CASTLE TSM-22 User manual
CASTLE USA
Owner’s Manual
TSM-22 Pocket Hole Machine
CASTLE USA TSM-22 OWNER’S MANUAL V2.0 PAGE 3 OF 37
1 Table Of Contents
1 Introduction ...................................................................................................................................5
1.1 DenitionofTerms......................................................................................................................................................5
1.2 IdenticationofOperatingFeaturesandControls......................................................................................................6
1.3 Manual Contents Notice.............................................................................................................................................9
2 Machine Safety .............................................................................................................................9
2.1 Safety Rules...............................................................................................................................................................10
2.2 Inventory.....................................................................................................................................................................11
2.3 MachineRequirements ..............................................................................................................................................12
3 SettingUpYourTSM-22 ...............................................................................................................13
3.1 InstallingtheWorkTop ...............................................................................................................................................15
3.2 InstallingtheGasSpring ............................................................................................................................................16
3.3 InitialConguration.....................................................................................................................................................17
4 Adjustments ..................................................................................................................................18
4.1 RouterFeedRateAdjustment ....................................................................................................................................18
4.2 PocketWebAdjustment .............................................................................................................................................19
4.3 PocketDepthAdjustment ...........................................................................................................................................20
4.4 DrillFeedRateAdjustment.........................................................................................................................................21
4.5 PilotDrillDepthAdjustment........................................................................................................................................22
4.6 PilotDrillHeightAdjustment .......................................................................................................................................23
5 Operation ......................................................................................................................................24
6 Service and Maintenance .............................................................................................................26
6.1 Router Bit ...................................................................................................................................................................26
6.2 Pilot Drill Bit................................................................................................................................................................27
6.3 GeneralMachineMaintenance ..................................................................................................................................28
6.4 Motors and Bits ..........................................................................................................................................................29
7 Troubleshooting ............................................................................................................................31
7.1 Dry Cycle Test ............................................................................................................................................................31
7.2 Safety Switch (Stock Sense)......................................................................................................................................33
7.3 FootSwitch.................................................................................................................................................................34
7.4 PressureRegulator ....................................................................................................................................................35
7.5 RouterStopSwitch.....................................................................................................................................................36
7.6 DrillStopSwitch .........................................................................................................................................................37
CASTLE USA TSM-22 OWNER’S MANUAL V2.0 PAGE 4 OF 37
7.7 SerialNumberLog .....................................................................................................................................................38
8 WarrantyInformation.....................................................................................................................38
CASTLE USA TSM-22 OWNER’S MANUAL V2.0 PAGE 5 OF 37
1 Introduction
ThankyouformakingtheCastleTSM-22ScrewPocketMachine(ToeScrewMortise)thelatest
additiontoyourshop.Since1985ourgoalhasbeentomanufactureanddevelopmachines
thatmakecabinetmakingandcaseworkeasier,fasterandmoreprotableforthewoodworker.
Thismachinerepresentsourcommitmenttoyourproductivity.Castlemachinesaremade
inPetaluma,Californiaandaremanufacturedtothehigheststandardsusinglocalvendors
whereverpossible.
TheCastlemodelTSM-22isdesignedforuseonawidevarietyofmaterials.Themachine
preformswellinhardwoods,softwoods,melamine,particleboardandMDF.Themachinewill
workonmaterialsvaryinginthicknessfrom1/2”to13/4”.
Thisinstructionmanualisintendedforusebyanyonesettinguporservicingthismachine.It
shouldbekeptavailableforimmediatereferencesothatalloperationscanbeperformedwith
maximumefciencyandsafety.
Note:Donotattempttoperformmaintenanceoroperatethismachineuntilyouhaveread
andunderstandtheinformationcontainedinthismanual.
1.1 DenitionofTerms
TERM DEFINTION
Pocket Thedepressioncutsintomaterialtoallowfortoe-screwmortisejoinery.
