Castle TSM-21 User Manual
Screw Pocket Machine
Model TSM-21
Operator Manual
Read and understand this manual
before using machine
1364 N. McDowell Blvd, Ste 1
Petaluma, CA 94954
(800)282-8338
U.S. Patent No. 4603719
Castle, Inc.
Table of Contents
Customer Promise_______________ Page 1
Safety Notification_______________ Page 1
Introduction
Definition of Terms_______________________ 2
Operating Features and Controls_____________ 3
Manual Contents Notice___________________ 5
Safety
Types of Warnings_______________________ 6
General Safety Rules_____________________ 6
Machine Inventory_______________ Page 8
Electrical and Air Requirements____ Page 8
Set Up and Installation____________ Page 9
Initial Configuration ______________ Page11
Adjustments
Router Feed Rate _________________________ 13
Pocket Web _____________________________ 14
Pocket Depth Position__________________ ___ 15
Drill Feed Rate __________________________ 16
Pilot Drill Depth _________________________ 17
Pilot Drill Height ________________________ 18
Operation______________________ Page 19
Service and Maintenance
Tool Changes____________________________ 21
Machine Maintenance_____________________ 23
Motors and Bits_______________________ ___ 24
Troubleshooting
Dry Cycle Test __________________________ 26
Safety Switch ___________________________ 28
Foot Switch ____________________________ 29
Pressure Regulator _______________________ 30
Router Stop Switch ______________________ 31
Drill Stop Switch ________________________ 32
Warranty & Returns ______________ Page 33
Customer Promise
In a perfect world, there would be no need for Technical Support and Service. At Castle, Inc. we
recognize that the world is not perfect (yet), so please call Castle Technical Support if you
encounter a problem with your Castle machine.
1 (800) 282- 8338
The jog and jostle of shipping and handling can undo even the most strict quality measures.
Many difficulties that may occur in a new machine can be identified with a simple test or
resolved with a simple adjustment right over the phone.
Castle’s innovative machines are designed to be user serviceable and many Castle dealers offer
top-notch technical know-how. In the event that you require on-site service or support we ask
that you first contact the dealer, distributor, or reseller from whom you purchased your Castle
machine.
No one can promise a complete absence of problems and inconveniences, but we do promise
prompt, courteous, and professional assistance if you ever need it.
Safety Notification
WARNING: The Castle Model TSM-21 Pocket Cutter
was designed with operator safety as a priority.
This machine was carefully prepared for shipment at
our factory. Upon receipt of the machine, inspect for
shipping damage. IMMEDIATELY report any
damage to the freight company, to your Castle dealer,
and to Castle, Inc. DO NOT attempt to operate the
machine if you observe any physical damage. Contact
Castle, Inc. at 800-282-8338 for instructions.
1
Introduction
Fortify Your Shop
Thank you for making the Castle TSM-21 Screw Pocket Machine the latest addition to your
shop. Since 1985 our goal is to manufacture and develop machines that make cabinetmaking and
casework easier, faster, and more profitable for the woodworker. This machine represents our
patented screw pocket cutting technology. Castle machines are made in Petaluma, California
and are manufactured to the highest standards using local vendors wherever possible.
The Castle model TSM-21 is designed for use on a wide variety of materials. The machine
performs well in hardwoods, softwoods, melamine, particleboard and MDF. The machine will
work on materials varying in thickness from ½” to 1 ¾”.
This instruction manual is intended for use by any one working with this machine. It should be
kept available for immediate reference so that all operations can be performed with maximum
efficiency and safety.
Do not attempt to perform maintenance or operate this machine until you have read and
understand the information contained in this manual.
Definition of Terms
Pocket…………………………………….. The depression cut into material to allow for
toe-screw mortise joinery.
Pocket Cycle……………………………… The procedure by which the machine clamps
the work piece, cuts the mortising pocket,
drills the pilot hole, then releases the work
piece.
Web………………………………………. The offset distance from the end of the
pocket to the edge of the work piece.
