Castle TSM-21 Diagnostic Manual Uživatelský manuál

CASTLE INC Diagnostic Manual TSM-21

Castle Inc TSM-21 Diagnostic Manual v2 Page 10 of 63 4 Diagnostic Descriptions 4.1 Clamp Operation Page Procedure Clamp doesn’t come down, b

Castle Inc TSM-21 Diagnostic Manual v2 Page 11 of 63 Page Procedure Clamp releases slowly, Machine Routs and Drills: □ Check Clamp cylinder and

Castle Inc TSM-21 Diagnostic Manual v2 Page 12 of 63 4.2 Router Operation Page Procedure Router doesn’t cut pocket…Machine Clamps and Drills, but

Castle Inc TSM-21 Diagnostic Manual v2 Page 13 of 63 4.3 Drill Operation Page Procedure Drill DOES NOT come out, Machine Routs, Clamp DOES NOT r

Castle Inc TSM-21 Diagnostic Manual v2 Page 14 of 63 Page Procedure Drill bit breaking: □ Adjust air pressure, Machine cycling too fast …………………….

Castle Inc TSM-21 Diagnostic Manual v2 Page 15 of 63 Page Procedure Pocket ragged or crooked: □ Adjust Router Feed Rate, may be too fast……………………

5 Procedures 5.1 Clamp Foot Pad or Cylinder Replacement 21.01 5.1.1 TO REPLACE THE CLAMP FOOT PAD: 1. The Clamp Foot Pad is not attached by ad

Castle Inc TSM-21 Diagnostic Manual v2 Page 17 of 63 3. The Clamp foot can now be removed for replacement, or to allow for removal of the Clamp Cy

Castle Inc TSM-21 Diagnostic Manual v2 Page 18 of 63 5. Reconnect power and air to the machine, and turn the Power Switch ON. 6. Place a board ag

Castle Inc TSM-21 Diagnostic Manual v2 Page 19 of 63 Pilot Valve, up to SN: 61076 Clamp Exhaust Clamp Solenoid Router Solenoid Drill Solenoid Ai

Castle Inc TSM-21 Diagnostic Manual v2 Page 2 of 63 Table of Contents 1 ...

5.4.1 TROUBLESHOOTING STEPS: 1. Disconnect power and air from the machine. 2. Disconnect the air line from the “push in” fitting of the Clamp Cylin

Castle Inc TSM-21 Diagnostic Manual v2 Page 21 of 63 Clamp Solenoid Air “OUT” line to Clamp Pilot Valve, up to SN: 61076 Clamp ExhaustAir “OUT” li

Pilot Valve, up to SN: 61076Clamp Solenoid Air “OUT” line to Clamp Clamp ExhaustAir “OUT” line from Clamp Solenoid Fig 6 2. Make sure that this por

Castle Inc TSM-21 Diagnostic Manual v2 Page 23 of 63 Air “OUT” line to Clamp SN:61076Pilot Valve, up to Air “OUT” line from Clamp Solenoid Fig 7

Castle Inc TSM-21 Diagnostic Manual v2 Page 24 of 63 7. Apply Teflon tape to the brass fitting still attached to the regulator. 8. Tighten the Pi

Castle Inc TSM-21 Diagnostic Manual v2 Page 25 of 63 Router T-Knob Router U-Bolt Router Motor Fig 8 3. Unplug the Router motor. 4. With your r

4. The Router Motor has two electrical brushes that should be periodically replaced. See Fig 9. Router Motor Brushes Fig 9 5.8 Adjusting the Web, Ro

Castle Inc TSM-21 Diagnostic Manual v2 Page 27 of 63 Lock Nut Adjust towards back for shorter web Adjust towards front for longer web Router Stop

the cycle to stall, or the router may not extend at all although the Pilot Hole Drill and Clamp finish the cycle. 5.9.1 TROUBLESHOOING STEPS: 1.

Castle Inc TSM-21 Diagnostic Manual v2 Page 29 of 63 8. If the switch continuously measures OPEN regardless how close the magnet is, replace the s

Castle Inc TSM-21 Diagnostic Manual v2 Page 3 of 63 5.20 ...43 DRIVE CYLINDER SQE (SUPER QUICK EXH

Castle Inc TSM-21 Diagnostic Manual v2 Page 30 of 63 7. Turn the Power Switch OFF and repeat steps 5 and 6 several times to ensure all contaminant

Castle Inc TSM-21 Diagnostic Manual v2 Page 31 of 63 Pilot Valve, up to sn:61076 Clamp Exhaust Clamp Solenoid Router Solenoid Fig 13 3. Attach t

5.12.1 TO RESET THE ROUTER FEED RATE: 1. Locate the Feed Rate knob on the left of the case and fully loosen the Jamb Nut. See Fig 14. FASTER Knob

Castle Inc TSM-21 Diagnostic Manual v2 Page 33 of 63 5.13 Drill Motor Operation 21.40 The Drill Motor has its own power switch located on

Castle Inc TSM-21 Diagnostic Manual v2 Page 34 of 63 5.13.2 REMOVING / INSTALLING THE DRILL MOTOR: 1. Disconnect power and air from the machine

Castle Inc TSM-21 Diagnostic Manual v2 Page 35 of 63 5.14.1 TESTING STEPS: 1. Hold the shank against a solid surface, and tap the end of the bit

5.15 Drill Single Coil Bar Spring 21.42 The Bar Spring is located inside the top of the machine, above the Control Box. The Motor Carriage

Castle Inc TSM-21 Diagnostic Manual v2 Page 37 of 63 6. Push the carriage forward by hand. The carriage should “spring” back when released. 7. R

