CASTLE AT Race User manual
Owners Manual
AT Race Assembly Table – 4x8
CASTLE INC
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Table of Contents
1INTRODUCTION.............................................................................................................................5
2MACHINE SAFETY.........................................................................................................................6
2.1SAFETY RULES..........................................................................................................................6
2.2KEY FEATURES..........................................................................................................................7
2.3INVENTORY................................................................................................................................7
2.4MACHINE REQUIREMENTS ........................................................................................................10
2.5OTHER SUPPLIES.....................................................................................................................10
3SETTING UP YOUR AT RACE 8’ TABLE....................................................................................11
3.1GETTING STARTED...................................................................................................................12
3.2UNPACKING YOUR TABLE .........................................................................................................12
3.3FRAME ASSEMBLY ...................................................................................................................14
3.4ATTACHING THE LEGS..............................................................................................................15
3.5FENCE INSTALLATION...............................................................................................................17
3.6WORKTOP INSTALLATION..........................................................................................................18
3.7OPEN BACK BEAM INSTALLATION..............................................................................................19
3.8CLAMP ARM INSTALLATION.......................................................................................................21
3.9CONNECTING AIR.....................................................................................................................24
4OPERATING INSTRUCTIONS.....................................................................................................26
4.1CYLINDER ACTUATION..............................................................................................................26
4.2DRILL HOLSTER.......................................................................................................................27
5MAINTENANCE............................................................................................................................28
6TROUBLE SHOOTING GUIDE ....................................................................................................29
6.1ADJUSTING THE ARM BEARINGS ...............................................................................................29
6.2ALIGNING THE ARM ..................................................................................................................30
6.3REMOVING THE CYLINDER........................................................................................................30
WARRANTY INFORMATION ...........................................................................................................32
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1 Introduction
Thank you for making the Castle AT Race Assembly Table 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.
Note: Do not attempt to perform maintenance or operate this machine until you have read
and understand the information contained in this manual.
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2 Machine Safety
NOTICE: The Castle AT Race Assembly Table 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. 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. Contact Castle, Inc. at 800.282.8338 for instructions.
2.1 Safety Rules
1. USE CAUTION WHEN OPERATING THIS MACHINE! Only skilled operators should
use this machine, or be within ten feet when the machine is in operation.
2. 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.
3. Always wear protective eyewear when operating or standing near an operating machine.
4. Keep all body parts away from the moving parts of this machine whether it is in operation
or at rest.
5. 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.
6. Do not wear gloves or loose clothing (such as sweaters, jackets, or jewelry) when
operating or standing near an operating machine.
7. Before attempting adjustments, maintenance, or repair, DISCONNECT this machine
from its air supply. Wait for all motion to stop.
8. Always keep the area around this machine clean and uncluttered. Poor housekeeping
could result in slips, falls, or other injuries.
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9. Concentrate at all times. Failure to pay attention to the task at hand is the cause of
most accidents.
2.2 Key Features
Your Castle AT Race Assembly Table’s ergonomic design places the bottom rail at 32” above
floor level to reduce bending, reaching and operator fatigue. The highly efficient design allows
the hold-down cylinders to be repositioned and clamped in one quick smooth action for fast
production. The super rigid, precision beam is both light and strong and moves effortlessly on
ball bearings.
The Castle AT Race Assembly Table is equipped with a pressure regulator, pressure gauge and
hose for a pneumatic air screw driver (sold separately). The convenient driver holster is inches
away from the work at all times.
2.3 Inventory
Included with each Castle AT Race Assembly Table are the following items. Please take a
moment to verify that each of the items listed below and on the following pages are included with
you shipment.
Owners Manual
Warranty Card – Please fill out and mail to Castle, Inc. or visit our website at
www.castleusa.com and register online.