2
Identification of Operating Features and Controls
1. Power Switch: Located on the left side of the machine, this
toggle switch turns on the Pocket Router Motor and the
Pilot Drill Motor as well as energizing the Controls.
2. Clamp Cylinder: The large cylinder on the top of the
machine is a clamp that holds the work piece safely in place
during operation. This is a single-acting, spring-return,
pneumatic cylinder with a padded foot on the end of the
cylinder rod.
3. Clamp Guard: The yellow metal Clamp Guard on top of
the machine serves to secure the Clamp Cylinder and to
safeguard the operator from the clamping and pocket cutting
action.
4. Router Stop Plate: Located just inside the rear door, this
black metal plate extends through the top of the case and
along the right side of the Clamp Guard. The position of
this plate determines the size of the “Web.”
5. Foot Pedal and Guard: Mounted inside a yellow metal
guard, the Foot Pedal is connected to the machine by an
electrical cord. Pressing the Foot Pedal will activate the
machine cycle (but only if the Safety Buttons are depressed
by the work piece as well).
6. Safety Buttons: Two small, silver button-head screws
under the Clamp Guard detect if a work piece is in place for
pocketing. The machine will not cycle unless these buttons
are depressed simultaneously with the Foot Pedal.
3
7. Safety Switch: This magnetic proximity switch is mounted
inside, near the top of the TSM-21. It is activated when the
Safety Buttons are depressed by the work piece.
8. Motor Carriage: The Motor Carriage is the yellow,
pivoting A-frame structure inside the machine. Both the
Router Motor and the Drill Motor are mounted to this
carriage. The forward and back carriage motion during the
machine cycle is provided by the Drive Cylinder.
9. Drive Cylinder: This double-acting pneumatic cylinder
connected to the Motor Carriage and the machine case,
moves the carriage through the routing and drilling phases
of the cycle. When the cylinder rod extends (moving the
carriage toward the rear) the router cuts the pocket. When
the cylinder rod retracts (moving the carriage forward) the
pilot drill bores the pilot hole into the pocket. Note: SQE
valves are replaced by elbow fittings in models with Serial
Number 62481 and higher.
10. Router Stop Switch: This magnetic proximity switch is
mounted on the Router Stop Plate inside of the machine. At
the full extension of the routing stroke, the carriage
interrupts this switch to signal the start of the drilling stroke.
11. Drill Stop Switch: This magnetic proximity switch is
mounted inside the machine case near the Safety Buttons.
At the full extension of the drilling stroke, the carriage
interrupts this switch to signal the end of the cutting cycle.
The carriage returns to the neutral position and the clamp
releases the work piece.
12. Control Box: The Control Box is the sheet metal enclosure
containing the electrical and pneumatic controls. Mounted
in the Control Box are the power switch and the power
outlets for the motors. Mounted on the underside of the
Control Box are the air inlet, the Pressure Regulator, the
Router Speed Control valve, and the solenoid valves.
4
Manual Contents Notice
This manual is not totally comprehensive. It does not and cannot convey every possible safety
and operational problem which may arise while using this machine. The manual will cover
many of the basic and specific safety procedures needed in a shop environment.
All federal and state laws and any regulations having jurisdiction covering the safety
requirements for use of this machine take precedence over the statements in this manual. Users
of this machine must adhere to all such regulations.
Most national and international standards that may apply to your machines and accessories
contain requirements for manuals. These change from time to time and will require constant
monitoring to assure that your products and manuals are in compliance.
Castle products and the information in this manual are the proprietary property of Castle, Inc. or
its licensers, and may not be copied, disclosed, or used for any purpose not expressly authorized
by the owner thereof.
Since Castle, Inc. constantly strives to improve all of its products, we reserve the right to change
this manual and hardware mentioned therein at any time without notice.
5
Safety
Types of Warnings
Obey all safety messages that follow this symbol to avoid possible injury or death.
This indicates an imminently hazardous situation which, if not avoided, WILL result in death or
serious injury.
This indicates a potentially hazardous situation which, if not avoided, COULD result in death or
serious injury.
