11

Definition and Description of Parts Page 12-14

Maintenance .. Page 15

Troubleshooting. Page
16-17

Warranty Page
18

1

DO NOT OPERATE THIS MACHINE
UNTIL YOU HAVE READ THIS
MANUAL COMPLETELY.






Safety Notification

WARNING:

This machine was carefully prepared for shipment at
our factory. Upon receipt of this machine, inspect for
shipping damage. The Castle 30 Express System Drill
was designed with operator safety as a priority.
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.

Contact Castle, Inc. at 800-282-8338 for instructions.






Inventory

With your Castle machine, you should have received the following:


Warranty Card (Please fill out & mail to Castle, Inc. to activate
your warranty)

30 Express Operators Manual

One bottle of Line Boring Oil

Left and Right Side Stop Assemblies

4 Dust Collection Port Tube

Magnetic Sheet for Dust Collection






Machine Requirements

Electricity: 220V, Single Phase

Air Supply: 80 PSI minimum, 150 PSI maximum















Never use an extension cord to
power this machine.

Use of an extension cord can
cause motor damage and may void
your warranty


2
3
Setting Up Your 30 Express

Your Castle 30 Express system drill was set up at the factory and tested for proper operation.
It is normal to find a small amount of sawdust residue in the machine as a result of this process.


Begin set up on your 30 Express by removing the Phillips head screws from each corner
of the machine that attach the machine to the pallet. Position and secure your machine
in a chosen location.


The holes on the inside base of the machine are for securing your machine to the floor,
should you wish to do so.


Supply a compressed air hose to the lower right side of the machine and connect it to the
Air Fitting.


Castle strongly recommends adding filtration to this, and any Castle machine, that uses
compressed air as part of its operation. Parker filters are available from Castle that will
extend a 5 year warranty over all Parker components used in the machine.


A � female pipe thread is provided for the connection.


It is suggested that a minimum 3/8 air line be used to operate this machine. A smaller
line may slow the drilling process considerably.


Plug in your machine. A 15 Amp circuit or larger will run your new 30 Express Line
Boring Machine. DO NOT use an extension cord.


Castle recommends attaching a dust collection system. This will clear particles of dust,
as well as vent the Motor to keep it cool. Doing so will also help extend the life of the
Motor Bearings.


The Clamp Beam is found inside the machine wrapped in foam. Unwrap it and locate
the Triple T-nut. Connect the 2 pieces of aluminum extrusion so that the side stops are
facing the same direction, and are mirrors of one another. From the side of the machine,
slide the extrusion over the 4 carriage bolt heads on the underside of the Yellow Clamp
Frame. Use a � socket through the Clamp Frame to tighten the Clamp Beam extrusion
into place.


If dust collection is available, remove the Magnetic Strip from the inside of the machine
and attach it to the under side of the Dust Collection Chute.


To set your Side Stop Rules use a piece of scrap panel and push it up against the Side
Stop on the right side. Drill a line of holes, measure the distance from the edge of the
panel to the first hole, then set the rule to match. Repeat on the left side.



Now that the tape is calibrated you are ready to drill your first test panel.



The Front Auto-Fence is factory set to 37mm from the center of the Drill Bits to
the front edge of the board.
.

Insert your first test panel under the Clamp Beam with the front edge of the panel
facing in, toward the Front Auto-Fence and the bottom edge of the panel toward
the Right Stop. If the Front Fence is up tap the Foot Pedal to toggle it down.




The panel should now be in a position for the Clamp to come down and the Drill
Bits to come up from the bottom to drill the first row of holes.


Press the green Start Button. (The red Safety Button must be pulled out to the
ready position before green button will activate your machine.)


Step on the Foot Pedal and hold it down until the drill completes the drilling cycle
(approximately 3 seconds). You may hear a released air sound after the panel has
been drilled. This is normal.


NOTE: If at any time during the clamping and drilling cycle you release the Foot
Pedal, the drilling process will be interrupted and will stop drilling. The Clamp will
release, the Auto-Fence will change position, and the drill will retract to the ready
position.

This has completed the first row of holes in the under side of your panel.







4

Pull the Black Fence Knob toward you, dropping the Middle Fence into place.




Again, slide the panel to the right until it is pressed against the Right Stop.


Keep Your Fingers Away From the Clamping Beam.



Step on the Foot Pedal again and wait for the machine to complete its drilling
cycle.


Release the Foot Pedal.

You have just drilled the rear line of holes for a 12 panel
OR the middle row of a deeper panel.


Check to see that the holes are in satisfactory position and if necessary, make fine
adjustments to satisfy your specific line boring needs.


If you are drilling a Lower, then the Middle Fence should stay up and the panel
should be pushed all the way in to the Rear Fence.














5 Operating Instructions

Always use eye protection when operating power equipment.

Your 30 Express was designed for boring both European type 32mm panels
and American Face Frame type cabinet construction. Since the distance
between the Bits is only critical for European style panels, your drill is using
32mm increments center to center between drill bits and will drill 5mm
diameter holes. This hole placement should not effect American style panels.

Note: Your 30 Express Line Boring Machine will shut off automatically in 2
minutes and 40 seconds if it is left running without use. Simply push the
green button to restart.


Plug your 30 Express Line Boring Machine into 220V single phase electrical
outlet. DO NOT use an extension cord!


Hook up the proper air supply and filtration. (3/8 line)


Set the Toggle Switch located on the Clamp Frame to the center or off position for
drilling standard panels.

Top View



Your machine is factory set for a cycle time of 2 � to 3 � seconds.


The Fence Drop Gauges have been factory set for Lower Panels of 24 depth and
Upper Panels of 12 depth.
Do not adjust these until you have read
the entire manual.




Always put your panels into the machine with the front edge leading into the
machine and the bottom edge indexed to the correct end of the Stop. Left Stop for
right hand panels and Right Stop for left hand panels.


6
7

Drilling Panels Longer than 42 in length

If you are drilling a 96 x 12 panel for full height shelving units, use the same
procedures as you did for the 42 x 12 panel in the previous application.


Drill the first row of holes using the Right Stop. Whenever the Toggle Switch is
flipped, the first cycle will drill, then the second cycle will index.


Since the first row of holes is started from the Right Stop, you will need to flip the
Toggle Switch located in the middle of the Yellow Clamp Frame to the right to
activate the Right Side Index Pin.


Hold your left hand in the approximate position where the last hole at the left end
of the panel was just drilled.


Use your right hand to lift the Right Stop up and out of the way of the panel and
slide the panel to the right under the Yellow Clamp Frame until your left hand is
lined up with the right side of the Clamp Frame at approximately the first drill bit
location.


Step on the foot pedal and both Index Pins will try and come up to seat in a hole.
With the Toggle Switch in the right position only the right Index Pin will inform
the machine to operate.


If a hole is not in line with the pin, the machine will not cycle. This will be the
case until you move the panel slowly to the right or left slightly.
WHEN THE PIN LOCATES AN EXISTING HOLE, THE MACHINE WILL
CYCLE IMMEDIATELY AFTER THE PIN SEATS.


After you have finished with the front side of the panel, flip the Toggle Switch to
the center and then back to the right or left side to change Auto Gauge.


For 12 panel or a center row of holes pull the Black Knob toward you, dropping
the Middle Fence into working position.


Push the panel to the Middle Fence and flip the Right Stop back down into the
working position.


Press the Foot Pedal and the machine will drill the second row of holes on the back
edge (or middle) of the panel.


After drilling has finished, pop the Right Stop up and out of the way of the panel.