CASTLE TSM-22 User manual

CASTLE INC PO BOX 750236 PETALUMA CA 94975
WWW.CASTLEUSA.COM
Owners Manual
TSM-22 Pocket Hole Machine
CASTLE
,
INC.

CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 2 of 41

CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 3 of 41
Table of Contents
1INTRODUCTION.............................................................................................................................5
1.1DEFINITION OF TERMS................................................................................................................5
1.2IDENTIFICATION OF OPERATING FEATURES AND CONTROLS .........................................................6
1.3MANUAL CONTENTS NOTICE.......................................................................................................8
2MACHINE SAFETY.........................................................................................................................9
2.1SAFETY RULES..........................................................................................................................9
2.2INVENTORY..............................................................................................................................10
2.3MACHINE REQUIREMENTS ........................................................................................................11
3SETTING UP YOUR TSM-22 .......................................................................................................12
3.1INSTALLING THE WORK TOP .....................................................................................................14
3.2INSTALLING THE GAS SPRING ...................................................................................................15
3.3INITIAL CONFIGURATION ...........................................................................................................16
4ADJUSTMENTS............................................................................................................................19
4.1ROUTER FEED RATE ADJUSTMENT ...........................................................................................19
4.2POCKET WEB ADJUSTMENT......................................................................................................20
4.3POCKET DEPTH ADJUSTMENT...................................................................................................21
4.4DRILL FEED RATE ADJUSTMENT ...............................................................................................22
4.5PILOT DRILL DEPTH ADJUSTMENT ............................................................................................23
4.6PILOT DRILL HEIGHT ADJUSTMENT ...........................................................................................24
5OPERATION.................................................................................................................................25
6SERVICE AND MAINTENANCE ..................................................................................................27
6.1TOOL CHANGES.......................................................................................................................27
6.2ROUTER BIT ............................................................................................................................27
6.3PILOT DRILL BIT.......................................................................................................................28
6.4GENERAL MACHINE MAINTENANCE ...........................................................................................28
6.5MOTORS AND BITS...................................................................................................................29
7TROUBLESHOOTING..................................................................................................................31
7.1DRY CYCLE TEST.....................................................................................................................31
7.2SAFETY SWITCH (STOCK SENSE)..............................................................................................33
7.3FOOT SWITCH..........................................................................................................................34

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7.4PRESSURE REGULATOR...........................................................................................................35
7.5ROUTER STOP SWITCH ............................................................................................................36
7.6DRILL STOP SWITCH ................................................................................................................37
7.7SERIAL NUMBER LOG...............................................................................................................38
8WARRANTY INFORMATION .......................................................................................................39
8.1WARRANTY..............................................................................................................................39
8.230-DAY REFUND POLICY..........................................................................................................40
8.3WARRANTY SERVICE POLICY....................................................................................................40
8.4WARRANTY PART REPLACEMENT .............................................................................................40

CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 5 of 41
1 Introduction
Thank you for making the Castle TSM-22 Screw Pocket Machine (Toe Screw Mortise) 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 woodworking professionals.
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-22 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.
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 machine function that clamps the work piece, cuts the mortised pocket,
drills the pilot hole and 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
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.
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.
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.
Router Stop Plate: Located on the operator right side, this black
metal plate extends through the top of the case and along the side of
the Clamp Guard. The position of this plate determines the size of the
“Web.”
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).
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.
Safety Switch: This magnetic proximity switch is mounted inside,
near the top of the TSM-22. It is activated when the Safety Buttons
are depressed by the work piece.

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Motor Carriage: The Motor Carriage is the red, 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.
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 “Castle” plate on the carriage interrupts this
switch to signal the start of the drilling stroke.
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.
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.

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1.3 Manual Contents Notice
This manual is not fully comprehensive. It may not convey every possible safety and operational
problem that 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.

