CASTLE TSM-35 User manual

TSM-35 Screw Pocket Machine Troubleshooting
35.10 Machine will not start:
Confirm that the machine will not turn on – no motor running vs the cycle will not start
!***ALWAYS DISCONNECT POWER AND AIR WHEN CHECKING SWITCHES ***!
•Check the safety interlock switch (See 35.11)
oOne of the most common reasons
oSwitch is a failsafe and will not allow the machine to start if the lid is
up
oOften becomes impacted with sawdust and will not function
Open switch and blow out
•There have been several different types of switches
used over time. Get brand name of switch:
oABB – E03300
oIDEC – E03340
oOmron – E03340 (IDEC and Omron have the same key.)
oTelemechanique – E35001
oSiemens – use E03340 and request Omron type
•Check the contacts at the back of the start and stop buttons (E03000 Stop & E35041 Start)
oSee 35.12 & 35.13
oThis is a continuity check – there should be a change in continuity when the buttons are
depressed. Can be done with no power to the machine.
•Check the air pressure switch (E35420)(See 35.14)
oThe air pressure switch is set at 40 psi at the factory. It can often go bad and be hard to
diagnose.
oThe easiest way to check is to bridge the two wires and see if the machine will turn on.
oWe no longer use the air pressure switch. Customers can keep the bridge in place if they do
not wish to replace.

TSM-35 Screw Pocket Machine Troubleshooting
•Check the transformer (E35713)
o*** CAUTION: ONLY A QUALIFIED ELECTRICIAN SHOULD PERFORM THE
FOLLOWING STEPS. POWER MUST BE SUPPLIED TO THE MACHINE TO CHECK THE
TRANSFORMER. THIS PRODUCES A SHOCKING HAZZARD. DO NOT TOUCH THE CONTROL
BOX COMPONENTS WITH ANYTHING OTHER THAN ELECTIRCAL TESTING PROBES. ***
oThere should be 230V 3ph or 480V 3ph going into the transformer (Check H1 (480V) or H2
(230V) AND H4 at top of transformer)
If no power into the transformer, check main power to the machine.
oThere should be 24V AC coming out of the transformer and entering the board at terminals
1 and 2
oCheck to make sure the fuse is intact (E16224)
•If all switches and transformer check out OK, then problem is with the contactor and/or overload.
(E91024 Contactor / E91827 480V Overload / E94060 230V Overload / E94061 Single phase
overload)
oCheck for loose wires on Contactor and Overload
oIt is recommended to change both components. Currently the Sprecher & Schuh (S & S)
brand we use will need both pieces to be changed, regardless if there is an old S & S in the
machine. The new revision will not work with the old.
o**** Components from different manufacturers cannot be combined. ****

TSM-35 Screw Pocket Machine Troubleshooting
35.11 Test Safety Interlock Switch (NO)
•Disconnect power and air from the machine.
•Unplug the black wire on the pressure switch located in the control box just above the control
board.
•Touch continuity tester to “A1” on the contactor and to the black wire that was removed from the
pin on the pressure gauge.
•When lid is closed, the switch tester should read closed. When the lid is opened, the tester should
read open.
For Machines without the Air Pressure Switch:
•Disconnect power and air from the machine.
•Touch the continuity tested to “A1” on the
contactor and pin #2at the back of the stop
switch.
•When the lid is closed, the switch tester should
read closed. When the lid is opened, the tester
should read open.

TSM-35 Screw Pocket Machine Troubleshooting
35.12 Test Start Switch (NO)
•Disconnect air and power from the machine
•Locate the contact block for the start switch located on the back side of the control box enclosure
door.
•With a continuity tester, touch “-3” and “-4” terminals on the contact block.
•The switch should read (NO) at rest. When the start button is depressed the switch should close.
35.13 Test Stop Switch (NC)
•Disconnect air and power to the machine
•Locate the stop switch contact block on the back of the control box enclosure door.
•Use continuity tester and touch the pins to “-1” and “-2” on the stop switch contact block.
•When the stop switch is pushed in, the continuity tester should read open.
•When the switch is in the out position, the tester will read closed.

