Castle TSM-35 User Manual
CASTLE INC
Owner’s Manual
TSM-35 Swing Front Heavy Duty Pocket Cutter
CASTLE, INC TSM-35 OWNERS MANUAL V1.2 Page 2 of 33
Table of Contents
1 INTRODUCTION.............................................................................................................................4
2 MACHINE SAFETY.........................................................................................................................5
2.1 SAFETY RULES..........................................................................................................................5
2.2 INVENTORY................................................................................................................................6
2.3 MACHINE REQUIREMENTS ..........................................................................................................7
3 SETTING UP YOUR TSM-35 .........................................................................................................8
4 OPERATING INSTRUCTIONS.....................................................................................................10
5 MACHINE ADJUSTMENTS..........................................................................................................11
5.1 WEB ADJUSTMENT...................................................................................................................11
5.2 POCKET DEPTH ADJUSTMENT...................................................................................................12
5.3 PILOT DRILL DEPTH ADJUSTMENT ............................................................................................13
5.4 PILOT DRILL HEIGHT ADJUSTMENT ...........................................................................................14
5.5 LEFT AND RIGHT PILOT DRILL ADJUSTMENT ..............................................................................14
5.6 LEFT AND RIGHT ROUTER ADJUSTMENT....................................................................................16
5.7 ROUTER FEED SPEED..............................................................................................................17
5.8 DRILL FEED SPEED..................................................................................................................18
5.9 DRILL DELAY ADJUSTMENT ......................................................................................................19
5.10 DRILL STOP SWITCH ................................................................................................................19
5.11 ROUTER STOP SWITCH ............................................................................................................21
6 DEFINITION AND DESCRIPTION OF PARTS............................................................................23
7 SERVICE AND MAINTENANCE ..................................................................................................29
7.1 GENERAL ................................................................................................................................29
7.2 MOTORS AND BITS...................................................................................................................30
7.3 SWING FRONT ACCESS: HOW TO OPEN YOUR MACHINE .............................................................31
7.4 SERIAL NUMBER LOG...............................................................................................................32
9. WARRANTY INFORMATION...........................................................................................................33
10 APPENDIX B – GLOSSARY OF TERMS.........................ERROR! BOOKMARK NOT DEFINED.
CASTLE, INC TSM-35 OWNERS MANUAL V1.2 Page 3 of 33
1 Introduction
Thank you for making the Castle TSM-35 the latest addition to your shop. Since 1985 our goal
has been to manufacture and develop machines that make cabinetmaking and casework easier,
faster and more profitable for the woodworker. This machine represents our commitment to your
productivity. Castle machines are made in Petaluma, California and are manufactured to the
highest standards using local vendors wherever possible.
This instruction manual is intended for use by anyone setting up or servicing this machine. It
should be kept available for immediate reference so that all operations can be performed with
maximum efficiency and safety.
Your TSM-35 will pocket any material you would normally rout. It is designed for material from 1
½” to ½”. Use of materials thinner than ½” is not recommended. Every TSM-35 machine is
factory adjusted and tested with sample material. If you should find a small amount of saw dust
in the bottom of your TSM-35, please don’t be alarmed.
Note: Do not attempt to perform maintenance or operate this machine until you have read
and understand the information contained in this manual.
CASTLE, INC TSM-35 OWNERS MANUAL V1.2 Page 4 of 33
2 Machine Safety
This machine was carefully prepared for shipment at our factory. Upon receipt of the machine,
inspect for shipping damage. Report any damage IMMEDIATELY to the freight company, your
Castle dealer and to Castle, Inc. DO NOT attempt to operate the machine if you observe any
physical damage. Please contact Castle, Inc. at 800-282-8338 for instructions.
2.1 Safety Rules
The Castle Model TSM-35 Pocket Machine was designed with operator safety as a priority,
which is why Castle highly recommends the following:
1. Always use a qualified electrician in hard wiring your machine to 3-phase electrical
power.
2. Do not electrically wire machine until ready to operate.
3. Always wear eye protection when operating or servicing mechanical equipment.
4. Always wear hearing protection when the machine is in operation.
5. Always check for proper tooling tightness prior to use.
6. Do not at any time put hand under the clamp guard, in the path of router bit or drill bit.
7. Familiarize yourself with the clamping action, routing and drilling functions of the ma-
chine before electrically wiring the machine to any 3-phase electrical power supply.
8. Double check the tag on the electrical box of your machine to be sure it reads the
proper 3-phase voltage that you are using with your machine.