This indicates a potentially hazardous situation which, if not avoided, COULD result in minor or
moderate injury.
IMPORTANT
This indicates useful information about proper operation of the machine.
General Safety Rules for Machine Operators
and Persons in the Operating Area
• USE CAUTION WHEN USING THIS MACHINE! Only skilled operators should use
this machine, or be within ten feet when the machine is in operation.
• Read the Operator Manual carefully before operating. An Operator Manual should be
attached to this machine. It contains important information and warnings concerning the
use and operation of this machine. Improper use of this machine may result in serious
injuries to persons and property.
• Always wear protective eyewear when operating or standing near an operating machine.
• Be certain that this machine is properly grounded before operating it.
6
• Keep all body parts away from the moving parts of this machine whether it is in operation
or at rest.
• Do not place hands or fingers between the work piece and the clamp or near the cutters at
any time. Always use a securing device when undertaking close work.
• Do not wear gloves or loose clothing (such as sweaters, jackets, or jewelry) when
operating or standing near an operating machine.
• Keep two hands on the work piece when initiating a pocket cycle on this machine.
• Before attempting adjustments, maintenance, or repair, TURN OFF this machine,
disconnect it from its power source and air supply. Wait for all motion to stop. Failure to
disconnect this machine from its power source and air supply or wait for all motion to
stop could result in electrocution or injury.
• Always keep the area around this machine clean and uncluttered. Poor housekeeping
could result in slips, falls, or other injuries.
• Concentrate at all times. Failure to pay attention to the task at hand is the cause of most
accidents.
7
Inventory
With your Castle machine you should have received the following:
Warranty Card (Please fill out & mail to Castle, Inc. to activate warranty)
TSM-21 Operator Manual and Parts Explosion
Two (2) PC 6902 Router Wrenches
One (1) PC 7301 Router Wrench
One (1) #2 x 6” Square Driver bit
Manual and Warranty Card for PC 6902 Router
Manual and Warranty Card for PC 7301 Router
Bit Gauge
Two Door Handle Assemblies
2- Door Springs
2- Bolts (¼ x 20)
2- T-handles
Electrical and Air Requirements
Power Supply: 115 VAC ± 10%, 60 Hz, 20 Amp Service
IMPORTANT Do not use an extension cord.
Using and extension cord to power your TSM-21 may void your Warranty!
Air Supply: 80psi (minimum), 150psi (maximum) 1.5cfm; Minimum ¼” ID air line
IMPORTANT
Failure to provide an adequate supply of CLEAN, DRY air may void your Warranty!
Dust Collection: The TSM-21 will function better with proper dust collection attached. A vent
for this purpose has been provided. When attaching a dust collection system, remove
the cover plate over the vent opening in the back door. Attaching dust collection will
prolong motor life by keeping the router motors cooler and free from sawdust buildup.
IMPORTANT
Failure to clean sawdust from your machine may void your Warranty!
8
Set-up / Installation
Always use eye protection when operating power equipment.
Your Castle TSM-21 Pocket Cutter was set up and tested for proper operation at the
factory. It is normal to find a small amount of sawdust in the TSM-21 from this process.
Verify that the Power Switch is turned off. Remove the Power Cord and Foot Pedal from
inside the machine.
Remove the swivel elbow from the black urethane hose by pushing the floating ring
toward the elbow and pulling the hose at the same time.
Thread the elbow into the top of the Clamp Cylinder. It is pre-primed and self-sealing.
Point it toward the rear of the machine and firmly push the hose back into the fitting.
(Figure 1)
Figure 1
Connect a clean, dry air supply to the left side of the machine with a minimum supply of
80psi. (Figure 2) Using an air supply of less than 80psi. will result in insufficient
clamping force, which can cause material shifting and possible injury to the operator.
We strongly recommend that you use an inline filter/water trap.
Figure2
IMPORTANT
Do not introduce lubricants, oils, or solvents into the pneumatic system. Irreparable
damage to pneumatic seals and components may occur.
Using lubricants in the pneumatics of your TSM-21 may
9
void your Warranty!
Loading...