TSM-35 Screw Pocket Machine Troubleshooting
35.14 Test Air Pressure Switch (NO)
•Disconnect power and air from the machine.
•Unplug the black and red wires from the pressure switch
•Touch both of the pins on the pressure switch with the tester pins.
•The switch should read open with no air attached to the machine.
•Attach air to the machine and the switch should then read closed.
NOTE:
The air pressure switch is no longer used in the TSM-35. Its removal does not constitute a safety
issue.
To bypass the switch in the system:
•Unplug the black and red wires from the pressure switch
•Cut the terminals off the wires, and strip the insulation
•Twist the ends together lightly
•Used a locknut to secure the wires

TSM-35 Screw Pocket Machine Troubleshooting
35.15 Motor starts, but cycle does not initiate:
•Confirm machine is receiving air.
!*** ALWAYS DISCONNECT POWER AND AIR WHEN CHECKING SWITCHES ***!
•Check the stock sense switch (E10850) and safety blade (C35101)
oCheck switch for continuity: (Also See 35.16)
Remove one wire from the switch
Check for continuity at the switch by placing probes on the screws
and moving the stock sense lever out of the way, then back
oCheck safety blade to make sure it swings and moves out of the way of the
magnet when safety buttons are depressed
•Check the foot pedal switch (E07041 Switch only / E00491 Foot Pedal with Cord)
(Also See 35.17)
oCheck for continuity change when depressed – can check at the switch or
at terminals 3 & 4 on the terminal strip
oJust switch can be changed. Buy from Castle or Grainger part 6X283
•Check to make sure there is power (24V AC) going into the board at terminals 1 & 2
o*** CAUTION: ONLY A QUALIFIED ELECTRICIAN SHOULD PERFORM THE
FOLLOWING STEPS. POWER MUST BE SUPPLIED TO THE MACHINE TO CHECK THE
TRANSFORMER AND CONTROL BOARD. THIS PRODUCES A SHOCKING HAZZARD. DO NOT
TOUCH THE CONTROL BOX COMPONENTS WITH ANYTHING OTHER THAN ELECTIRCAL
TESTING PROBES. ***
oCheck the transformer if no power (E35713)
oThere should be 230V 3ph or 480V 3ph going into the transformer (Check H1 (480V) or H2
(230V) AND H4 at top of transformer)
If no power into the transformer, check main power to the machine
oThere should be 24V AC coming out of the transformer and entering the board at terminals
1 and 2
oCheck to make sure the fuse is intact (E16224)
•Check to make sure that when a cycle is initiated, that there is 24V DC coming from the board to the
clamp solenoid at terminals 11 & 12
o*** CAUTION: ONLY A QUALIFIED ELECTRICIAN SHOULD PERFORM THE
FOLLOWING STEPS. POWER MUST BE SUPPLIED TO THE MACHINE TO CHECK THE
CONTROL BOARD. THIS PRODUCES A SHOCKING HAZZARD. DO NOT TOUCH THE CONTROL
BOX COMPONENTS WITH ANYTHING OTHER THAN ELECTIRCAL TESTING PROBES. ***
oRun a cycle on the machine (put the stock in place, depress the safety buttons, and press the
foot pedal), then check the pins at terminals 11 & 12, then the screws at 11 & 12
If there is no power at the pins, change the board (E35424)
If there is power at the pins, but not at the screws, change the terminal strip
(E21016)

TSM-35 Screw Pocket Machine Troubleshooting
35.16 Test Stock Sense / Safety Blade Switch
•Disconnect power and air to the machine.
•Make sure the case top is shut.
•Locate pins “5” and “6” on the pin strip in the control box.
•Touch continuity tester to “5” and “6” on the pin strip.
•Continuity tester should read open.
•Press in safety buttons under the clamp guard and tester should read closed.

TSM-35 Screw Pocket Machine Troubleshooting
35.17 Test Foot Switch
•Disconnect air and power to the machine
•Locate pins “3” and “4” on the pin strip of the control board.
•Touch continuity tester pins to “3” and “4” on the pin strip and the switch should read open.
•Step on the foot peddle while still touching the pins and the continuity tester should read closed.

TSM-35 Screw Pocket Machine Troubleshooting
35.18 Machine starts, but shuts down when cycle is initiated:
!***ALWAYS DISCONNECT POWER AND AIR WHEN CHECKING SWITCHES ***!
•Check the air pressure switch. Most common reason. (E35420) (See 35.14)
oThe air pressure switch is set at 40 psi at the factory. It can often go bad and be hard to
diagnose.
oThe easiest way to check is to bridge the two wires and see if the machine will turn on.
oWe no longer use the air pressure switch. Customers can keep the bridge in place if they do
not wish to replace.
o
•Check the overload (E91827 480V Overload / E94060 230V Overload / E94061 Single phase overload)
oIncrease the amperage capacity on the overload.
oIf this does not solve the issue, then most likely the problem is with the contactor or
overload.
oIt is recommended to change both components. Currently the Sprecher & Schuh (S & S)
brand we use will need both pieces to be changed, regardless if there is an old S & S in the
machine. The new revision will not work with the old. (E91024 – Contactor)
o**** Contactors and overload components from different manufacturers cannot be
combined. ****