3. Test for continuity across the terminals of the switch. The switch should be CLOSED with the Motor Carriage in neutral position. 4. If the switch

Castle Inc TSM-21 Diagnostic Manual v2 Page 39 of 63 “Push In” rim while pulling out air line Drill Solenoid Air OUT LineAir IN LineFig 19 2. Re

Castle Inc TSM-21 Diagnostic Manual v2 Page 4 of 63 1 Introduction Thank you for making the Castle TSM-21 Screw Pocket Machine a vital part of yo

5.18 Drill Solenoid Check 21.51 The Drill Solenoid controls air pressure to the Drive Cylinder, which provides the forward motion of the Dril

Castle Inc TSM-21 Diagnostic Manual v2 Page 41 of 63 3. Attach the air supply to the machine and see if the router now extends instead of the dri

Drive Cylinder Router SQE Valve Drill SQE Valve Router Solenoid line Drill Solenoid line Fig 21 5. Cycle the machine a few more times to see if the

Castle Inc TSM-21 Diagnostic Manual v2 Page 43 of 63 5.20 Drive Cylinder SQE (Super Quick Exhaust) Valve 21.61 The Drive Cylinder provides the for

2. Un-plug or turn off both routers 3. Place two boards on opposite sides of the slot on the Table Top, press them against the Safety Buttons, and d

Castle Inc TSM-21 Diagnostic Manual v2 Page 45 of 63 5.21 Pilot Hole Alignment 21.72 The Pilot Hole should be drilled in the center of the

5.22.1 TESTING STEPS: 1. Turn the Power Switch OFF. 2. Remove the two small screws that hold the Pedal to the yellow guard. 3. Use a flat tip scr

Castle Inc TSM-21 Diagnostic Manual v2 Page 47 of 63 5.23 Resetting the Machine 21.81 If the Power Switch is ON and the footswitch is pre

Safety Switch Safety Switch Magnet Safety Blade Fig 26 3. Test for continuity at the terminals of the switch with the Safety Blade resting between

Castle Inc TSM-21 Diagnostic Manual v2 Page 49 of 63 5.25 Tooling Check and Replacement 21.83 5.25.1 ROUTER: 1. Disconnect power and a

Castle Inc TSM-21 Diagnostic Manual v2 Page 5 of 63 1.1 How to Use This Manual 1. Closely observe the behavior of the machine noting which compo

7. Tighten the black T-Knob onto the U-Bolt. When the motor has been fully secured by the U-Bolt you might observe that the motor face is no longer

Castle Inc TSM-21 Diagnostic Manual v2 Page 51 of 63 5.26 Air Pressure Regulator Setting 21.90 The Pressure Regulator determines Drill F

5. Cut test pockets and adjust slightly more or less than 6 turns until the appropriate opera-tional speed is reached. NEVER EXCEED 7 FULL ROTATIONS

Castle Inc TSM-21 Diagnostic Manual v2 Page 53 of 63 4. Label the three solenoids and remove the two hex nuts and lock washers that hold the solen

Castle Inc TSM-21 Diagnostic Manual v2 Page 54 of 63 9. Reassemble the solenoids in a stack and tighten the hex nuts and lock washers. Do not ove

Castle Inc TSM-21 Diagnostic Manual v2 Page 55 of 63 6 Appendix A – Machine Safety 21.80 It is your responsibility to ensure that you under

Castle Inc TSM-21 Diagnostic Manual v2 Page 56 of 63 to stop. Failure to disconnect this machine from its air supply and power, or failure to wait

Castle Inc TSM-21 Diagnostic Manual v2 Page 57 of 63 7 Appendix B – Wiring Diagram 21.84 1413121110987654321 Drill Solenoid ValveClamp Sol

8 Appendix C – Control Box Works 21.93 Note: Up to SN: 61036 Pilot Valve, up to SN: 61076Clamp Exhaust Clamp Solenoid Router Solenoid Drill So

Castle Inc TSM-21 Diagnostic Manual v2 Page 59 of 63 9 Appendix D – Solenoid, Pneumatic Diagram 21.94 Note: Up to SN: 61036

Castle Inc TSM-21 Diagnostic Manual v2 Page 6 of 63 2 Dry Cycle Testing 21.95 2.1 Purpose Dry Cycle testing allows observation of the TSM-2

10 Appendix E – Control Box Works 21.93 Note: SN: 61076 and above Castle Inc TSM-21 Diagnostic Manual v2 Page 60 of 63 Fig 33 Fig 34 Regula

Castle Inc TSM-21 Diagnostic Manual v2 Page 61 of 63 11 Appendix F – Solenoid, Pneumatic Diagram 21.94 Note: SN: 61076 and Above

Castle Inc TSM-21 Diagnostic Manual v2 Page 62 of 63 12 Appendix G – Index Page Section Air Pressure Regulator, Setting…………………………………………………. 51

Castle Inc TSM-21 Diagnostic Manual v2 Page 63 of 63 Page Section Resetting the Machine………………………………………………………….. 47 21.81 Router Feed Rate Adju

Castle Inc TSM-21 Diagnostic Manual v2 Page 7 of 63  If the cycle stalls with the drill extended or if the cycle skips over the drill stroke en

Castle Inc TSM-21 Diagnostic Manual v2 Page 8 of 63 3 Definitions Term Definition Air Pressure Regulator Used to set the main operational speed

Castle Inc TSM-21 Diagnostic Manual v2 Page 9 of 63 Solenoids Electrically controlled air valves which send pressurized air to the Clamp Cylinde