Pocket Cycle Themachinefunctionthatclampstheworkpiece,cutsthemortised
pocket,drillsthepilotholeandthenreleasestheworkpiece.
Web- Theoffsestdistancefromtheendofthepockettotheedgeofthework
piece.
CASTLE USA TSM-22 OWNER’S MANUAL V2.0 PAGE 6 OF 37
1.2 IdenticationofOperatingFeaturesandControls
Power Switch: Located on the left side of the
machine,thistoggleswitchturnsonthePocket
Router Motor and the Pilot Drill Motor as well as
energizingtheControls.
Clamp Cylinder:Thelargecylinderonthetop
ofthemachineisaclampthatholdsthework
piecesafelyinplaceduringoperation.Thisisa
single-acting,spring-return,pneumaticcylinder
withapaddedfootontheendofthecylinderrod.
Clamp Guard:TheyellowmetalClampGuard
ontopofthemachineservestosecurethe
ClampCylinderandtosafeguardtheoperator
fromtheclampingandpocketcuttingaction.
Router Stop Plate:Locatedontheoperator
rightside,thisblackmetalplateextendsthrough
thetopofthecaseandalongthesideofthe
ClampGuard.Thepositionofthisplatedeter-
minesthesizeofthe“Web”.
CASTLE USA TSM-22 OWNER’S MANUAL V2.0 PAGE 7 OF 37
Foot Pedal and Guard: Mounted inside a yellow
metalguard,theFootPedalisconnectedtothe
machinebyanelectricalcord.PressingtheFoot
Pedalwillactivatethemachinecycle(butonly
iftheSafetyButtonsaredepressedbythework
pieceaswell).
Safety Buttons:Twosmall,silverbutton-head
screwsundertheclampguarddetectifawork
pieceisinplaceforpocketing.Themachinewill
notcycleunlessthesebuttonsaredepressed
whentheFootPedalisdepressed.
Safety Switch:Thismagneticproximityswitch
ismountedinside,nearthetopoftheTSM-22.It
is activated when the Safety Buttons are de-
pressedbytheworkpiece.
Motor Carriage: TheMotorCarriageisthered,
pivotingA-framestructureinsidethemachine.
Both the Router Motor and the Drill Motor are
mountedtothiscarraige.Theforwardandback
carriagemotionduringthemachinecycleispro-
vided by the Drive Cylinder.
Drive Cylinder:Thisdouble-actingpneumatic
cylinderconnectedtotheMotorCarriageandthe
machinecase,movesthecarriagethroughthe
routinganddrillingphasesofthecycle.When
thecylinderrodextends(movingthecarriageto-
wardtherear)theroutercutsthepocket.When
thecylinderrodretracts(movingthecarriage
forward)thepilotdrillboresthepilotholeintothe
pocket.
CASTLE USA TSM-22 OWNER’S MANUAL V2.0 PAGE 8 OF 37
Router Stop Switch:Thismagneticproximity
switchismountedontheRouterStopPlate
insideofthemachine.Atthefullextensionofthe
routingstroke,theCastleplateonthecarriage
interruptsthewhiteswitchtosignalthestartof
thedrillingstroke.
Drill Stop Switch:Thismagneticproximity
switchismountedinsidethemachinecase
neartheSafetyButtons.Atthefullextension
ofthedrillingstroke,thecarriageinterruptsthis
switchtosignaltheendofthecuttingcycle.The
carriagereturnstotheneturalpositionandthe
clampreleasestheworkpiece.
Control Box:TheControlBoxisthesheetmetal
enclosurecontainingtheelelctricalandpneu-
maticcontrols.MountedintheControlBoxare
thepowerswitchandthepoweroutletsforthe
motors.MountedontheundersideoftheControl
Boxaretheairinlet,thePressureRegulater,the
RouterSpeedControlValve,andthesolenoid
valves.