TSM-35 Screw Pocket Machine Troubleshooting
35.19 No cycle - Clamp begins to come down, and immediately goes back
up (flutters):
•Change the drill stop switch (E35010/ E35009 – Strap)
oThis is the most common reason

TSM-35 Screw Pocket Machine Troubleshooting
35.20 Clamp does not come down, but router and drill cycle:
!***ALWAYS DISCONNECT POWER WHEN CHECKING SOLENOIDS ***!
•Check the clamp solenoid (P21224) – first of the stack. The solenoids are located inside the case of
the machine, behind the control box.
oPress the red manual override button
Listen for air leaks and look for loose hose
If the clamp goes down, change the solenoid (P21224) – it is not working electrically
If the clamp does not go down, remove the hose from the top of the clamp and
override again. (It is a push in fitting, hold the plastic ring at the end of the fitting
down to the fitting, and pull out the hose. When replacing the hose, push hose in
firmly – no need to hold the ring.)
•If there is air out of the hose, change the clamp cylinder (P00215)
•If there is no air coming out of the hose, change the clamp solenoid
(P21224)
Push in Fitting Example

TSM-35 Screw Pocket Machine Troubleshooting
35.21 Clamp comes down, no router cycle, clamp does not retract:
•Run a dry cycle – put a piece of material next to, but not covering the router slot. Run a cycle.
oIf the clamp comes down and the router bit moves forward at normal speed
Check to make sure the router bit is spinning (and in the proper direction). If the
belt (H12075) is broken or the spindle (C35003) not spinning, then the bit cannot
move through the material to cut the pocket.
oIf the clamp comes down, but the router bit does not move:
Check the router feed rate valve (P00117)
•See if the valve has been turned all the way down
•The valve will usually fail completely open, but can get plugged with debris
on rare occasions.
!***ALWAYS DISCONNECT POWER WHEN CHECKING SOLENOIDS ***!
Check the router solenoid (P49410) – middle of the stack. The solenoids are located
inside the case of the machine, behind the control box.
•Press the red manual override button.
oIf the router comes up with force when the override is pressed, but
does not move when in cycle
Change the solenoid (P49410). There is a problem with the
electrical portion of the valve.
oIf the router begins to move very slowly
Adjust the router feed rate to see if there is any change.
Listen for air leaks at the solenoid. If there is a continual air
leak as the solenoid override is held down press a finger
over the exhaust port.
•If the carriage begins to move forward, change the
solenoid (P49410)
•If the carriage does not move the router cylinder
needs to be replaced (P35300 / or C35021–
complete cylinder assembly)
Remove the muffler / breather at the exhaust port and
override. If the router moves with force, clean or change
the muffler / breather (P00018).

TSM-35 Screw Pocket Machine Troubleshooting
If no air leaks, change the solenoid. (P49410)
oIf the router does not move when the override button is pushed,
check to make sure air is coming out of the solenoid:
Remove the air line from port #4 (air out to router feed rate
valve) and override.
•If no air – replace the solenoid (P49410)
•If air, reinsert the air line in fitting
Remove air line from the top of the router feed rate valve
and override
•If no air – replace the hose between the solenoid
and router feed rate valve (P35018)
•If air, reinsert the air line on fitting
Remove the air line from the bottom of the router feed rate
valve and override
•If no air – replace the router feed rate valve and
fittings (P00117 & P18165 x2)
•If air, reinsert the air line on fitting
Remove the air line from the bottom (operator end) of the
router cylinder and override
•If no air – replace the air line between the router
feed rate valve and the cylinder (P16181)
•If air – replace the router cylinder (P35300 / or
C35021 assembly)

