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Summary of Contents for CASTLE TSM-21
- Page 1 CASTLE, INC. Installation Instructions TSM-21 Bosch Motor Carriage CASTLE INC PO BOX 750236 PETALUMA CA 94975 WWW.CASTLEUSA.COM...
- Page 2 CASTLE, INC TSM-21 Bosch Motor Carriage Install Page 2 of 25...
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Page 3: Table Of Contents
SERVICE AND MAINTENANCE ....................20 ........................20 HANGES ....................... 20 OCKET OUTER ........................22 ILOT RILL ................... 22 ENERAL ACHINE AINTENANCE ........................23 OTORS AND ....................... 25 ERIAL UMBER CASTLE, INC TSM-21 Bosch Motor Carriage Install Page 3 of 25... -
Page 4: Introduction
1 Introduction Thank you for purchasing a TSM-21 Bosch Motor Carriage upgrade. Since 1985 our goal is to manufacture and develop machines that make cabinetmaking and casework easier, faster, and more profitable for woodworking professionals. This upgrade represents our patented screw pocket cutting technology. -
Page 5: Identification Of Operating Features And Controls
Router Stop Plate inside of the machine. At the full extension of the routing stroke, the carriage interrupts this switch to signal the start of the drilling stroke. CASTLE, INC TSM-21 Bosch Motor Carriage Install Page 5 of 25... -
Page 6: Installation Instructions
Router Stop Plate must be changed as the old style will interfere with the Bosch carriage movement. 2.1 Safety Rules The Castle Model TSM-21 Pocket Machine was designed with operator safety as a priority, which is why Castle highly recommends the following: Read this Instruction Manual carefully before beginning the carriage exchange. -
Page 7: Inventory
2.2 Inventory With your Castle TSM-21 Bosch Motor Carriage upgrade pack you should have received the following: CASTLE TSM-21 Bosch Carriage Upgrade Parts Part # Part Description G21123 TSM-21 Router Carriage – Bosch N21142 TSM-21 U-Bolt (Router) Installed N21143 TSM-21 U-Bolt (Trimmer) -
Page 8: Replacing The Router Carriage
Make sure your machine is unplugged from its electrical outlet and the air supply has been detached. These instructions will detail the steps required to upgrade your TSM-21 to use Bosch Motors. Videos of these processes are available on line. -
Page 9: Removing The Router Stop Plate
Note: Removing the Work Top will allow easier access to the router motor, spring, and drive cylinder. • Remove the Set Screws on the sides of the machine • Loosen the ¼-20 Nylock nuts with a 7/16 Wrench CASTLE, INC TSM-21 Bosch Motor Carriage Install Page 9 of 25... -
Page 10: Install The New Bosch Motor Carriage
Re-grease the Brass Hex Pivot Bushings with lithium grease (provided) • Place Brass Hex Pivot Bushings on new Motor Carriage • Move the new carriage into the machine through the back door. CASTLE, INC TSM-21 Bosch Motor Carriage Install Page 10 of 25... -
Page 11: Install The New Router Stop Plate
Replace reserved washer and tighten with new ¼-20 Nylock nut and 7/16 wrench. • From the back door replace the switch portion of the Router Stop Switch with the reserved screws and square nuts. CASTLE, INC TSM-21 Bosch Motor Carriage Install Page 11 of 25... - Page 12 Note: The Router Stop Switch magnet and switch should be as close together as the spacing on the plate will allow without interfering with the travel of the carriage. Leave the screws slightly loose to help with positioning later. CASTLE, INC TSM-21 Bosch Motor Carriage Install Page 12 of 25...
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Page 13: Final Installation And Adjustments
Adjust the nut as needed to position the pilot hole bit in the center of the hole in the case, and to the center of the pocket. Note: Only tighten the nut as needed. Overtightening can reduce the ability to move the bit in the opposite direction. CASTLE, INC TSM-21 Bosch Motor Carriage Install Page 13 of 25... -
Page 14: Pocket Web Adjustment
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. CASTLE, INC TSM-21 Bosch Motor Carriage Install Page 14 of 25... -
Page 15: Pocket Depth Adjustment
Refer to the “Pilot Drill Depth Adjustment” for this procedure. Fig 11 CASTLE, INC TSM-21 Bosch Motor Carriage Install Page 15 of 25... -
Page 16: Drill Feed Rate Adjustment
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 toward the Control Box. CASTLE, INC TSM-21 Bosch Motor Carriage Install Page 16 of 25... -
Page 17: 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 and reinstall the router motor. CASTLE, INC TSM-21 Bosch Motor Carriage Install Page 17 of 25... -
Page 18: Pilot Drill Height Adjustment
To raise the pilot hole, slide the plate upward one or two hole positions (each hole position equals ” of drill position). To lower the pilot hole, slide the plate downward. CASTLE, INC TSM-21 Bosch Motor Carriage Install Page 18 of 25... - Page 19 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-21 Bosch Motor Carriage Install Page 19 of 25...
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Page 20: Service And Maintenance
Support the bottom of the Router Motor with your left hand (Fig 21). Use your right hand to loosen the T-Knob a few turns to provide slack on the U-bolt. (Push slightly forward on the T-knob if necessary.) Fig 21 CASTLE, INC TSM-21 Bosch Motor Carriage Install Page 20 of 25... - Page 21 • Remove the ¼-20 Nylock Nuts from the (4) bolts holding the Work Top with a 7/16” wrench. Access the Router Motor collet for tolling changes. (Fig 22) CASTLE, INC TSM-21 Bosch Motor Carriage Install Page 21 of 25...
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Page 22: Pilot Drill Bit
The model TSM-21 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 23: Motors And Bits
This will lead to excessive bit wear and shortened motor life. 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-21 as standard equipment from the factory. Castle recommends these bits for all applications:... - Page 24 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-21.
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Page 25: Serial Number Log
5.6 Serial Number Log SERIAL NUMBER LOG MANUFACTURER PART NUMBER SERIAL NO. Castle, Inc A00022 – TSM-21 Pocket Hole Machine Robert Bosch Co. E21610 – Bosch PR20EVS 1.0 HP Motor Robert Bosch Co. E21617 – Bosch 1617 2.25 HP Motor PURCHASE DATE:...
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