CASTLE USA TSM-22 OWNER’S MANUAL V2.0 PAGE 9 OF 37
1.3 Manual Contents Notice
Thismanualisnotfullycomprehensive.Itmaynotconveyeverypossiblesafetyandoperational
problemthatmayarisewhileusingthismachine.Themanualwillcovermanyofthebasicand
specicsafetyproceduresneededinashopenvironment.
Allfederalandstatelawsandanyregulationshavingjurisdiction,coveringthesafety
requirementsforuseofthismachine,takeprecedenceoverthestatementsinthismanual.Users
ofthismachinemustadheretoallsuchregulations.
Mostnationalandinternationalstandardsthatmayapplytoyourmachinesandaccessories
containrequirementsformanuals.Thesechangefromtimetotimeandwillrequireconstant
monitoringtoassurethatyourproductsandmanualsareincompliance.Castleproductsandthe
informationinthismanualaretheproprietarypropertyofCastleUSAoritslicensers,andmay
notbecopied,disclosed,orusedforanypurposenotexpresslyauthorizedbytheownerthereof.
SinceCastleUSAconstantlystrivestoimproveallofitsproducts,wereservetherighttochange
thismanualandhardwarementionedthereinatanytimewithoutnotice.
CASTLE USA TSM-22 OWNER’S MANUAL V2.0 PAGE 10 OF 37
2 Machine Safety
TheCastleTSM-22wasdesignedwithoperatorsafetyasapriority.Thismachinewascarefully
packagedforshipmentatourfactory.Uponreceiptofthemachine,inspectforshippingdamage.
ReportanydamageIMMEDIATELYtothefreightcompany,yourCastledealerandtoCastle
USA. DO NOTattempttooperatethemachineifyouobserveanyphysicaldamage.Contact
Castle USA at 800.282.8338 for instructions.
2.1 Safety Rules
TheCastleModelTSM-22PocketMachinewasdesignedwithoperatorsafetyasapriority,
whichiswhyCastlehighlyrecommendsthefollowing:
1. USECAUTIONWHENOPERATINGTHISMACHINE!Onlyskilledoperatorsshouldusethis
machine,orbewithintenfeetwhenthemachineisinoperation.
2. ReadtheOperatorManualcarefullybeforeoperating.AnOperatorManualshouldbe
attachedtothismachine.Itcontainsimportantinformationandwarningsconcerningtheuse
andoperationofthismachine.Improperuseofthismachinemayresultinseriousinjuriesto
personsandproperty.
3. Alwayswearprotectiveeyewearwhenoperatingorstandingnearanoperatingmachine.
4. Becertainthatthemachineisproperlygroundedbeforeoperatingit.
5. Keepallbodypartsawayfromthemovingpartsofthismachinewheteritisinoperationorat
rest.
6. Donotplacehandsorngersbetweentheworkpieceandtheclampornearthecuttersat
anytime.Alwaysuseasecuringdevicewhenundertakingclosework.
7. Donotwearglovesorlooseclothing(suchassweaters,jackets,orjewelry)whenoperating
orstandingnearanoperatingmachine.
8. Keeptwohandsontheworkpiecewheninitiatingapocketcycleonthismachine.
9. Beforeattemptingadjustments,maintenance,orrepair,TURN OFFthismachine,disconnect
itfromitspowersourceandairsupply.Waitforallmotiontostop.Failuretodisconnectthis
machinefromitspowersourceandairsupplyorwaitforallmotiontostopcouldresultin
CASTLE USA TSM-22 OWNER’S MANUAL V2.0 PAGE 11 OF 37
electrocution or injury.
10. Alwayskeeptheareaaroundthismachinecleananduncluttered.Poorhousekeepingcould
resultinslips,falls,orotherinjuries.
11. Concentrateatalltimes.Failuretopayattentiontothetaskathandisthecauseofmost
accidents.