TSM-35 Screw Pocket Machine Troubleshooting
35.22 Clamp comes down, pocket routes, no pilot hole, clamp stays
down:
•Run a dry cycle – put a piece of material next to, but not covering the router slot. Run a cycle.
oIf the clamp comes down and the router bit goes up and stays in
place until the machine is turned off, then it retracts
Check the router stop switch for position on the cylinder
- move slightly toward the operator
Change the router stop switch. (E35010/ E35009 – Strap)
oIf the clamp comes down, the router bit comes up, and the router
stays up after the machine is turned off
Disconnect main air
If router retracts, change router solenoid (P49410)
If router does not retract even after air has been
disconnected, remove and clean the muffler/breather on
the router solenoid (P00018)
Check for a crimped air line
oIf the clamp comes down, the router moves slowly, and then the drill runs at speed:
Check the router solenoid (P49410) and router cylinder (P35300)
!***ALWAYS DISCONNECT POWER WHEN CHECKING SOLENOIDS ***!
•Override the router solenoid (middle of the stack) with the red button
oMake sure the router feed rate valve has not been turned down
oListen for air leaks at the solenoid. If there is a continual air leak as
the solenoid override is held down press a finger over the exhaust
port.
If the carriage begins to move forward, change the solenoid
(P49410)
If the carriage does not move the router cylinder needs to
be replaced (P35300 / or C35021 – complete cylinder
assembly)
oIf there is no leak and the router moves forward slowly remove the
muffler / breather (P00018) and override again. If it still moves
slowly, replace the solenoid (P49410).

TSM-35 Screw Pocket Machine Troubleshooting
oIf the clamp comes down, the router moves normally, and the drill does not move forward or
begin to spin:
Override the drill solenoid (last of stack) with red button
•If the carriage does not move, and the drill does
not spin, remove the air line at port #4 on the
solenoid and override again
oIf no air blows out of the port, replace
the drill solenoid (P49410)
oIf air comes out of the solenoid port,
check for clogs in the air line to the
cylinder and the drill delay assembly.
If no clogs, change the drill
solenoid (P49410). It is not
working electrically.
oIf the clamp comes down, the router moves normally, the drill
does not move forward but begins to spin:
Check the drill feed rate valve to make sure it is not turned all the way down
Override the drill solenoid (last in stack) with red button
•Listen and feel for air leaks at the super quick exhaust
oIf there is an air leak with the override button depressed, change
the SQE (P10320)
oIf there is an air leak at the SQE when the override button is NOT
depressed, change the drill cylinder (P35125 / or C35022 complete
drill cylinder assembly)
Remove the air line to the super quick exhaust on the drill feed rate valve and
override the drill solenoid
•If no air from the line, check the air line for clogs
•If air from the line, change the drill cylinder
oIf the clamp comes down, the router and drill cycles both run at speed and the drill is
spinning:
Check the router solenoid (P49410) and router cylinder (P35300)

TSM-35 Screw Pocket Machine Troubleshooting
•Override the router solenoid (middle of the stack) with the red button
oListen for air leaks at the solenoid. If there is a continual air leak as
the solenoid override is held down, press a finger over the exhaust
port.
If the carriage begins to move forward, change the solenoid
(P49410)
If the carriage does not move the router cylinder needs to
be replaced (P35300 / or C35021 – complete cylinder
assembly)
oRemove the muffler / breather (P00018) at the exhaust port on the
router solenoid and run a pocket. If the cycle completes, change or
clean the muffler / breather.
Check the drill solenoid (P49410)
•Override the drill solenoid (last of the stack) with the red button and try to
stop the carriage from moving forward
oIf you can stop the carriage:
Listen / feel for air leaks at the muffler breather on the drill
solenoid
•If there is a constant leak when trying to stop the
carriage, replace the drill cylinder (P35125)
•If there is a constant leak when the machine is at
rest, change the drill solenoid (P49410)
Listen / feel for air leaks at the super quick exhaust (SQE)
(P10320) on the drill feed rate assembly.
•If there is a constant leak without overriding the
solenoid, replace the drill cylinder (P35125)
•If there is a constant leak when the drill solenoid is
overridden, replace the SQE (P10320)
If there are no air leaks, replace the drill solenoid (P49410)
Check the drill (P01957)(See 35.23)

TSM-35 Screw Pocket Machine Troubleshooting
35.23 – Checking the Drill Motor for function
!NOTE: The drill should have a visible slick of oil and sawdust mix at the front vent
area. If not, this indicates a drill that is not receiving lubrication and will most likely
need to be replaced.
•Run a dry cycle – put a piece of material next to, but not covering the router
slot. Run a cycle.
•If the clamp comes down, the router moves forward normally, the drill carriage comes forward, but
the drill does not begin to spin:
oRemove the small red or black hose (air in from solenoid) from the drill delay assembly and
override the drill solenoid (last in stack) *** CAUTION – the drill carriage will move forward
when overriding the solenoid ***
If no air comes out of the small red or black
hose AND the drill carriage comes forward,
check for a blockage in the red hose. (There
is a T Barb fitting in this hose.)
If air comes out of the red hose:
•Replace the red hose and override
the solenoid - listen for air blowing
through the drill
oIf there is air blowing
through the drill, but it is not
spinning, replace the drill
(P01957)
If there is no air blowing through the drill
when the solenoid is overridden:
•Remove the drill from the drill
carriage by removing the carriage
bolts that hold the drill mounting
plate to the yellow carriage (mark drill height before removing).
•Then remove the drill from the brass fitting that connects it to the pilot
valve and drill delay assembly.
•Override the drill solenoid (last one in the stack) and see if air blows out of
the brass fitting. ** Caution: the drill carriage will move forward when
overriding the solenoid. **
•If no air comes out of the fitting from the pilot valve / hose assembly:
oRemove the small red or black hose (air in from solenoid) from the
push in fitting on the drill delay assembly and override again.
oIf air comes out of the small hose, replace the pilot valve (P35250)

