintenance or service on the
TSM-21.
If trouble occurs, in most cases one of the major components is either not starting its function
or not completing its function. This may lead to a skip or stall in the operational sequence.
Troubleshooting the TSM-21 is greatly aided by understanding the machine’s
operational sequence which occurs in this order:
1. The Clamp extends to secure the work piece
2. The Router creates the pocket then retracts
3. The Drill creates the Pilot screw Hole then retracts
4. The Clamp releases the work piece
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1.1 How to Use This Manual
1. Closely observe the behavior of the machine noting which component is involved and
when in the operational sequence the problem is occurring.
2. Go to Section IV-Diagnostic Descriptions, which is organized by the operational
sequence of the machine.
3. Find the description which most closely matches the problem and systematically perform
the Diagnostic Procedures listed, checking them off as you go.
Example:
Page Procedure
Clamp comes down as soon as air is attached…with Machine power OFF:
□Check clamp Solenoid for function or blockage 12-13 21.11
Note: If you are unsure of your observations or if the fault behaviour seems irregular you
should “Dry Cycle” test the machine. See Procedure 21.95, page 4.
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2 Dry Cycle Testing 21.95
2.1 Purpose
Dry Cycle testing allows observation of the TSM-21’s mechanical, electrical, and pneumatic
functions without routing pockets or drilling holes.
Caution: Careful observation is essential when troubleshooting or seeking Technical Support
2.2 Dry Test TSM-21
1.
2. Connect air and power to the machine. Turn the machine’s MAIN Power Switch ON.
3. Depress one of the Safety Buttons with a piece of scrap wood positioned out of the path
of both the router and drill bits. Position yourself to see both the Router and Drill bits
when they extend.
4. Press the Foot Pedal and observe the following actions in this order.
1. The Clamp extends to secure the scrap wood
2. The Router extends then retracts
3. The Drill extends then retracts
4. The Clamp releases the scrap wood
Total elapsed time should be approximately two seconds.
5. If the cycle does not begin, check the Air Supply, the Foot Switch, and the Safety
Switch: Procedures 21.92, 21.80 and 21.82
6. If the cycle stalls with the router extended or if the cycle skips over the router stroke
entirely, check the Router Stop Switch: Procedure 21.22
Locate the ON/OFF switches on the Router and Drill and turn them both off or uplug
the routers.
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•
•
•If the Dry Cycle is successful, but a regular cycle fails when routing actual pockets
and drilling holes, check the Tooling, the Motor Operation, and the Drive Cylinder:
Procedures 21.83, 21.20 and 21.60
If the cycle stalls with the drill extended or if the clamp starts to extend and then immediately
retracts, check the Drill Stop Switch: Procedure 21.43
If the complete cycle takes significantly longer than two seconds, check the Air
Supply, the Pressure Regulator, and the Router Feed Rate: Procedures 21.92, 21.90
and 21.32
Note: A normal cycle when cutting pockets should take approximately 2 seconds.
If the complete cycle takes significantly longer than two seconds, check the Air
Supply, the Pressure Regulator, and the Router Feed Rate: Procedures 21.92,
21.90 and 21.32
Note: For comprehensive diagnostic descriptions and procedures refer to Section IV.
After testing is complete, turn the MAIN Power Switch OFF and switch both motors back ON or
plug the routers back in to the outlet.
Note: If a dry cycle is preformed to confirm function of the switches and the router bit or
the drill bit stays extended, verify that the carriage plate is not hitting the front of the switch/
magnet. The carriage plate should land in between the switch and the magnet.
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2.3Manual Override on Solenoids
The solenoids can be manually overridden to allow air flow to the cylinder while air is
attached to the machine. This can also be used to flush air through the solenoid to remove
any moisture or debris. The manual override buttons are located on the end of the solenoids
opposite of the air ports. See Fig 1a and 1b.
2.3.1TO TEST SOLENOID FUNCTION AND FOR LEAKS:
1. Unplug the machine, but make sure air is attached.
2. From the rear access door, locate the stack of solenoids below the control box.
3. Depress the red button to allow air to flow through the solenoid to the cylinder to test for
function or listen for air leaks.