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2 Machine Safety
The Castle Model TSM-22 pocket machine was designed with operator safety as a priority. This
machine was carefully prepared for shipment at our factory. Upon receipt of this 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 this machine if you observe any
physical damage. If you detect any damage to your machine contact Castle, Inc. at 800-282-
8338 for instructions.
2.1 Safety Rules
The Castle Model TSM-22 Pocket Machine was designed with operator safety as a priority,
which is why Castle highly recommends the following:
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. Be certain that this machine is properly grounded before operating it.
5. Keep all body parts away from the moving parts of this machine whether it is in operation
or at rest.
6. 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.
7. Do not wear gloves or loose clothing (such as sweaters, jackets, or jewelry) when
operating or standing near an operating machine.

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8. Keep two hands on the work piece when initiating a pocket cycle on this machine.
9. 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.
10. Always keep the area around this machine clean and uncluttered. Poor housekeeping
could result in slips, falls, or other injuries.
11. Concentrate at all times. Failure to pay attention to the task at hand is the cause of
most accidents.
2.2 Inventory
With your Castle machine you should have received the following:
CASTLE TSM-21 POCKET CUTTER MACHINES HARDWARE PACK
Part # Part Description Qty
S90022 TSM-22 Operator Manual with Warranty Activation Card 1
Router Wrench Bosch 1617 2
Trimmer Wrench Bosch PR10E 2
B00622 #2x 6” Square Driver Bit 1
G00234 Bit Gauge 1
G00101 Door Spring 1
F14125 ¼ x 20 Bolt 1
H00141 T-Handle 1
F51616 5/16 SAE Flat Washer 4
F51699 5/16 -18 Nylon Locknut 2
H24002 Gas Spring – 20.12” Extended 1
F14553 ¼-20 x 1-1/4 FH Socket Head Cap Screw 6
F01420 ¼-20 Nylon Locknut 9
F01410 1/4 SAE Flat Washer 9
F44100 ¼-20 X 1 FH Socket Head Cap Screw 1
M24010 Stainless Lid Plate 1
F14340 ¼-20 x ¾ Carriage Bolt 2
T00532 Allen Hex L-Key – 5/32” 1
H55202 Rare Earth Magnet 1

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2.3 Machine Requirements
Power Supply: 115 VAC ± 10%, 60 Hz, 20 Amp Service
Warning: Do not use an extension cord. Using an extension cord to power your TSM-22 may void
your warranty!
Air Supply: 80psi (minimum), 150psi (maximum) 1.5cfm; Minimum ¼” ID air line
Warning: Failure to provide an adequate supply of CLEAN, DRY air may void your warranty!
Dust Collection: The TSM-22 will function better with proper dust collection attached. A vent
for this purpose has been provided. Attaching dust collection will prolong motor life by keeping
the router motors cooler and free from sawdust buildup.
Warning: Failure to clean sawdust from your machine may void your warranty!

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3 Setting Up Your TSM-22
Caution: Always use eye protection when operating power equipment.
Your Castle TSM-22 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-22 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. (Fig 1)
Connect a clean, dry air supply to the left side of the machine with a minimum supply of
80psi. (Fig 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.
Fig 1 Fig 2

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Warning: Do not introduce lubricants, oils, or solvents into the pneumatic system. Irreparable
damage to pneumatic seals and components may occur. Using lubricants in the pneu-
matics of your TSM-22 may void your Warranty!
Inspect the U-Bolts on the carriage (Fig 3), making sure that the motors are secure and tight.
Using the wrenches located inside the rear of the machine make sure the router bit and the
drill bit are secure in the respective collets. (Fig 4)
Fig 3
Fig 4

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3.1 Installing the Work Top
Install the Work Top with the 4 flat head bolts and Nylock nuts supplied. (Fig 5)
Install the Stainless Steel Lid Plate using the ¼-20 Carriage Bolts, washers and ¼-20 Nylock
Nuts. (Fig 6) & (Fig 7)
Lower the Work Top and place the ¼-20 x 1’ Flat Head Socket Head Cap Screw in the hole
in the Work Top. Start the screw in the Lid Plate to position the Lid Plate. (Fig 8)
Bolt Locations
Fig 5
Fig 6 Fig 7
Fig 8

