Related Manuals for CASTLE TSM-22
Summary of Contents for CASTLE TSM-22
- Page 1 CASTLE, INC. Owners Manual TSM-22 Pocket Hole Machine CASTLE INC PO BOX 750236 PETALUMA CA 94975 WWW.CASTLEUSA.COM...
- Page 2 CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 2 of 41...
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Page 3: Table Of Contents
.......................... 9 AFETY ULES ..........................10 NVENTORY ......................11 ACHINE EQUIREMENTS SETTING UP YOUR TSM-22 ....................... 12 ..................... 14 NSTALLING THE ....................15 NSTALLING THE PRING ......................16 NITIAL ONFIGURATION ... - Page 4 WARRANTY INFORMATION ....................... 39 ..........................39 ARRANTY 30-D ......................40 EFUND OLICY ....................40 ARRANTY ERVICE OLICY ..................... 40 ARRANTY EPLACEMENT CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 4 of 41...
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Page 5: Introduction
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”... -
Page 6: Identification Of Operating Features And Controls
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. CASTLE, INC TSM-22 OWNERS MANUAL V1.0... - Page 7 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.
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Page 8: Manual Contents Notice
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. -
Page 9: Machine Safety
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. -
Page 10: Inventory
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 #... -
Page 11: Machine Requirements
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. -
Page 12: Setting Up Your Tsm-22
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. - Page 13 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 4 CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 13 of 41...
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Page 14: Installing The Work Top
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) Fig 8 CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 14 of 41... -
Page 15: Installing The Gas Spring
Case Right as shown. Fig 11 Secure the stud using a 5/16” Washer and Nylock Nut provided on the inside of the case. (Fig 12) Fig 12 CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 15 of 41... -
Page 16: Initial Configuration
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 15 CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 16 of 41... - Page 17 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. CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 17 of 41...
- Page 18 If the rate is too fast it can cause the wood to shift. Flow Control Knob Fig 19 Turn the Power Switch off when initial configuration is complete. CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 18 of 41...
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Page 19: Adjustments
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. CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 19 of 41... -
Page 20: Pocket Web Adjustment
If you are using 1¼” screws you may choose to shorten the Web to ”. Note: Castle does not recommend a web under ”. The Web is adjusted by shortening or lengthening the travel of the router’s cutting stroke. ... -
Page 21: Pocket Depth Adjustment
Refer to the “Pilot Drill Depth Adjustment” for this procedure. Fig 23 CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 21 of 41... -
Page 22: Drill Feed Rate Adjustment
Turn the knob counter-clockwise until it reaches a mechanical stop. Turn the knob clockwise five full revolutions (it’s helpful to make an index mark on the knob.) Lock the knob by pushing it slightly inward. CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 22 of 41... -
Page 23: Pilot Drill Depth Adjustment
Loosen the motor collet and slide the bit to the desired height. (If the bit does not move easily, try gently tapping on the shank of the bit near the collet with a wrench.) Secure the collet. CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 23 of 41... -
Page 24: Pilot Drill Height Adjustment
On the outside of the machine, secure the Carriage Centering Screw with a ” Allen wrench and tighten the nuts securing the pivot point of the Motor Carriage to the machine case. CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 24 of 41... -
Page 25: Operation
Place the Foot Pedal in front of the machine in a safe and comfortable position (Fig 30). Fig 30 Fig 31 Turn the Power Switch on (Fig 31). CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 25 of 41... - Page 26 Foot Pedal again to activate the next cutting cycle. Be sure to turn off the Power Switch when you are finished. If the machine fails to cycle properly, call Castle at (800) 282-8338 CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 26 of 41...