Hardware: (See following page for hardware details)
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CASTLE AT RACE ASSEMBLY TABLE HARDWARE PACK
ITEM PART # DESCRIPTION QTY
SPLICE ASSEMBLY
F51835 5/16-18 x ¾” Carriage Bolt 16
F51628 5/16-18 Hex Nuts 16
AT RACE LEG BRACE
F51835 5/16-18 x ¾” Carriage Bolt 10
F51628 5/16-18 Hex Nuts 10
AT RACE FENCE
F44134 ¼-20 X 1-3/4 21
F01422 ¼-20 Kep Nut 21
N00344 3/4 Large Aluminum Spacer
(Fence Installation) 21
AT RACE TABLE TOP
F10212 #10 x 2-1/2” Phillips Pan Head
Sheet Metal Screw 30
F14312 ¼-20 x 3-1/2” Draw Bolt 5
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CASTLE AT RACE ASSEMBLY TABLE PARTS LIST
ITEM PART # DESCRIPTION QTY
SPLICE ASSEMBLY
G48006 AT Race Splice 2
AT RACE LEG BRACE
G48013 AT LEG BRACE, 1 L, 1 R
AT RACE BEAM BRACKETS
G48218 AT Race Beam Bracket,
Left w/Set Screws 1
G41219 ATRaceBeamBracket,
Rightw/SetScrews 1
AT RACE CLAMPARM
C48010 AT Race Clamp Arm As-
sembly 1
ATRACESIDE&BOTTOMFENCE
O08474 AT Race Side & Bottom
Fence 3
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2.4 Machine Requirements
Your Castle AT Race Face Frame Assembly Table requires a minimum of 85 PSI air not to
exceed 150 PSI.
Supply Line should be a minimum of ¼” line.
Install an air filter trap to reduce the potential for foreign particles and water from
your air supply prior to entry into the machine. The filter should be mounted to the
wall where your supply comes from and SHOULD NOT be mounted to your machine.
2.5 Other Supplies
Plywood sheet at least 8’ X 4’ (not included)
(2) Scrap 2 X 4’s
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3 Setting Up Your AT Race 8’ Table
Your Castle AT Race Assembly Table is shipped knocked-down, with the legs bolted to a pallet
and the frame and top inside with the rest of the components securely attached. Inspect your
table components carefully to insure that there is no damage before proceeding with set-up.
Fig 1
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3.1 Getting Started
Safe assembly of your Castle AT Race Assembly Table takes two people. In addition, you will
need the following tools to uncrate and assemble your Castle AT Race Assembly Table.
1. 1/2” Open End Wrench
2. 1/2” Socket w/ratchet
3. Socket extension
4. 9/16” Socket w/ratchet
5. 5/32” Allen Wrench
6. Framing square
3.2 Unpacking your Table
1. Cut zip ties and remove the Beam Brackets (Fig 2), Fences (Fig 3), and Clamp Arm As-
sembly (Fig 4), and Splice Brackets (Fig 5).
Fig 5
Fig 2
Fig 3
Fig 4
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1. Using a 1/2” Open End Wrench, remove the bolts hold-
ing the threaded rod used to secure the AT Race parts
for shipping. (FIG 6)
2. The triangular Leg Braces and (4) Hardware Packs will
be inside each of the leg. Once you have removed the
legs from the pallet you should be able to pull the leg
braces out. (Fig 7)
3. Using a 9/16” Socket Wrench, remove the Lag
Bolts holding the legs to the pallet. (Fig 12)
4. Lift the 2 table tops out and set them aside for
later use. Set a few 2 x 4’s on the floor to pre-
pare for the next step.
Fig 11
Fig 10
Fig 9
Fig 8
Fig 7
Fig 6
Fig 12
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3.3 Frame Assembly
1. Place the frame sections face down on the 2 x 4’s so that the leg brace flanges are
facing up (Fig 13).
