CASTLE TSM-21 User manual

CASTLE INC
Diagnostic
Manual
TSM-21

Castle Inc TSM-21 Diagnostic Manual v2 Page 2 of 63
Table of Contents
1.............................................................................................................................4INTRODUCTION
1.1 ........................................................................................................5HOW TO USE THIS MANUAL
2...................................................................................................6DRY CYCLE TESTING 21.95
2.1 ..................................................................................................................................6PURPOSE
2.2 ....................................................................................................................6DRY TEST TSM-21
3.................................................................................................................................8DEFINITIONS
4....................................................................................................10DIAGNOSTIC DESCRIPTIONS
4.1 ..................................................................................................................10CLAMP OPERATION
4.2 ................................................................................................................12ROUTER OPERATION
4.3 ....................................................................................................................13DRILL OPERATION
4.4 .......................................................14OVERALL MACHINE OPERATION AND POCKET ADJUSTMENT
5.............................................................................................................................16PROCEDURES
5.1 ...........................................................16CLAMP FOOT PAD OR CYLINDER REPLACEMENT 21.01
5.2 ..........................................................................17UNCLOGGING THE CLAMP SOLENOID 21.10
5.3 ........................................................................................18CLAMP SOLENOID CHECK 21.11
5.4 .........................................................................................19CLAMP CYLINDER CHECK 21.12
5.5 .......................................................................21PILOT VALVE,CLAMP EXHAUST CHECK 21.13
5.6 ....................................................................22PILOT VALVE CHECK AND REPLACEMENT 21.14
5.7 ...................................................................................24ROUTER MOTOR OPERATION 21.20
5.8 ...............................................................26ADJUSTING THE WEB,ROUTER STOP PLATE 21.21
5.9 ....................................................................................27ROUTER STOP SWITCH (NC) 21.22
5.10 ........................................................................29UNCLOGGING THE ROUTER SOLENOID 21.30
5.11 .......................................................................................30ROUTER CHECK SOLENOID 21.31
5.12 .............................................................................31ROUTER FEED RATE ADJUSTMENT 21.32
5.13 .......................................................................................33DRILL MOTOR OPERATION 21.40
5.14 ...............................................................................34DRILL SETTINGS AND BIT DEPTH 21.41
5.15 ...............................................................................36DRILL SINGLE COIL BAR SPRING 21.42
5.16 .......................................................................................37DRILL STOP SWITCH (NC) 21.43
5.17 ...........................................................................38UNCLOGGING THE DRILL SOLENOID 21.50
5.18 ..........................................................................................40DRILL SOLENOID CHECK 21.51
5.19 ..........................................................................................41DRIVE CYLINDER CHECK 21.60

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5.20 .................................................43DRIVE CYLINDER SQE (SUPER QUICK EXHAUST)VALVE 21.61
5.21 ...........................................................................................45PILOT HOLE ALIGNMENT 21.72
5.22 ................................................................................................45FOOT SWITCH (NO) 21.80
5.23 ........................................................................................47RESETTING THE MACHINE 21.81
5.24 .....................................................................47SAFETY SWITCH/SAFETY BUTTONS (NO) 21.82
5.25 .........................................................................49TOOLING CHECK AND REPLACEMENT 21.83
5.26 ........................................................................51AIR PRESSURE REGULATOR SETTING 21.90
5.27 .................................................................................52REPLACING SOLENOID VALVES 21.91
5.28 ..........................................................................................54ATTACHING AIR SUPPLY 21.92
6.................................................................................55APPENDIX A – MACHINE SAFETY 21.80
6.1 ................................................................55GENERAL SAFETY RULES FOR MACHINE OPERATORS
7................................................................................57APPENDIX B – WIRING DIAGRAM 21.84
8.......................................................................58APPENDIX C – CONTROL BOX WORKS 21.93
9......................................................59APPENDIX D – SOLENOID, PNEUMATIC DIAGRAM 21.94
10 ....................................................................60APPENDIX E – CONTROL BOX WORKS 21.93
11 ..................................................61APPENDIX F – SOLENOID, PNEUMATIC DIAGRAM 21.94
12 .............................................................................................................62APPENDIX G – INDEX

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1 Introduction
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:
PageProcedure
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. Locate the ON/OFF switches on the Router and Drill and turn them both off, or unplug
both motors at the Control Box outlet.
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.
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
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

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If the cycle stalls with the drill extended or if the cycle skips over the drill stroke
entirely, 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
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
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 them both back into the Control Box outlet.

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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 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.
Pilot Valve Provides full pressure to the Clamp cylinder. It is controlled by the
Clamp Solenoid.
Note: Used up to machine SN: 61076 only
Pocket The pocket cut in the material by the Pocket Router motor.
Router Motor Porter Cable 6902 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.
SQE Super Quick Exhaust valves which release air pressure from the drive
cylinder after the Router and Drill strokes.
Note: Used up to machine SN: 62481 only.
Switches Normally OPEN (NO) switches
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………………………… 19-20 21.12
□Check Clamp Solenoid for blockage.……………………………… 17-18 21.10
□Check Pilot Valve for function or blockage………………………..
(up to machine sn: 61076 Only)
22-24 21.14
Clamp comes down and STAYS DOWN as soon as air is attached…with Machine power OFF:
□Check Clamp Solenoid for function………………………………... 18-19 21.11
Clamp comes down, but immediately retracts…Machine does not Rout or Drill:
□Check Drill Stop Switch……………………………………………... 37-38 21.43
Clamp doesn’t hold stock securely:
□Clamp footpad replacement………………………………………… 16 21.01
□Internal Air Pressure too low, adjust Pressure regulator………… 51-52 21.90
□Router Feed Speed too fast, adjust Router Feed Rate………….. 31-32 21.32
□Check Tooling, may be dull………………………………………… 49-50 21.83
□Check Pilot Valve for function or blockage………………………..
(up to machine sn: 61076 Only)
22-24 21.14