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1. s s 2 Switch Relay Board Black line to Router Feed Rate Control Control __ i Black air line out to Router end of Drive Cylinder E Clear air line out to Drill Brass Check N N Router end of Drive Cylinder Valve o Solenoid Mo Drill Solenoid Solenoid ci Air Pressure Regulator Black air line to Clamp SQE Super Quick Air In Exhaust Valve Castle Inc 1364 N McDowell Blvd PO Box 750236 Petaluma CA 94975 800 282 8338 Fax 707 765 0953 www castleusa com Castle TSM 20 Diagnostic Manual Rev 2 Page2. switch You will need to remove the orange cover plate to do this 3 Press in the button on the micro switch If the switch is working you should register continuity after you press in the button 4 If no continuity is registered then the switch needs to be replaced TSM 20 Operator s Manual Addendum 1 e A 2 0 INTERNAL AIR PRESSURE REGULATOR The internal air pressure determines the drill feed rate and the overall speed of the machine The factory setting is 75 PSI It is important for the machine function to have at 75 PSI to the machine Locate the regulator in the control box Fig 2 Unlock the yellow lock ring by pulling it slightly toward the black knob Turn the knob to the right clockwise to increase pressure Turn the knob to the left counter clockwise to decrease pressure Push the lock ring back in when done NOTE The speed of the cycle stroke is directly proportional to the pressure to the machine Cycling too slow may cause drill bits to heat up in the wood and may cause separation Cycling your machine too fast may cause undue pressure to the drill bits and may cause breakage and or over sized holes PRESSURE REGULATOR TSM 20 Operator s Manual Addendum 2 ate n 3 0 SOLENOID MANIFOLD CLEANING Begin by removing the control box from the machine This can be done by removing the four screws on the outside of the case and sliding the box out Once out remove the plate from the front of the cont
3. adi CASTLE CASTLE INC MORTISE MACHINE MODEL TSM 20 OPERATOR S MANUAL Addendum Revised December 16 2010 rev 2 CASTLE INC MORTISE MACHINE MODEL TSM 20 OPERATOR S MANUAL ADDENDUM TABLE OF CONTENTS Page 1 0 SAHELES 18 CEIEGITECK siss aaa vaja reer iter rere 1 2 0 AIR PRESSURE REGULATOR sua 2 3 0 SOLENOID MANIFOLD CLEANING 3 4 0 DRIVE CYLINDER SOE CEEANING ssosccii dalai 4 50 15M 20 PARIS TEIST bg 5 Appendix Ars Wirine Diagratt gl eee aaa 6 Appendix B Carriage Switch Diagramma 7 Appendix C Solenoid Pneumatic Diagram aiccisvicrvecicalidatinsinieslstteineeis des avatiniee eee ked ava 8 TSM 20 Operator s Manual Page ii ae ni MAINTENANCE OR TESTING ON YOUR CASTLE MACHINE nn 1 0 SAFETY SWITCH CHECK The safety switch on the TSM 20 is a micro switch located on the outside of the control box Fig 1 When the safety buttons at the rear of the worktop are depressed by the stock they actuate a blade inside the machine that presses against the button of the micro switch Combined with the micro switch in the foot pedal these two micro switches are responsible for initiating the cycle on the TSM 20 If the switch has failed then the machine will not begin the cycle essentially your clamp will not go down and the routers will not move though they will turn on 1 1 To Test 1 Disconnect air and power 2 Test for continuity at the switch by connecting the ohmmeter leads to wired side of the micro
4. noids This is done by following the air lines back to their connection at the control panel The hoses should remain attached to the air cylinder at the SQE s Fig 4 4 Dry cycle the machine a Unplug the router motors b Hold in the safety stock sensors below the clamp with two scraps of wood Be careful to leave room for the router to come up through the work surface unobstructed c Reach into the rear door opening and firmly grasp the yellow carriage d Steadily pull and push the carriage fully back and forth to force air through the hoses BE SURE TO ALLOW THE AIR PRESSURE TO FULLY EXHAUSE OUT THE HOSES 5 Make sure air is coming out of the ROUTER SQE a solenoids while dry cycling ve DRILL SQE 6 The hoses attached to the cylinder should exhaust air as you dry cycle knocking loose any blockage out of the brass SQE s as well as cleaning any debris out of the air hoses 7 Press the hoses firmly back into the push in fittings 8 Plug in the router motors CYLINDER TSM 20 Operator s Manual Addendum 4 TSM 20 PARTS LIST Drill amp Router Motors amp Accessories 23102 Porter Cable 3102 TimmerMoter Drilshele DISCONTINUED A E26902 Porter Cable 6902 Router Motor Routs pocket mount with F14232 bolt same router as TSM 21 1 4 Collet Assembly for E23102 motor Note Brassbushingnolongeravailable replacedby 1 4 shankonthebii OOO D50031 ColletNut 00000000 E60286 Snap action Mic
