CASTLE TSM-21 User manual

CASTLE INC PO BOX 750236 PETALUMA CA 94975
WWW.CASTLEUSA.COM
Installation Instructions
TSM-21 Bosch Motor Carriage
CASTLE, INC.

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Table of Contents
1INTRODUCTION.............................................................................................................................4
1.1 DEFINITION OF TERMS................................................................................................................4
1.2 IDENTIFICATION OF OPERATING FEATURES AND CONTROLS .........................................................5
2INSTALLATION INSTRUCTIONS ..................................................................................................6
2.1 SAFETY RULES..........................................................................................................................6
2.2 INVENTORY................................................................................................................................7
3REPLACING THE ROUTER CARRIAGE.......................................................................................8
3.1 REMOVING THE ROUTER STOP PLATE.........................................................................................9
3.2 REMOVING THE PORTER CABLE MOTOR CARRIAGE.....................................................................9
3.3 INSTALL THE NEW BOSCH MOTOR CARRIAGE ............................................................................10
3.4 INSTALL THE NEW ROUTER STOP PLATE ...................................................................................11
4FINAL INSTALLATION AND ADJUSTMENTS.............................................................................13
4.1 MOTOR REPLACEMENT ............................................................................................................13
4.2 CARRIAGE ADJUSTMENTS ........................................................................................................13
4.3 POCKET WEB ADJUSTMENT......................................................................................................14
4.4 POCKET DEPTH ADJUSTMENT ..................................................................................................15
4.5 DRILL FEED RATE ADJUSTMENT ...............................................................................................16
4.6 PILOT DRILL DEPTH ADJUSTMENT ............................................................................................17
4.7 PILOT DRILL HEIGHT ADJUSTMENT ...........................................................................................18
5SERVICE AND MAINTENANCE ..................................................................................................20
5.1 TOOL CHANGES.......................................................................................................................20
5.2 POCKET ROUTER BIT...............................................................................................................20
5.3 PILOT DRILL BIT.......................................................................................................................22
5.4 GENERAL MACHINE MAINTENANCE...........................................................................................22
5.5 MOTORS AND BITS...................................................................................................................23
5.6 SERIAL NUMBER LOG...............................................................................................................25

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1 Introduction
Thank you for purchasing a TSM-21 Bosch Motor Carriage upgrade. Since 1985 our goal is to
manufacture and develop machines that make cabinetmaking and casework easier, faster, and
more profitable for woodworking professionals.This upgrade 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”.
Warning: Do not attempt to perform maintenance or operate this machine until you have read and
understand the information contained in this manual.
1.1 Definition of Terms
TERM DEFINITION
Pocket The depression cuts 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.

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1.2 Identification of Operating Features and Controls
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.”
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.
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.
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.
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.

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2 Installation Instructions
These instructions are intended to illustrate how to remove the motor carriage designed for
Porter Cable motors and replace it with a carriage designed for Bosch motors. At the same time
the Router Stop Plate must be changed as the old style will interfere with the Bosch carriage
movement.
2.1 Safety Rules
The Castle Model TSM-21 Pocket Machine was designed with operator safety as a priority,
which is why Castle highly recommends the following:
1. Read this Instruction Manual carefully before beginning the carriage exchange.
2. 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.

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2.2 Inventory
With your Castle TSM-21 Bosch Motor Carriage upgrade pack you should have received the
following:
CASTLE TSM-21 Bosch Carriage Upgrade Parts
Part # Part Description Qty
G21123 TSM-21 Router Carriage – Bosch 1
N21142 TSM-21 U-Bolt (Router) Installed 1
N21143 TSM-21 U-Bolt (Trimmer) Installed 1
H00141 ¼-20 Bar Knob Installed 2
G21007 TSM-21 Rear Stop 1
D21638 Bosch 3/8” Collet for Router Motor 1
F01420 1/4-20 Nylon Insert Locknut 3
Lithium Grease 1
With purchase of Upgrade Kit with motors:
E21610 Bosch PR20EVS 1.0 HP Motor 1
E21617 Bosch 1617 2 HP Motor 1
B00338 Solid Carbide, 3/8” Rough Mill Three Flute Router Bit 1
B02964 9/64” Brad and Spur Premium Drill Bit with ¼” Shank 1

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3 Replacing the Router Carriage
Caution: Make sure your machine is unplugged from its electrical outlet and the air
supply has been detached.
These instructions will detail the steps required to upgrade your TSM-21 to use Bosch Motors.
Videos of these processes are available on line.
Here are the steps detailed in this instruction guide:
•Remove the Router Stop Plate (3.1)
•Remove the Porter Cable Router Carriage (3.2)
•Install the Bosch Router Carriage (3.3)
•Replace the Router Stop Plate (3.4)
•Adjust the carriage and center the pocket and pilot hole (4.1)
•You must adjust carriage to center after installation to reset drill and router
alignment. Please see section 4.2 once you have installed both motors
in the new carriage.

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3.1 Removing the Router Stop Plate
Note: Marking the location of the Router Stop Plate on the yellow Clamp guard will
save time and keep the same web depth when installing the new Router Stop
Plate.
•From the back door use a Phillips Screw Driver remove the screws holding the switch portion
(wires attached) of the two piece Router Stop Switch. (Save for installation of new stop
plate.)
•The switches are held in place with square nuts (save for installation of new stop plate).
•From the top of the machine use a 7/16 wrench to remove the ¼-20 Nylock Nut
•Remove the washer (save for installation of new stop plate)
•Push the bolt through into the clamp guard and remove by reaching through the back door
and up into the clamp guard. (Save for installation of new stop plate.)
•Remove the old plate by angling the top of the Router Stop Plate through the slot next to the
clamp guard and removing through the back door.
•Remove the magnet portion of the Router Stop Switch
•Save magnet, screws, and square nuts for installation of new stop plate.
3.2 Removing the Porter Cable Motor Carriage
•Remove the Porter Cable motors from the Carriage.
•Disconnect the Spring from the Carriage with a pair of pliers but leave attached to the case.
•Disconnect the Drive Cylinder from the Carriage but leave attached to the case.
•Remove the cotter pin from the clevis pin (save for installation of new carriage)
•Remove the clevis pin from the rod clevis (save for installation of new carriage)
Note: Removing the Work Top will allow easier access to the router motor, spring,
and drive cylinder.
•Remove the Set Screws on the sides of the machine
•Loosen the ¼-20 Nylock nuts with a 7/16 Wrench

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•Use a 1/8” Allen Wrench to loosen and completely remove the Set Screws (save for
installation of new carriage)
•Through the back door twist the Motor Carriage to remove from the Bearing Jacks.
•The carriage will release with the Brass Hex Pivot Bushings in place
•Remove the old Motor Carriage through the back door
•Remove the Brass Hex Pivot Bushings from the carriage
•Wipe out to remove old grease and any sawdust or debris buildup
3.3 Install the new Bosch Motor Carriage
Note: We suggest that you test install the drill motor in the new carriage before it is
in the case. The drill motor is held in place by two braces on either side of the u-
bolt, and rests against a stop at the front. You will need to remove it before in-
stalling the carriage.
•Re-grease the Brass Hex Pivot Bushings with lithium grease (provided)
•Place Brass Hex Pivot Bushings on new Motor Carriage
•Move the new carriage into the machine through the back door.