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Page 27: Service And Maintenance
Using the wrenches provided, loosen the collet nut on the router motor. Tap the collet nut with the wrench if the router bit is difficult to remove. (Fig 34) Fig 34 CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 27 of 41... -
Page 28: Pilot Drill Bit
The model TSM-22 requires some maintenance. To ensure the productivity and longevity of your Castle Pocket Cutter, it is essential to follow a few simple steps. How often these steps are performed depends upon the number of hours the machine is operated each day. As a general... -
Page 29: Motors And Bits
Note: Failure to clean sawdust from your machine may void your Warranty! Castle provides premium versions of the Router Bit and Drill Bit in the TSM-22 as standard equipment from the factory. Castle recommends these bits for all applications: CASTLE, INC TSM-22 OWNERS MANUAL V1.0... - Page 30 An alternative for larger diameter pilot hole ” Shank To purchase bits feel free to contact your local Castle dealer or contact our Parts Department TOLL FREE at 800-282-8338 or visit our website at www.castleusa.com for information and pricing on tooling and accessory products for your TSM-22.
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Page 31: Troubleshooting
7 Troubleshooting Warning: Electrical Hazard: Do not attempt to service Control Box components. Contact a Castle Support Technician for proper service information. 7.1 Dry Cycle Test Dry Cycling is an extremely useful troubleshooting technique if your Pocket Machine’s performance and cycling sequence seem irregular or questionable. It affords the opportunity to closely observe the mechanical, electrical, and pneumatic systems without routing pockets or drilling holes. - Page 32 The list of possible behaviors described in Steps 5 through 13 is by no means exhaustive. Careful observation and description of the cycle behavior is essential when troubleshooting or seeking Technical Support. CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 32 of 41...
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Page 33: Safety Switch (Stock Sense)
7.2 Safety Switch (Stock Sense) The Safety Switch (or Stock Sense) on the TSM-22 consists of a magnet (no wires) mounted near a magnetic reed switch (with wires). (Fig 36) When the Safety Buttons are pushed by the work piece, they raise an L-shaped metal blade that rests between the reed switch and the magnet inside the machine. -
Page 34: Foot Switch
Without depressing the spring plate, the switch should register as an open circuit. When depressing the plate, the switch should register as a closed circuit (approximately 0 ohms). If an open circuit is still registered, then a new switch should be installed. CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 34 of 41... -
Page 35: Pressure Regulator
The Pressure Regulator determines the Drill Feed rate and overall speed of the machine. It’s important that at least 80 PSI is going into the machine from the compressor. Other machines on the same line as your Castle machine can affect this pressure. Note: Do not adjust the internal Pressure Regulator unless absolutely necessary. -
Page 36: Router Stop Switch
If the router still stalls in the pocket test with a continuity tester as described in Section 7.2 Safety Switch (page 33). If no continuity registers, a new switch assembly is needed. CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 36 of 41... -
Page 37: Drill Stop Switch
Although the mounts are not slotted, spread the magnet and the reed switch as far from each other as possible, then retighten the screws. Fig 41 Turn on the power to the machine and make a test pocket. CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 37 of 41... -
Page 38: Serial Number Log
Castle, Inc A00022 – TSM-21 Pocket Hole Machine Robert Bosch Co. E21610 – Bosch PR10E 1.0 HP Motor Robert Bosch Co. E21617 – Bosch 1617 2.25 HP Motor PURCHASE DATE: CASTLE, INC TSM-22 OWNERS MANUAL V1.0 Page 38 of 41... -
Page 39: Warranty Information
Castle, Inc. uses only the highest quality materials available for the construction of our machines. Your TSM-22 is warranted for one (1) full year from the date of purchase against workmanship or material defects under normal use and service. Castle, Inc. is not responsible for failures or injuries due to negligence, misuse, alteration, unauthorized service, or accidents. -
Page 40: 30-Day Refund Policy
Castle does not employ on-site service technicians. On-site technical support and service are to be provided by the DDR or by an authorized Castle agent. If a DDR cannot provide on-site technical support and service, the DDR is expected to partner with an authorized Castle agent. - Page 41 Castle will initiate an RMA and provide pre-paid shipping for these returned items. In order to protect Castle’s assets, the customer will be billed for replacement parts if the returned parts are not received at the Castle factory within 30 days of the End User’s receipt of the replacement parts.
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