CASTLE 110 User manual

The CASTLE 110
Owner’s Manual
Castle Inc., Petaluma California

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UAL V1
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1 Machine Safety
The Castle 110 was designed with operator safety as a priority. All Castle
machines are carefully assembled and individually tested before shipment from
our California factory. Upon receipt of the machine, inspect for shipping damage
or missing parts. Report any damage IMMEDIATELY to the shipping company
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.
Safety Rules:
1. Read all safety warnings and instructions. Failure to follow all instructions listed
below may result in electric shock, fire and/or serious injury.
2. Familiarize yourself with the clamping action, routing and drilling functions
before plugging the machine into electrical power supply. Push the pocket cutting
lever to its stop several times and observe the router bit travel above the work
deck. Note that a properly-adjusted bit will retract completely below the work
surface when the lever is released.
3. Do not attempt to perform maintenance or operate this machine until you have
read and understand the information contained in this manual.
4. Do not plug the Castle 110 in until ready to operate.
5. Always verify that the router bit is securely tightened and the height properly
adjusted. The bit is adjusted and tested at the factory for 5/8” and thicker stock.
To adjust for thinner stock dimensions, see section 9.1.
6. Always be sure to securely clamp stock before routing or drilling any material.
7. NEVER PUT YOUR HAND UNDER THE CLAMP OR IN THE PATH OF THE ROUTER
BIT. Serious injury can result!
8. Always wear eye and hearing protection when the machine is in operation.
9. Never drink alcohol or take medications that may cause drowsiness when you will
be operating the machine.
10.Router bits are extremely sharp and if handled improperly may result in personal
injury.
11.Never allow the machine to get wet or be used in a wet environment.
12.To prevent personal injury, ALWAYS remove the plug from the power source
before removing, installing or adjusting router bits.
13.This instruction manual should be kept available for immediate reference so that
all operations can be performed with maximum safety and efficiency.

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Table of Contents
1 MACHINE SAFETY 2
2 INTRODUCTION 5
3 THE CASTLE 3 DEGREE SYSTEM 7
4 PACKAGING LIST 8
5 INSTRUCTIONS FOR USE 10
6 POSITIONING THE POCKETS 13
7 VACUUM PORT 15
8 CLAMPING TO A WORK BENCH 16
9 MACHINE ADJUSTMENTS 17
9.1 USING THE THIN STOCK OVERLAY PLATE FOR THINNER STOCK 17
9.2 INSTALLING AND ADJUSTING ROUTER BIT 18
9.3 WEB ADJUSTMENT 21
9.4 PILOT HOLE HEIGHT ADJUSTMENT 22
10 USING THE OPTIONAL WORK STOPS 22
11 MOTOR, BITS, AND GENERAL INFORMATION 24
12 WARRANTY INFORMATION 30
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 Introduction
Castle invented the low-angle Professional Pocket in 1985 to meet the needs of
cabinetmakers and woodworkers who require a fast, strong joint in wood, plywood, and
other structural materials for cabinet making, furniture construction, and other
carpentry tasks. With this system, the screws are driven into the side grain of the
wood, creating a strong joint that is not prone to splitting and holds firmly for the life of
the structure. The exclusive 3-degree screw angle minimizes the problem of
component shifting (misalignment caused by tightening the screw) that is commonly
associated with pocket joinery. With the Castle 110, it is now possible to create the
same fully machined Castle Professional Pocket used by cabinetmakers in your own
workshop or on the jobsite.
Pilot Hole: The pilot hole is drilled from the edge of the stock creating a clean, chip-
free hole for the pocket screw which eliminates end-grain pop-out (common on drilled
pockets) that can interfere with a tight joint.
Low 3° Angle: The exclusive Castle 3-degree angle virtually eliminates forces
that can result in shifted or misaligned joints. Note: the 3-degree system
requires cheese head torx screws for proper assembly.
Web: The web easily adjusts to suit a variety of screw lengths.
Pocket: The routed pocket leaves a clean recess which requires no additional
sanding or finishing before the components are assembled.

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Below are samples of applications for Castle screw pockets.
WARNINGRead all safety warnings and instructions. Failure to follow all
instructions in this manual may result in electric shock, fire and/or seriousinjury.

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3 The Castle 3 Degree System
The Castle 110 has been designed to produce pockets joints with a 3-degree angle
that virtually eliminates shifting and misalignment while assembling your work. The
Castle 3-degree system requires the use of “Cheese” head pocket holes screws with
a Torx drive head. Note: Square drive or washer head pocket screws are not
compatible with the Castle 3-degree system as the Torx drive is necessary to
maintain proper alignment when the screws are installed.