2.2 Inventory
WithyourCastlemachineryshipment,youshouldreceivethefollowing:
CASTLE TSM-22 POCKET CUTTER MACHINES HARDWARE PACK
Part # PartDescription Qty
S90022 TSM-22OperatorManualwithWarrantyActivationCard 1
TSM-22 Outer Shell 1
StorageDoor 1
M24013 Dust Diverter 1
FootPedal 1
TrimmerWrenchBoschPR10E 2
RouterWrenchBosch16172 2
B00622 #2x6”SquareDriverBit 1
G00234 BitGauge 1
G00101 DoorSpring 1
F14125 ¼x20Bolt 1
H00141 T-Handle 1
F51616 5/16SAEFlatWasher 4
F51699 5/16-18NylonLocknut 2
H24002 GasSpring–20.12”Extended 1
F14553 ¼-20x1-1/4FHSocketHeadCapScrew 6
F01420 ¼-20 Nylon Locknut 9
F01410 1/4SAEFlatWasher 9
F44100 ¼-20X1FHSocketHeadCapScrew 1
M24010 Stainless Lid Plate 1
F14340 ¼-20x¾CarriageBolt 2
T00532 AllenHexL-Key–5/32” 1
H55202 RareEarthMagnet 1
CASTLE USA TSM-22 OWNER’S MANUAL V2.0 PAGE 12 OF 37
2.3 MachineRequirements
Power Supply: 115VAC±10%,60Hz,20AmpService
WARNING:Donotuseanextensioncord.UsinganextensioncordtopoweryourTSM-22
willVOIDYOURWARRANTY.
Air Supply:80psi(minimum),150psi(maximum)1.5cfm;Minimum¼”IDairline.
WARNING:FailuretoprovideanadequatesupplyofCLEAN,DRYairwillVOIDYOUR
WARRANTY.
Dust Collection: TheTSM-22willfunctionbetterwithproperdustcollectionattached.Aventfor
thispurposehasbeenprovided.Attachingdustcollectionwillprolongmotorlifebykeepingthe
routermotorscoolerandfreefromsawdustbuildup.
WARNING:FailuretocleansawdustfromyourmachinewillVOIDYOURWARRANTY.
CASTLE USA TSM-22 OWNER’S MANUAL V2.0 PAGE 13 OF 37
3 SettingUpYourTSM-22
CAUTION:Alwaysuseeyeprotectionwhenoperatingpowerequipment.Pleasebesureto
visitourYouTubepageforvideosonsetupanduseoftheTSM-22.Clickheretogotoour
TSM-22 Playlist.
WatchtheTSM-22PocketCutterAssemblyVideohere.
1. Step1:Inspectshippingcartonforsignsoffreightdamage.
Pocketmachinesareallshippedinawhitecardboardcover
(Fig 1),withplasticshrink-wrapunderneathtohelphighlight
anypotentialdamage.Removecardboardcoveringto
furtherinspectanysignsofmarringandpotentialdamage.
2. Step2:Removewrapping,powercord,footswitch,and
accessoriesfrominsidethemachine(Fig 2).Remove2x4
skidsusedforshippingpurposes,removingboltsonthe
interior of the base (Fig 3).
Fig.1
Fig.2
Fig.3
CASTLE USA TSM-22 OWNER’S MANUAL V2.0 PAGE 14 OF 37
3. Step3:Removetheswivelelbowfromblackurethanehose(Fig 4)bypushingtheoating
ringtowardtheelbow,thenpullingonthehoseatthesametime.
4. Step4:ThreadtheelbowintothetopoftheClampCylinderandtighten.Itispre-primedand
self-sealing.Pointittowardtherearofthemachineandrmlypushthehosebackintothe
elbowtting(Fig 5).
Fig.4 Fig.5
CASTLE USA TSM-22 OWNER’S MANUAL V2.0 PAGE 15 OF 37
5. Step5:Openthelidandlocatethewrapped
RouterStopPlatehanginginsidethebackofthe
machine.(Fig 6)Unwraptobegininstallation
process.
NOTE:Themachinewillnotcyclecorrectlywithout
theRouterStopPlateinplace.