9. NEVER ALLOW MACHINE TO GET WET OR BE USED IN A WET ENVIRONMENT.
CASTLE, INC TSM-35 OWNERS MANUAL V1.2 Page 5 of 33
2.2 Inventory
CASTLE TSM-35 SWING FRONT HEAFY DUTY
POCKET CUTTER HARDWARE PACK
Part # Part Description Qty
S90011 TSM-35 Operator Manual with Warranty Activation Card 1
T30465 Collet Wrench 1
T30466 Collet Wrench 1
G00234 Bit Gauge 1
S00350 Air Tool Oil for Sioux Drill 1
M00400 Castle Front Door, Black w/ Logo 1
D00720 Female Hinge 2
H00141 Door Handle 1
G00101 Door Spring Clip 1
F14125 ¼ - 20 x ¾ Bolt 1
CASTLE, INC TSM-35 OWNERS MANUAL V1.2 Page 6 of 33
2.3 Machine Requirements
Electricity: 3-Phase 208VAC, 230VAC OR 460VAC
Warning: See voltage tag on the machine or wiring diagram inside the voltage box to con-
firm the electrical requirements for your machine before wiring and running your
machine.
Caution: Always have a qualified electrician do any machine wiring.
Shop Air Supply: 80 PSI minimum, 150 PSI maximum
Dust Collection: The TSM-35 relies on motor cooling from dust collection. A 4” dust collection
tube is located in the rear of the machine.
CASTLE, INC TSM-35 OWNERS MANUAL V1.2 Page 7 of 33
3 Setting Up Your TSM-35
Caution: Always use eye protection when operating power equipment.
1. Remove the machine from the pallet, position and secure your machine in its chosen lo-
cation.
Note: Holes in the base are for securing the machine to the floor. In some operations the
machine should be elevated for better ergonomic operation but it still must be
secured in place so that it cannot rock or tip.
2. Remove the brass elbow from the black urethane hose by pushing the floating ring to-
wards the elbow and pulling the hose at the same time.
3. Thread the elbow into the top of the Clamp Cylinder. It is pre-primed and self-sealing.
Point it toward the back of the machine and firmly push the hose back into the fitting.
Supply compressed air to the Regulator/ Lubricator Assembly at the front of the machine. The
regulator is factory set at approximately 85 PSI. (Check the gauge to confirm this setting.)
Castle suggests that a minimum of 3/8 inch air line should be used to operate this machine.
Quick disconnects are not recommended as they generally restrict the air flow (volume).
Note: Inadequate air supply may cause the machine to malfunction.
4. Remove Lubricator bowl and fill to Maximum Oil Level line with proper oil (supplied), then
replace full bowl.
5. Electrically hard wire to correct voltage as tagged on the machine. This is a 3-phase
machine and the voltage tag attached to the gray voltage box will show the voltage.
Caution: Use only a qualified electrician to hard wire your machine.
Note: The machine will not start if the air is off and/or the Case Top is in the lifted position.
6. Connect a dust collection system to the machine. Collection systems clear particles of
dust as well as venting heat away from your machine motor.
7. In the event that you are using your TSM-35 for face frames, we have provided adjust-
able stops for faster, more efficient pocket cutting.
CASTLE, INC TSM-35 OWNERS MANUAL V1.2 Page 8 of 33
8.
Check the rotation direction of the router before operation. The bit should turn counter
clockwise. To check direction, start machine by pressing the green Start Button on the
gray electrical box at the front of the machine. Press red Stop Button and look into the
slot where the bit comes up to make the pocket. As the machine slows to a stop, notice
the direction.
Warning: Do not open the lid to check the direction as it will continue to turn for several seconds
after the motor has been shut off.
CASTLE, INC TSM-35 OWNERS MANUAL V1.2 Page 9 of 33
4 Operating Instructions
Caution: Always use eye and hearing protection when operating machinery.
1. With the air on and the Case Top down, press the green Start Button. Note: the red Stop
Button must be in the “out” position before the Start Button will activate your machine. If
the red button is pushed in, simply turn the button ¼ turn counter clockwise to release.
2. Place stock to be pocketed under the yellow Clamp Guard.
3. To cut a pocket, push in the Safety Buttons under the Clamp Guard with the material to
be pocketed and depress the Foot Pedal to activate the machine.
4. The cycle start up must be achieved by both the Foot Pedal AND the Safety Buttons.
The Foot Pedal does not have to be released to repeat the machine cycle but the Foot
Pedal must be depressed to operate the machine.
5. The machine will extend the Hold-down Clamp, cut the pocket, drill the pilot hole, and
then release the Hold-down Clamp when the process cycle is complete.
6. Remove the stock and inspect the pocket. If the pocket and pilot hole look correct, you
are ready to proceed with production.
7. A typical machine cycle will take from 1 ½ to 2 seconds to complete if the machine is
functioning properly.
8. If the machine fails to cycle properly, call Castle at (800) 282-8338.
CASTLE, INC TSM-35 OWNERS MANUAL V1.2 Page 10 of 33
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