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4 Packing List
Within your Castle-110 shipment, you should receive the following:
THE CASTLE-110 PORTABLE POCKET MACHINE PACKING LIST
Part #
Part Description
Qty
A00110
The Castle-110
1
S90110
The Castle-110 Operator Manual with Warranty Activation Card
1
B06964
5/32” Drill Bit, 6”
1
B02516
5/16” Router Bit (Installed and factory adjusted for 3/4" stock)
1
B00620
T20 Torx Driver Bit, 6” Round Shaft
1
K11000
Collet Wrenches
1
C11010
Bit Set-up Block
1
C11001
Overlay Plate for pocketing thinner materials
1

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Optional accessories for the Castle 110:
THE CASTLE-110 Optional Accessories
Part #
Part Description
Qty
C11060
Work Stop Set, includes stop bar, left and right work stops
1
B02517
Roughing Cutter for cutting in hardwoods
1

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5 Instructions for Use
1. With the clamp lever in the material loading
position, place stock to be pocketed on the
work deck under the clamping plate and
squarely against the rear fence. (Figure 5a)
2. Place the clamp lever in the stock thickness
adjustment position. The half-moon cutout on the
clamp lever will align with the top of the 110 as
shown in figure 5b.
3. Turn the stock thickness adjustment knob
clockwise until the clamping plate firmly
touches the workpiece. (Figure 5c)
Figure 5a
Figure 5b
Figure 5c

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4. Push the clamp lever all the way down to
secure the workpiece (Figure 5d) and confirm
that it is held securely by manually pulling on
it. If the workpiece is loose, adjust the stock
thickness adjustment knob as needed until a
firm grip is achieved as described in step 3.
5. With the workpiece firmly clamped in place, push the
power switch on the motor to the ON position. One side of
the switch is marked “I” for “ON” and the other side of
switch is marked “O” for “OFF”.
6. To cut the pocket, push the pocket cutting
lever down smoothly until it hits the stop.
When the cut is complete, release the
lever and the bit will return to the starting
position below the work deck. When
routing in wood, the best finishes will
result if the depth of cut and feed rate are
regulated to keep the motor operating at
high speed. Feed the bit at a moderate
rate. Soft stock generally requires a faster
feed rate than harder materials.
Figure 5d

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Note: Feed the cutter at a steady rate. Cutting too fast can cause
overheating, leave burn marks in the pocket, and wear the
cutting edges prematurely. Too fast of a feed rate may also
produce excess vibration and a rough pocket. A dull cutter
will not cut freely and can also leave burn marks and when a
cutter will no longer produce a smooth, clean pocket it
should be replaced.
7. To drill the screw pilot hole, place the 5/32-inch bit (provided) into the drill guide
and drill steadily until you feel the bit break through into the routed pocket. The
pocket is now complete and ready for assembly.
Caution: Always wear safety goggles and hearing protection when
operating power tools.

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6 Position the Pockets
The number of pockets used in a joint is determined by the stock width and the
function of the components being assembled. For example, it is possible to fasten a
narrow rail in a cabinet face frame with a single pocket and glued joint on either end
to minimize the risk of splitting. You may wish to fasten wider rails with two pockets.
Wide panels generally require pockets spaced about 6 to 8 inches apart on center,
with the first and last pocket spaced about 2 to 3 inches from the edges of the panel.
In your design layout, note all pocket locations to ensure that there is no interference
and then mark the locations on the individual components to ensure accurate
positioning. Note that precise pocket spacing is not critical for a strong joint if these
general guidelines are followed.
Your Castle 110 provides several methods to accurately locate the pockets. The
clamping plate has a centerline and inch scale which can be used to position the
pockets freehand, or the centerline or inch scale can be aligned with pencil marks to
indicate where the pockets should be located. (Figure 6a) For example, if you wish
to locate the outside pockets 1⁄2 inch from either edge, simply align the stock with
the 1⁄2 inch mark on the plate, cut the first pocket, and repeat this operation to
position the second pocket on the other side. (Figure 6b)
Figure 6a