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Once the Lid Plate has been positioned, reach up inside the
case through the front door opening to secure the Nylock Nuts
for the Lid Plate. (Fig 9)
A magnet has been provided to secure the Allen wrench to the
case in a convenient location for quick access during tooling
changes. (Fig 10)
3.2 Installing the Gas Spring
Remove the plastic covers on the studs and insert the
stud on the bottom of the gas spring into the hole
located on the bottom of the Case Right as shown.
Secure the stud using a 5/16” Washer and Nylock Nut
provided on the inside of the case. (Fig 12)
Fig 9
Fig 10
Fig 11
Fig 12

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Raise the Case Top and place the stud located at the top of the
gas spring through the hole shown. Secure with a 5/16” washer
and Nylock Nut. (Fig 13)
Lower the lid and secure the Work Top with the ¼-20 Flat
Head Socket Head Cap Screw. (Fig 14)
Plug the machine into a grounded 115VAC, 20-amp outlet.
3.3 Initial Configuration
Now that the machine is connected to a power source and air supply, it is suggested that you
test the machine’s controls for proper function.
Caution: Read the Operator Manual carefully before operating. Make sure that you
have followed all assembly and installation instructions correctly. Make sure that you
are familiar with the functions described in the rest of the manual as well. Failure to fol-
low this warning may result in serious injuries to persons and property.
Turn on the Power Switch. (Fig 15)
Power Switch
Fig 13
Fig 14
Fig 15

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Place a piece of scrap wood under the Clamp Guard against the Face Plate to depress the
Safety Buttons (Fig 16).
Be sure to keep your hands clear of the clamp, and then step on the Foot Pedal. A full cycle
should take 1½ to 2 seconds.
Inspect the pocket. If the drilled hole is off center (Fig 17), it can be centered using the
adjusting nut on the Pilot Hole Adjustment Nut just below the drill motor. (Fig 18)
Caution: Do not overtighten the adjustment nut. Overtightening may cause an uneven
bias to the pilot hole position.
Tightening the nut moves the drill tip left relative to the operator. Adjust accordingly.
Pilot Hole
Ali
g
nment Nut
Fig 16
Fig 17 Fig 18

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The Router Feed rate can be adjusted by using the flow control knob next to the air supply
port. (Fig 19) Turning it clockwise will reduce Router Feed rate, and turning it counter-
clockwise will increase it. If the feed rate is too slow it can cause burning of the bit and
burning of the pocket. If the rate is too fast it can cause the wood to shift.
Turn the Power Switch off when initial configuration is complete.
Flow Control Knob
Fig 19

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4 Adjustments
4.1 Router Feed Rate Adjustment
The Router Feed Rate Adjustment knob is located right next to the air inlet port on the back side
of the machine. (Fig 20) The adjustment knob only affects the cutting stroke of the pocket
router.
Fig 20
Turning the knob clockwise selects a slower Feed Rate. Turning the knob counter-clockwise
selects a faster Feed Rate. A suggested Router Feed Rate Adjustment for hardwoods such as
oak or maple is described as follows:
Loosen the jam nut on the threaded stem and spin the nut counter-clockwise.
Turn the knob clockwise until it reaches a mechanical stop.
Turn the knob counter-clockwise two full revolutions.
Adjust slower or faster in small increments as required.
Tighten the jam nut.
Note: If the work piece shifts noticeably during the Pocket Cycle, this usually means
the Router Feed Rate is faster than the tooling’s ability to clear the Pocket. In general
the desired Feed Rate is slower for harder, denser materials.

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4.2 Pocket Web Adjustment
The offset distance from the end of the pocket to the edge of the work piece is called the “Web.”
(Fig 21) It has been factory set at approximately 7/8” to accommodate 1 ½” screws.
Fig 21
If you are using 1¼” screws you may choose to shorten the Web to 5/8”.
Note: Castle does not recommend a web under 5/8”.
The Web is adjusted by shortening or lengthening the travel of the router’s cutting stroke.
Locate the Router Stop Plate nut on the right side of the yellow Clamp Guard on top of the
machine. (Fig 22)
Fig 22
Loosen the nylon locking nut.
To shorten the Web, slide the black Stop Plate toward the rear of the machine slightly.
To lengthen the Web, slide the plate toward the front of the machine slightly.
Web