• Removethenut,washerandcarriagebolt.
looselyattachedtotheclampguard.(Fig 7)
• InserttheRouterStopPlatefrominsidethelidthroughtheslotbytheclampguard.(Fig
8)Thewhitemagneticsensorsshouldfacetowardtheoperatorwhenthelidisclosed.
(Fig 9).
• Insertthecarraigeboltwiththeheadinsidethe
machine.(Fig 10)
Fig.6
Fig.7
Fig.8
Fig.9
Fig.10
CASTLE USA TSM-22 OWNER’S MANUAL V2.0 PAGE 16 OF 37
• Placethewasherandnutonthecarriageboltandleaveloose.PositiontheRouterStop
Platebetweenthetwopiecesoftapeandtightenthenut.(Fig 11)Removethetape
when done.
Fig.11
CASTLE USA TSM-22 OWNER’S MANUAL V2.0 PAGE 17 OF 37
6. Step6:InstallGasSpringonRightCaseSideandCaseTop.Insertthestudonthebottomof
thegasspringintotheholeontheCaseRightasshown.Secureusinga5/16”washerand
Nylock Nut on the inside of the case. (Fig 12)
• Raisethecasetopandplacethestudlocatedat
thetopofthegasspringthroughtheholeshown.
Securewitha5/16”washerandNylockNut.(Fig
13)
• Installworktopwiththe6atheadboltsand
nylonlocknutssupplied.Install4ontheouter
edgesofthetoprst.The2mountingholes
closesttorouterslotwillbeusedinnextstep.
(Fig 14)
• Installthedustdiverterusingthetworemaining
socketheadscrewsandnutsinthemounting
holes that sit closest to the router slot. See
properorientationofdustdiverterin(Fig 15)
Fig.12
Fig.13 Fig.14
Fig.15
CASTLE USA TSM-22 OWNER’S MANUAL V2.0 PAGE 18 OF 37
7. Step7:InstallStainlessLidPlate.Withthe1⁄4-20carriageboltsinsertedthroughthetopof
theplate,addthe1⁄4”washersandngertightenthe1⁄4-20Nylocknuts.(Fig 16)
• Lowertheworktopandplacethe1⁄4-20x1”FHSocketHeadCapscrewintheholein
theworktop.StarttheCapScrewwithincludedallenwrenchintheLidPlatetoposition
the Lid Plate. (Fig 17)
Fig.17
• OncetheLidPlatehasbeenpositioned,reachupinsidethecasethroughthefrontdoor
openingtosecuretheNylockNutsfortheLidPlate.(Fig 18)
• ARareEarthMagnethasbeenprovidedtosecuretheprovidedAllenWrenchtothecase
inaconvenientlocationforeasyaccesswhenmakingtoolingchanges.(Fig 19)
Fig.16
Fig.18
Fig.19
CASTLE USA TSM-22 OWNER’S MANUAL V2.0 PAGE 19 OF 37
8. Step8:Installthedoorbyplacingthehingesmountedtothedoorontheopposinghingepins
onthecabinet.Allowthedoortocompletelyseatonhinges.Fig 20 and Fig 21
• Installthedoorlatchbyusingtheincludeddoorspring,1/4-20bolt,andtheT-handle.
SeeproperoreintationinFig 22 and Fig 23.TightenT-handle.
Fig.20 Fig.21
Fig.22 Fig.23
CASTLE USA TSM-22 OWNER’S MANUAL V2.0 PAGE 20 OF 37
9. Step9:SincetheroutersmayhaveshiftedintransititisimportanttoinspecttheU-Boltson
thecarriage(Fig 24)makingsurethattheroutersaresecureandtight.
10. Step10:Usingthewrencheslocatedinsidethemanualpack,makesuretherouterbitand
thedrillbitaresecureintherespectivecollets.(Fig 25)Oncedone,lowertheWorkTopand
securetheworktopwiththe1⁄4-20SocketHeadCapScrew.(Fig 26)
Fig.24
Fig.25
Fig.26
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