CASTLE TSM-22 User manual

CASTLE INC PO BOX 750236 PETALUMA CA 94975
WWW.CASTLEUSA.COM
Diagnostic Manual
TSM-22 Pocket Hole Machine
CASTLE
,
INC.

Castle Inc TSM-22 Diagnostic Manual V1 Page 2 of 74
Table of Contents
1.............................................................................................................................4INTRODUCTION
1.1 ........................................................................................................5HOW TO USE THIS MANUAL
2...................................................................................................6DRY CYCLE TESTING 21.95
2.1 ..................................................................................................................................6PURPOSE
2.2 DRY TEST TSM-22...................................................................................................................6
3DEFINITIONS ................................................................................................................................11
4DIAGNOSTIC DESCRIPTIONS....................................................................................................13
4.1 CLAMP OPERATION..................................................................................................................13
4.2 ROUTER OPERATION................................................................................................................15
4.3 DRILL OPERATION....................................................................................................................17
4.4 OVERALL MACHINE OPERATION AND POCKET ADJUSTMENT.......................................................18
5PROCEDURES.............................................................................................................................20
5.1
5.3UNCLOGGING THE CLAMP SOLENOID 21.10 ..........................................................................22
5.4CLAMP SOLENOID CHECK 21.11 ........................................................................................24
5.5CLAMP CYLINDER CHECK 21.12 .........................................................................................26
5.6CLAMP EXHAUST CHECK 21.13............................................................................................27
5.7ROUTER MOTOR OPERATION 21.20 ...................................................................................29
5.8ADJUSTING THE WEB, ROUTER STOP PLATE 21.21 ...............................................................32
5.9ROUTER STOP SWITCH (NC) 21.22 ....................................................................................33
5.10 UNCLOGGING THE ROUTER SOLENOID 21.30 ........................................................................35
5.11ROUTER CHECK SOLENOID21.31.......................................................................................36
5.12ROUTER FEED RATE ADJUSTMENT 21.32 .............................................................................37
5.13DRILL MOTOR OPERATION 21.40 .......................................................................................38
5.14DRILL SETTINGS AND BIT DEPTH 21.41...............................................................................44
5.15DRILL SINGLE COIL BAR SPRING 21.42...............................................................................45
5.16DRILL STOP SWITCH (NC) 21.43 .......................................................................................47
5.17UNCLOGGING THE DRILL SOLENOID 21.50 ...........................................................................49
5.18DRILL SOLENOID CHECK 21.51..........................................................................................50
5.19DRIVE CYLINDER CHECK 21.60..........................................................................................52
2.3 Option #2 Dry Test TSM-22 With Work Top Open...................................................................8
5.2
MANUAL OVERRIDE ON SOLENOIDS 21.01.... ...................................................................20
CLAMP FOOT PAD OR CYLINDER REPLACEMENT 21.05 ...........................................................21

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5.21 PILOT HOLE ALIGNMENT 21.72 ...........................................................................................57
5.22FOOT SWITCH (NO) 21.80................................................................................................57
5.23RESETTING THE MACHINE 21.81........................................................................................59
5.24SAFETY SWITCH/SAFETY BUTTONS (NO) 21.82.....................................................................59
5.25TOOLING CHECK AND REPLACEMENT 21.83 .........................................................................61
5.26AIR PRESSURE REGULATOR SETTING 21.90 ........................................................................63
5.27REPLACING SOLENOID VALVES 21.91 .................................................................................64
5.28ATTACHING AIR SUPPLY 21.92 ..........................................................................................66
6APPENDIX A – MACHINE SAFETY 21.80.............................................................................67
6.1 GENERAL SAFETY RULES FOR MACHINE OPERATORS................................................................67
7APPENDIX B – WIRING DIAGRAM 21.84 ............................................................................69
8APPENDIX C – CONTROL BOX WORKS 21.93 ...................................................................70
9APPENDIX D – SOLENOID, PNEUMATIC DIAGRAM 21.94 ..................................................72
10APPENDIX E – INDEX .............................................................................................................73
5.20 EXHAUST MUFFLERS ON SOLENOID VALVES 21.65...........................................................55

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1Introduction
Thank you for making the Castle TSM-22 Screw Pocket Machine a vital part of your shop. The
TSM-22 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-22.
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-22 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 6.

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2 Dry Cycle Testing 21.95
2.1 Purpose
Dry Cycle testing allows observation of the TSM-22’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-22
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.

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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
Note: For comprehensive diagnostic descriptions and procedures refer to Section IV.
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
After testing is complete, turn the MAIN Power Switch OFF and switch both motors back ON

2.3 Option #2 Dry Test TSM-22 With Work Top Open
1. Connect air and power to the machine. Turn the machine’s MAIN Power Switch ON.
2. Lift the work top of the machine.
3. Depress one of the Safety Buttons with a piece of scrap wood. Position yourself in front
of the machine.
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 stops
3. Place a screw driver or a piece of metal in between the router stop switch and
the router stop magnetic. See Fig 1. The Drill should now extend and stop.
Fig 1
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5. Place a screw driver or a piece of metal in between the drill stop switch and the drill
stop magnetic. See Fig 2.The drill should return to its resting position and the clamp should release.

6. 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
7. If the router stop switch can not be triggered with a screw driver or a piece of metal or if the cycle skips
over the router stroke entirely, check the Router Stop Switch: Procedure 21.22
•If the drill stop switch can not be triggered with a screw driver or a piece of metal or if the clamp
starts to come down and immediately retracts, check the Drill Stop Switch: Procedure 21.43
•If the Dry Cycle with the Work Top up 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
Fig 2
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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Note: For comprehensive diagnostic descriptions and procedures refer to Section IV.
After testing is complete, turn the MAIN Power Switch OFF, then lower and secure the work top.
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
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