2. Position splice brackets inside the frame C-channels on the LEFT FRAME.
3. Use the AT Race Splice hardware pack (Pack #1). Align the holes in the splice
bracket with the holes in the frame. Insert the carriage bolts, from the outside in, into
the frame and through the splice bracket. Loosely tighten the nuts onto the carriage
bolts (Fig 15). Do Not Overtighten.
Fig 14 Fig 15
Fig 13
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Fig 16
4. Slide the RIGHT FRAME over the splice brackets and align the holes. Insert the
5/16” Carriage Bolts from outside the frame and into the splice bracket. Loosely
tighten the nuts onto the carriage bolts. Do Not Overtighten!
5. Using a ½” Socket with Ratchet Extension tighten the nuts against the back of
the channel. Remove the Ratchet Extension and use the just the ½” socket to
tighten the nuts on the side of the channel.
3.4 Attaching the Legs
1. Use the AT Race Leg Brace Hardware pack (Pack #2) for installing the legs. The
legs bolt onto the longer flange on the back side of the table frame.
2. Have someone hold the leg while you fasten it to the frame using the 3/8-16 x ¾”
Carriage Bolts. The flat part of the angle iron should face the inside of the leg. The
nuts are easiest to tighten if the head of the bolts are inserted from inside the leg
channel.
Fig 17 Fig 18
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3. Attach the leg support braces using bolts supplied. Repeat this process for the other
side.
4. Roll the assembly onto the legs by rolling it first over the top tube, then onto the leg
backs, and finally up and into a fully upright position.
5. Check that all the leg braces and bolts are securely tightened.
Fig 19
Fig 20
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3.5 Fence Installation
1. Attach the fences using the ¼-20 Flat Head bolts [F44134], aluminum spacers [N00344]
and the ¼-20 Kep Nuts [F01422] found in Hardware Pack #3.
NOTE: The holes closest to the bottom left side of the table frame are round and the holes
going away from the lower left corner grow slightly to an obround at the upper left side of the
table and towards the middle of the bottom beam of the table frame. This allows for adjust-
ment to insure that the fences are square to each other.
2. Only tighten the nuts at the lower left corner for the side fence and bottom left fence and
at the bottom right corner of the bottom right fence. You will tighten the remaining nuts
once the table top is installed.
NOTE: When fastening the fences be sure to only tighten one bolt on each fence at
the bottom left corner of the frame. You will tighten the rest later.
Fig 21
Fig 22
Fig 23
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3.6 Worktop Installation
1. Place the left side of the table top onto the frame. Make sure the top is sitting as far left
as it will go and flush with the bottom edge of the frame.
2. Slide the right side of the table top onto the frame. (Fig 24)
3. Push both sides together tightly from right edge.
4. Install (5) draw bolts at the rear of the table top
to secure. (Fig 25)
5. Using the (30) #10 X 2-1/2” pan Phillips sheet metal
screws [F10212] fasten the table down through the
rear of the frame. (Fig 26)
Fig 24
Fig 26
Fig 25
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6. Place a sheet of plywood measuring AT LEAST 4’ x 8’ on the table, and rest it on the
bottom fence.
7. Push up on the end of the fence opposite the end with the tight bolts until the fence is
flush with the wood.
8. Now tighten all of the bolts for the fences.
3.7 Open Back Beam Installation
NOTE: This part of the installation may require (2) two
people
1. Install the Beam Brackets as shown. Note the position of
the upper set screw. (Fig 28)
Fig 27
Fig 28
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2. Slide the top beam through yellow bracket on one side of the table then on the other.
(Fig 28a).
3. Once the beam is in place tighten the set screws in the beam brackets in all (3) places
on each using a 7/64” Allen Wrench. (Fig 29)
NOTE: For proper alignment of the upper beam to the table, use a
framing square to insure that the beam is 90 degrees to the table. If
not, loosen the set screws at the bottom of each [yellow] beam
bracket and rotate the [green] beam up until it is 90 degrees to the
table top.
Fig 28a
Fig 29
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