5. rol box The coil located closest to the regulator in the upper left side of the control box Fig 3 operates the Clamp The middle coil actuates the Drill cycle and the coil furthest from the regulator actuates the Router TOOLS 1 Pliers 2 Cloth or foam wrap to cushion the pliers to prevent damage to the coil when removing 3 Rubbing alcohol Clean rag 5 Compressed air SOLUTION STEPS 1 Use the pliers to remove the nut from the top of the coil GENTLY remove the coil housing 2 Cushion the pliers and CAREFULLY remove the stem Once you have removed the stem verify that the plunger actuates on the bottom Blow out the manifold with air and wipe away any debris Wipe down the stem with rubbing alcohol Make sure that all parts of the manifold and the stem are clean CAREFULLY replace the stem using the cushioned pliers Replace the coil and nut AREA TSM 20 Operator s Manual Addendum 3 ate n 4 0 DRIVE CYLINDER SQE CLEANING The drill solenoid is an air switch that controls the flow of air to the drive cylinder The drive cylinder in turn provides the pressure to move the drill carriage through its cycle If the air line becomes clogged the drive cylinder may not have enough pressure to cycle the drill completely SOLUTION STEPS 1 Open the back door 2 Inspect the hoses coming FROM THE DRIVE CYLINDER for holes and or pinches 3 Unplug the two DRIVE CYLINDER hoses from the sole
6. roswitch Silver push button Drill Stop Rout Stop and Wood Sensor Switch Note Grainger Part No 6X286 Manufacturer Part No Z 15GQ B7 K E60284 Snap action Microswitch with Lever Used in older versions Note Grainger Part No 6X284 Manufacturer Part No Z 15GW B7 K E07033 Microswitch Small white with Lever Used in oldest versions Note Grainger Part No 64884 Manufacturer Part No TMCG40 e A Ra t E07041 Snap action MicroSwitch Small push button Foot Switch for TSM 20 21 amp 35 Note Grainger Part No 6X283 Control Board DISCONTINUED A ne D i 2 DI U en 14 Pin Terminal Strip for Relay Control Board Regulator P53000 Monnier Regulator Note Must be calibrated to 85psi by shipping dept prior to shipping J a lt D O lt 5 Q D C21004 Drive Cylinder Note Same as TSM 21 drive cylinder D 5 k Si Q TI 9 o Fabco Valve Assembly 3 valves included with Manifold Fabco Solenoid Valve Clamp Rout and Drill valves Vv 2 D o Q O 9 Flow Control P00117 SMC Flow Control Note Same as Feed Speed valve used on TSM 21 8 35 O O O Q Gi D ma O gt E75762 On Off Switch silver metal SQE Super Quick Exhaust SQE 10 32 Clippard Note small brass O O m O c D IG O O x m lt gt Q c Ss P10001 Humphrey SQE 1 Note larger
7. than P10320 octagonal nickel SQE White Nylon Barb 10 32 x 5 32 ID Black Barb for P10320 when used as Clamp Exhaust P31032 10 32 x 10 32 White Nylon Coupling for P10320 when used as Clamp Exhaust 18 AWG Hook Up Wire E18061 o Rk 1 Rk R R OS o Rk R O o uu Castle TSM 20 Appendix B Wiring Diagram 20 80 Neutral Power In 12 14 10 13 11 13 Relay Board Terminal Strip Hot Power In Clamp Solenoid Valve Router Solenoid Valve Drill Solenoid Valve Drill Stop Switch 6 8 NO Normally Open Router Stop Switch 6 7 NO Normally Open Foot Switch 4 5 NO Normally Open Wood Sensor Switch 2 3 NO Normally Open Castle Inc 1364 N McDowell Blvd PO Box 750236 Petaluma CA 94975 800 282 8338 Fax 707 765 0953 Castle TSM 20 Diagnostic Manual Rev www castleusa com Page Castle TSM 20 Apendi B Carriage Switch Diagram 20 82 Router Stop Switch Points to REAR of Machine 1 M NOTE Both Switches are wired Normally Open NO Black Jumper Wire Drill Stoo Switch Points to FRONT of Machine he NO Black Lead VVhite Lead Green Lead Castle Inc 1364 N McDowell Blvd PO Box 750236 Petaluma CA 94975 800 282 8338 Fax 707 765 0953 www castleusa com Castle TSM 20 Diagnostic Manual Rev 2 Page Castle TSM 20 pn C Solenoid Pneumatic Diagram 20 81 a g lslidrlidolo r o
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