2.3.2 TO FLUSH THE SOLENOID:
1. Remove the air line out fitting and the exhaust muffler and press the override button for
several seconds. Air should flow through the solenoid. Reassemble and cut a test
pocket. See FIG. 1a and 1b.
Fig 1a
Fig 1b
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3 Definitions
Term Definition
Air Pressure
Regulator
Used to set the main operational speed of the machine. Factory set at
approximately 75 PSI. / approximately 6 full clockwise turns from stop.
Bar Spring Provides pressure to return the Motor Carriage to neutral after the
Pilot Drill stroke.
Continuity Testing “Visual Indicator” type testers use batteries and a light
bulb.
“Audible Indicator” type testers use batteries and a
beeper or buzzer.
Normally OPEN (NO) switches read no continuity at rest, IE; NO light
or sound from tester.
Normally CLOSED (NC) switches read continuity at rest, IE: light or
sound from tester.
Drill Motor Porter Cable 7301, Bosch PR10E ,or PR20EVS Trimmer motor used
to drill the Pilot Hole.
Drive Cylinder A double acting air cylinder which moves the Motor Carriage
backwards for the Pocket Router stroke and forwards for the Pilot Drill
stroke.
Pilot Hole The Screw hole drilled by the Drill motor.
Pocket The pocket cut in the material by the Pocket Router motor.
Router Motor Porter Cable 6902, Bosch 1617, or 1617EVS used to cut the Pocket.
Router Feed Rate
Valve
Controls the speed at which the Pocket Router moves through the
material when cutting the Pocket.
Note: Should be adjusted AFTER the main operational speed of
the machine has been set with the Air Pressure Regulator.
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Solenoids Electrically controlled air valves which send pressurized air to the
Clamp Cylinder and Drive Cylinder.
See Appendix C & E for illustrations.
Exhaust Muffler The exhaust mufflers on the solenoid valves release air pressure
from the clamping cylinder, and the drive cylinder after the Router
and Drill strokes.
Switches Normally OPEN (NO) switches at rest
Foot Switch
Safety Switch
Normally CLOSED (NC) switches
Router Stop Switch
Drill Stop Switch
Web The distance between the deepest part of the pocket and the edge of
the material.
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4 Diagnostic Descriptions
4.1 Clamp Operation
Page Procedure
Clamp doesn’t come down, but Machine Routs and Drills:
□ Check Clamp cylinder air line for leakage………………………… 21 21.12
□ Check Clamp Solenoid for blockage.……………………………… 1921.10
Clamp comes down and STAYS DOWN as soon as air is attached…with Machine power OFF:
□ Check Clamp Solenoid for function………………………………... 21 21.11
Clamp comes down, but immediately retracts…Machine does not Rout or Drill:
□ Check Drill Stop Switch……………………………………………... 39 21.43
Clamp doesn’t hold stock securely:
□ Clamp footpad replacement………………………………………… 18 21.01
□ Internal Air Pressure too low, adjust Pressure regulator………… 5621.90
□ Router Feed Speed too fast, adjust Router Feed Rate………….. 3321.32
□54 21.83
□
Check Tooling, may be dull…………………………………………
Check Clamp Solenoid for blockage…………………….........….. 19 21.10
□ Check Clamp Cylinder for function.……………………………… 21 21.12
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Page Procedure
Clamp releases slowly, Machine Routs and Drills:
□23 21.12
□21.13
Check Clamp cylinder and air line………………………………….
