CASTLE INC Owners Manual TSM-11
Table of Contents 1 INTRODUCTION.............................................................................................................................3 2 MACHINE SAFETY.........................................................................................................................4 2.1 SAFETY RULES ..........................................................................................................................4 2.2 INVENTORY .....................................................
1 Introduction Thank you for making the Castle TSM-11 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.
2 Machine Safety The Castle TSM-11 was designed with operator safety as a priority. This machine was carefully packaged 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.
2.2 Inventory Your TSM-11 will pocket any material you would normally rout. It is designed for material from ½” to 1 ½”. Use of materials thinner than ½” is not recommended. Every TSM-11 machine is factory adjusted. If you should find a small amount of sawdust in the bottom of your TSM-11, please don’t be alarmed. This is an indication that your machine has been factory tested prior to shipping. With your Castle machine, you should have received the following: Fig 1 CASTLE, INC TSM‐11 OWNERS MANUAL V1.
Fig 2 CASTLE TSM-11 BENCHTOP POCKET MACHINE HARDWARE PACK Part # Part Description Qty S90011 TSM-11 Operator Manual with Warranty Activation Card 1 V11001 TSM-11 work top 1 H11001 Non-slip machine feet 4 F51628 5/16” - 18 nuts 4 F44114 ¼” - 20 x 1” flathead machine screws 4 F01420 ¼” - 20 locknuts 5 F01410 ¼” flat washers 2 F14412 1/4-20 x 1/2 socket cap screw 1 N11001 Motor mount U-Bolt 1 E26902 Porter Cable 6902 router motor 1 B00338 3/8” solid carbide 3-flute premium ro
2.3 Tools To complete assembly of Castle machine, you will require the following tools: (1) 7/16” wrench or ratchet (1) ½” wrench or ratchet Fig 3 2.4 Machine Requirements ELECTRICITY: Your TSM-11 is designed to run on a 110 volt -15 AMP standard 3 prong power supply. 2 prong power adapters are not recommended for use on this machine and could cause electric shock to the user. Be sure your unit is properly grounded.
3 Setting Up Your TSM-11 Caution: Always use eye and hearing protection when operating power equipment. 1. Remove the machine from the carton and plastic over-wrap, and place on its back as shown. Be careful to place it on a clean surface free of debris to avoid damage to the powder coated finish. Fig 4 2. Secure the (4) non-slip machine feet to the machine using a ½” wrench and (4) 5/16”-18 nuts. Fig 5 3. Unpack the Porter Cable trimmer motor and collet.
4. Carefully insert the ¼” -20 x ½” button head screw into the hole at the top of the case using the supplied 5/32” hex key. The threaded portion of the screw should be fully inserted through the stainless steel motor carriage. Fig 7 Fig 8 5. While holding constant pressure on the screw head to prevent it from falling out, position the router motor in the carriage as shown and tighten the screw. Plug the motor into the lower outlet. Fig 9 6.
7. Unpack the Porter Cable router motor, collet wrenches and 3/8 collet. DO NOT UNTIE THE POWER CORD! Screw the 3/8” collet onto the motor and insert the Castle Premium carbide router bit until it is fully seated. Secure the router bit with the collet wrenches. Toggle the motor switch to the “ON” position. Fig 11 8. Install the router in the yellow carriage, carefully noting the orientation depicted in Fig 12.
10. Inspect each motor cord to verify that they are plugged into the duplex power outlet box inside the machine and that they are clear of any moving parts. You may untie the main machine power cord at this time. Verify the router bit is positioned at the center of the cutout on the underside of the worktop. If it is not, refer to the Machine Adjustments section “Pocket Hole Alignment” before proceeding.
4 Operating Instructions 1. Check to be sure the switch on top of the machine is in the OFF position and then plug the TSM-11 into a 110 volt grounded power supply. 2. Place material to be pocketed on the work table under the clamp and squarely against the rear face. 3. Push forward on clamp lever (red handle). Confirm that the clamp is secure by manually pulling on the material. If material is loose, adjust the foot on the clamp as necessary to assure the material is held securely.
5. Push the black handle away from operator rapidly until it hits the stop. This routs the pocket. If you release the black handle, the machine will move to the neutral position on its own. It is not necessary to release the black knob before proceeding to step 6. Fig 19 Note: The first pocket you cut will create a through slot in the worktop. To insure a clean cut, make sure a work piece is securely clamped in place. 6. Pull black handle toward you rapidly until it hits the stop.
Note: For optimal performance it is recommended that your cycle time be as quick as possible. A slow cycle will result in your tooling dwelling in the material and contribute to shortened tool life. 4.1 General Information The hand clamp should be tight enough for a “Brisk” travel of both the routing and drilling strokes. If your material moves during the cycle, tighten the clamp slightly.
Included with you machine is a template for cutting out a cover for the bottom of your TSM-11, necessary for creating a vacuum for pulling dust and air out of the case. Using the template provided; cut out a cover for the hole in the bottom of the case from any 1/8” thick material. 3" 114 161 2 Fig 24 At the underside opening of the case, slip the clips over the holes provided with the flat face of the clips facing out.
5 Machine Adjustments Your TSM-11 is factory adjusted to handle typical pocket-hole needs. Some adjustment may be necessary. Note: Before making any adjustments, please sure that the machine is disconnected from the electrical power outlet. 5.
5.2 Web Adjustment To move the pocket (routed portion) closer to, or further from, the edge of the material, use a 7/16” wrench and loosen the Nylock nut next to the operating handle. Moving the nut away from you will make the pocket cut closer to the edge of the material, pulling the nut toward you will make the pocket farther from the edge of the material. Tighten the nut each time before testing. This is a trial and error method until you get the pocket where it suits you best. Fig 29 5.
6 Service and Maintenance In order to ensure productivity and longevity for your Castle Benchtop Screw Pocket Machine, 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 rule, operators should visually inspect the machine at the start of each work shift in the following manner: 6.1 Router Bit Replacement 1. Unplug the TSm-11 from the electrical outlet. 2.
4. Re-install the router in the yellow carriage, carefully noting the orientation depicted below. With the motor firmly engaged against the carriage, tighten the locknuts with a 7/16” wrench and the bar knob alternating between both to ensure even tension on the U-bolt. Fig 32 6.2 Pilot Bit Replacement 1. Unplug the TSM-11 from the electrical outlet. 2. Remove the cap screw which holds the drill in place, and pull the drill out of the machine. Fig 33 3. Remove the dull bit using the wrench provided.
4. Reinsert the cap screw, and while holding constant pressure on the screw head to prevent it from falling out, re-position the router motor in the carriage as shown and tighten the screw. Fig 35 Note: It is not necessary to remove the router motor to perform this action. It has been removed in Fig 35 for clarity. CASTLE, INC TSM‐11 OWNERS MANUAL V1.
6.3 Motors and Bits Because the motors are enclosed in the machine, it is important that the maintenance guidelines provided in the manufacturer’s instruction manual are strictly observed. Periodically during operation, blow out the air passages on both motors with 30 PSI compressed air. Let motors rest/cool down after 2 hours of continual use. Use dust collection for clearing sawdust out of your machine case and creating air flow through the case to aid in cooling the motors.
7 Warranty Information Castle, Inc. uses only the highest quality materials available for the construction of our machines. Your TSM-11 Bench Top Pocket Machine is warranted for one full year from the date of purchase against workmanship or material defects under normal use and service. We are not responsible for negligence, misuse or accidents. We suggest any and all machine maintenance or repair be discussed with an authorized Castle Representative prior to any disassembly.