TSM-35 Screw Pocket Machine Troubleshooting
**** Drain the air tank with the drain cock prior to
working on the pilot valve. We recommend purging the air
lines and tank to remove as much debris as possible.
To confirm that there is air reaching the pilot valve:
•Remove main air from machine
•Use the drain cock to drain the air tank
•Remove the pilot valve from the large red hose that
supplies air from the air tank
•Place a towel over the fitting on the red hose and
reattach main air to the machine **CAUTION – air
and air tool oil should immediately blow from the
red hose, make sure the hose is secure when main
air is reattached.
oIf air does blow from the hose, the pilot
valve needs to be replaced.
oIf there is no air out of the hose, then the
issue is with the air supply to/from the air
tank. Check the lubricator to make sure it is
providing air, check the check valve to make
sure it is allowing air through, check to
make sure the air tank is able to hold air
and deliver air, check the red hose from the
tank to make sure it is not blocked.
•If air comes out of the fitting from the pilot valve / hose assembly:
oPlace a towel over the fitting and override the solenoid again. Look
for debris and or air tool oil on the towel.
If there is visible debris:
•Replace the pilot valve (P35250)
•Check the screen in the back of the air drill. If there
is visible debris, replace the air drill (P01957)
•**** Drain the air tank with the drain cock prior to
working on the pilot valve. We recommend purging
the air lines and tank to remove as much debris as
possible.

TSM-35 Screw Pocket Machine Troubleshooting
If there is no debris and no air tool oil on the towel:
!*** NOTE: The air drill must receive lubrication. If it does
not, it can become charred on the inside and must be
replaced. (P01957)
•Check the lubricator on the front of the machine. If
it does not have oil in the reservoir, add oil and
override the solenoid multiple times to help prime
the system.
•If there is oil in the reservoir, override the solenoid
to and check the top of the lubricator to see if drips
of oil are falling while the solenoid is depressed. Try
to turn up the lubricator feed rate to a drop every
few seconds.
•If the lubricator will not turn up, replace the
lubricator – check for brand.
oClippard (P35081 )
oParker (P35067 )
oWatts – Need to replace both units
(C35002)
•If the drill has stopped spinning due to lack of oil, it
will need to be replaced. (P01957)
If there is oil on the towel but no debris
•Replace the drill (P01957)
oIf the drill spins while moving forward, but bogs down when trying to drill the pilot hole:
Begin with the test information above. If the issue is not discovered with the above
diagnostics:
•Remove the drill from the drill carriage by removing the carriage bolts that
hold the drill mounting plate to the yellow carriage (mark drill height before
removing).
•Then remove the drill from the brass fitting that connects it to the pilot
valve and drill delay assembly.
oUse air from a secondary source into the air drill
oTry to use the drill as a hand tool to drill into material. If it bogs
down, it will need to be replaced. (P01957)
oIf the drill did not bog down outside the machine, reinstall the drill
on the fitting of the pilot valve assembly. Override the drill solenoid
and use the drill as a hand tool to see if the bit bogs down. If the
drill slows down or stops, replace the pilot valve (P35250)
If the drill does not bog down in either test, check the drill solenoid (P49410)
•Override the drill solenoid (last of the stack) with the red button and try to
stop the carriage from moving forward

TSM-35 Screw Pocket Machine Troubleshooting
oIf you can stop the carriage:
Listen / feel for air leaks at the muffler breather on the drill
solenoid
•If there is a constant leak when trying to stop the
carriage, replace the drill cylinder (P35125)
•If there is a constant leak when the machine is at
rest, change the drill solenoid (P49410)
Listen / feel for air leaks at the super quick exhaust (SQE)
(P10320) on the drill feed rate assembly.
•If there is a constant leak without overriding the
solenoid, replace the drill cylinder (P35125)
•If there is a constant leak when the drill solenoid is
overridden, replace the SQE (P10320)
If there are no air leaks, replace the drill solenoid (P49410)