Check Exhaust Muffler on Clamp Solenoid Valve………....………
Clamp doesn’t release…Machine Routs, and Drills:
□5621.90
□
Adjust internal Air Pressure…………………………………………
Check Exhaust Muffler on Clamp Solenoid Valve………….…….. 24 21.13
□ Check Drill Stop Switch……………………………………………... 3921.43
□ Check Exhaust Muffler on Router Solenoid Valve……………….. 32 21.31
□ Check Drill Solenoid for function or blockage…………………….. 4321.51
Clamp doesn’t release…Machine Routs, DOES NOT Drill:
Clamp doesn’t release…Machine Routs but Router DOES NOT retract, DOES NOT Drill:
□ Check Drive Cylinder for function..................…………………….. 21.60
□□ Check Bar Spring position..............................……………………. 21.42
□□
Check Bar Spring position................................……………...…… 21.42
21.11
□
Check Clamp Solenoid for blockage....................………......…….
24
21
45
38
38
□ Router Stop switch………………………………………………….
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21.43
39

4.2 Router Operation
Router doesn’t cut pocket… Machine Clamps, Drills and releases:
□ Check Router Stop Switch for function or adjustment…………… 3921.43
Router comes up and STAYS UP as soon as air is attached…..with Machine power OFF:
□ Check Router Solenoid for function or blockage…………………. 3221.31
□ Unclog Router Solenoid…………………………………………….. 31 21.30
Router cuts pocket and STAYS UP, Drill doesn’t come out and Clamp doesn’t release:
□ Check Router Stop Switch for function or adjustment…………… 39 21.43
Router cuts pocket, Drill doesn’t come out and Clamp doesn’t release:
□43 21.51
□
Adjust internal Air Pressure…………………………...…………… 21.90
□
Adjust the Router Feed Rate Valve...……………………..……… 21.32
Check Drill Solenoid for function or blockage……………………..
Router advances too aggressively:
□
   ..............……………………………………… 21.60
□
   Exhaust ……..………….………… 21.61
□
   ………………………...….………… 21.42
45
48
38
56
33
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43-44 21.61
Router doesn't cut pocket OR drill... Clamp doesn't release:
□
48
21.32 Check Router Feed Rate may be turned all the way down……....
□  Router Solenoid for function or blockage………........…… 21.31
□  Drive Cylinder for leaks..............…………………………… 21.60
□  for Blockage in Drill Solenoid Exhaust Muffler....………… 21.61
32
45
33
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4.3 Drill Operation
Page Procedure
Drill DOES NOT come out, Machine Routs, Clamp DOES NOT release:
□ Check Drill Solenoid for function or blockage…………………….. 4321.51
□41 21.50
Drill comes out and stays out as soon as air is attached…with Machine power OFF:
□ 21.51
□ Adjust Air pressure, may be too low……………………………….. 5621.90
□ Check Drill Solenoid for function or blockage …………………….. 4321.51
□
□
Check Router Solenoid Exhaust port for blockage…………..…… 4821.61
□ Check Drill Solenoid Exhaust port for blockage…………….....…. 4821.61
□ Adjust air pressure, Machine cycling too slowly………………….. 5621.90
□ Bit mounted too deep into collet……………………………………. 3621.41
Drill comes out and stops, Router cuts pocket and Clamp DOES NOT release:
Machine DOES finish cycle when carriage is pushed forward by hand:
Check Drill Solenoid for function / clean out drill solenoid
□□□ Unclog Drill Solenoid………………………………………………………………………………………………………………………………………………………………………………………………… 41
□□□□ Check drive cylinder for function..............................................…
Drill bit not completing pilot hole into Pocket:
45
□Check for inconsistent web depth-See Router Stop Switch...,..... 29 21.22
Unclog Drill Solenoid……………………………………..............…
□
Check Bar Spring position.......................………………...…....….. 38 21.42
□
Check Drill Stop Switch………………………………...................... 39 21.43
□ Check Router Stop Switch.......................……………………......... 39 21.43
□Check Tooling, may be dull..........................................................5421.83
43
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21.50
21.60

Page Procedure
Drill bit breaking:
□ Adjust air pressure, Machine cycling too fast …………………….. 5621.90
□ Bit extended too far out of collet…………………………………… 3621.41