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The other inch scale marks can be used to position pockets up to 2 inches from the
edge of your work. This scale can be used to accurately locate pockets with the 110
mounted to a workbench or when the tool is clamped directly to a wide panel. In
cases where the 110 must be mounted to the work in an inverted position, the
notched cutaway in the work deck can be used to align the pocket with reference
marks on the stock or provide a visual reference for the pocket positions. (Figure 6c).
Note that when the 110 is inverted, the pocket will be cut on the top surface of the
workpiece.
Figure 6b
Figure 6c

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For repetitive cuts on multiple pieces, Castle offers an optional work stop assembly
which can be adjusted to position pockets where desired and allow the operator to
simply place the stock against the stops on either side for accurate and repeatable
positioning. This accessory is especially useful for production of multiple parts where
speed and repeatability are important. See section 10 in the manual.
7 Vacuum Port
When possible, Castle recommends using a dust extraction vacuum to keep the tool
free of chips and dust. The Castle 110 includes a vacuum port that is sized to fit
most modern shop vacs and universal shop vacuum hose adapters. Select the dust
extraction hose adapter that will work with your system.When operating your Castle
110 without dust extraction connected, we recommend removing any dust
accumulation inside the housing after several cuts. Excessive dust accumulation
restricts air flow and can damage to the motor. Additionally, inspect the router motor
to ensure excessive chips and dust are not obstructing the air intake vents of the
motor.
Vacuum Port

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8 Clamping to a Work Bench
The Castle 110 comes with 2 clamping ports, one on
each side of the machine. To use a clamp to secure
your Castle 110 to a work bench, simply insert the top
of the clamp in the opening provided at the base of the
main housing and tighten the clamp to your work
surface. There are also two holes in the base of the 110
to allow the tool to be fastened directly to a workbench
or other work surface with screws or bolts as needed.
(Fasteners not provided)
Additional Operating Instructions - Stationary vs. Freehand
Your Castle 110 has been designed for maximum efficiency and can be operated in
two modes: Stationary or Freehand. In the Stationary mode, the tool is clamped or
screwed firmly to a work surface and the stock is clamped in place on the work deck.
In the Freehand mode, the tool is clamped directly to the stock on heavy or
cumbersome parts such as panels, partitions, or large drawer fronts. This exclusive
freehand feature eliminates the need to vertically support heavy items for machining
pockets, as well as the tedious and time-consuming task of clamping a guide to drill
each pocket hole on larger work.

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9 Machine Adjustments
9.1 Using the Thin Stock Overlay Plate for Thinner Stock
The Castle-100 is factory adjusted for 5/8 inch and thicker stock. To machine 1/2
inch to 5/8 inch stock, an overlay plate is provided. Simply push the clear plate onto
the work deck of the Castle 110 as shown in figure 9a. Follow the instructions in
section 6 for setting the clamp pressure and cutting the pocket.
Figure 9a

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9.2 Installing and Adjusting the Router Bit
•Before making any adjustments, please sure that the machine is disconnected
from the electrical power outlet.
1.Unplug the Castle 110. Remove the vacuum cover
from the front of the Castle 110 by placing a finger
inside the vacuum port and firmly pull away from
the main housing.
.
2.Clamp the setup block with the block flush to left
side of work deck as shown in figure 9b and
place the machine on its side with the Castle
logo up.
Figure 9b

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3.Use the 13mm wrench to secure the
spindle by sliding the wrench over
the spindle flats until it is fully
engaged. (figure 9c)
4. Next, while holding the spindle securely
with the 13mm wrench, use the 22mm
collet wrench to loosen the collet chuck
assembly in a counter-clockwise
direction.(figure 9d) With the collet chuck
assembly loosened, pull down on the
pocket cutting lever enough so that you
can remove and replace the router bit.
CAUTION- Router bits are extremely sharp and if handled improperly may
result in personal injury.
Figure 9c
Figure 9d

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5. Adjust the height of the router bit until it
matches the height of the cutout in the setup
block as shown in figure 9e. (note: the router
bit will be 7/16 inch above work deck).
6. Once the router bit is positioned correctly, allow
the pocket cutting lever to return to its resting
position. Use the 13mm spindle wrench and
the 22mm collet wrench to firmly tighten the
collet chuck assembly in a clockwise direction.
The single hand squeeze method for tightening
the collet is pictured in figure 9f. Do Not
overtighten.
7. Finally, raise the pocket cutting lever to confirm the height of the router bit using
the setup block. Readjust if needed, repeating steps 3-7 above.
Note: To prevent damage to the tool, NEVER tighten the collet without a bit
inserted.
Figure 9e
Figure 9f