□
Check Drill Motor U-bolt nuts…………………………………..…… 3521.40
4.4 Overall Machine Operation and Pocket Adjustment
Page Procedure
Machine will not start cycle…motors are running:
□ Check Air Supply, minimum 85 PSI required…………………….. 60 21.92
□
Check Safety Switch (Stock Sense)……………………………,,… 52 21.82
□ Check Foot Switch…………………………………………………... 50 21.80
Machine can be cycled with no stock in place:
□ Check the Safety Switch……………………………………………. 52 21.82
Machine cycling too slowly
Note: A normal cycle is approximately 2 seconds
□ Adjust Air Pressure Regulator……………………………………… 56 21.90
□ Check Drive cylinder for air leak…………………………………… 4521.60
□ Check for other air driven machines on the same line…………... 5621.90
□ Check Exhaust Mufflers for blockage.........................…………... 48 21.61
Drill bit separating from the shank:
□ Adjust air pressure, Machine cycling too slowly………………….. 5621.90
□ Bit mounted too deep into collet……………………………………. 3621.41
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Page Procedure
Pocket ragged or crooked:
□ Adjust Router Feed Rate, may be too fast………………………... 3321.32
□ Check Clamp footpad, may need replacement…………………... 1821.01
□ Check Tooling, may be dull………………………………………… 54 21.83
Pocket burned or smoking:
□ Adjust Router Feed Rate, may be too slow………………………. 3321.32
□ Check Tooling, may be dull………………………………………… 54 21.83
Pocket misaligned with pilot hole:
□ Adjust Pilot Hole alignment…………………………………………. 4921.72
□ Check Drill motor mounting………………………………………… 3521.40
Pocket too close or too far from the edge of the stock, WEB adjustment:
□ Adjust Web with Router Stop Plate………………………………... 2821.21
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21.01
5.1Clamp Foot Pad or Cylinder Replacement
5.1.1 TO REPLACE THE CLAMP FOOT PAD:
1. The Clamp Foot Pad is not attached by adhesive. While the Clamp Foot is still attached
to the machine, use a flat blade screwdriver to remove the old Pad by carefully levering it
out of its seat.
2. The rim of the new Pad must be bent and popped into place. Insert an edge of the new
pad into the Clamp Foot and use a flat blade screwdriver to wedge the rest of the Foot
Pad into the Clamp Foot.
5.1.2 TO REPLACE THE CLAMP FOOT OR CLAMP CYLINDER:
1. Connect 85 PSI directly to the Clamp Cylinder to manually actuate it.
2. With the shaft fully extended, hold the shaft stationary with a ½” wrench and loosen the
jamb nut with a ¾” wrench. Continue holding the shaft stationary with the ½” wrench and
use large slip-joint pliers to turn the Clamp Foot and break it free of thread lock com-
pound. See Fig 2.
Jamb Nut
Clamp Foot
Foot Pad
Fig 2
5 Procedures
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5.2 Unclogging the Clamp Solenoid 21.10
1. Disconnect power from the machine.
2. Remove the air line from the clamp cylinder Push-In fitting (see Fig 3a). From the rear access
door, locate the clamp solenoid. Remove the exhaust muffler from the clamp solenoid (See Fig 3b)
and press the override button for several seconds to flush the solenoid. Air should flow through the
air line. Press the override switch several more times for several seconds to throughly flush the
solenoid. See Fig 3c
Fig 3a
Note: To remove the air line from the clamp cylinder, push in the plastic or metal rim of
the fitting and pull the air line out. To re-install, push the air line in until it meets
resistance and then push in another 1/2'”.
Note: All Solenoid Air Fittings are "Push In" connections. To remove an air line, push in the
plastic or metal rim of the fitting and pull the air line out. To re-install, push the air line in until
it meets resistance and then push in another 1/2".
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Fig 3c
3. Reinstall the air line on the clamp cylinder and exhaust muffler on the exhaust
port of the solenoid.
4. Reconnect power. Cut a test pocket.
Fig 3b
Note: If this procedure does not correct the problem, the Clamp Solenoid will need to be
replaced. Refer to Procedure 21.91, "Replacing Solenoids".
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