Clarke CMS251 Operating & Maintenance Manual

versatile machine is designed for DIY/Hobby use and for use by tradesmen in a light industrial environment Before operating the machine, please read this leaflet thoroughly and carefully follow all instructions. This will ensure the safety of yourself and that of others around you, and you can also look forward to the machine giving you long and satisfactory service. GUARANTEE This CLARKE product is guaranteed against faulty manufacture for a period of 12 months from the date of purchase. Please keep your receipt as proof of purchase. This guarantee is invalid if the product is found to have been abused or tampered with in any way, or not used for the purpose for which it was intended. Faulty goods should be returned to their place of purchase, no product can be returned to us without prior permission. This guarantee does not effect your statutory rights. CONTENTS Page Safety Precautions ......................................................................... 4 Additional precautions for Table/Mitre Saws .............................. 6 Electrical Connections .................................................................. 7 Principal Parts ................................................................................. 8 Features ........................................................................................... 9 Assembly and Installation ........................................................... 10 Operation ...................................................................................... 11 Cross Cutting ................................................................... 11 Mitre Cutting ................................................................... 11 Bevel Cutting................................................................... 12 Compound (Bevel/Mitre) Cutting................................. 12 Maintenance ................................................................................ 13 Blade renewal................................................................. 13 Motor Brush Renewal ..................................................... 15 Adjustments .................................................................................. 16 Specifications ............................................................................... 17 Accessories................................................................................... 17 Maximum Cutting Sizes ............................................................... 17 Parts and Service Contacts ......................................................... 18 Parts List ......................................................................................... 18 Parts Diagram ............................................................................... 19 3

WARNING: As with all machinery, there are certain hazards involved with their operation and use. Exercising respect and caution will considerably lessen the risk of personal injury. However, if normal safety precautions are overlooked or ignored, personal injury to the operator or damage to property, may result. 1. READ and BECOME FAMILIAR with the entire operating manual. Learn the machines’ applications and limitations as well as the specific potential hazards peculiar to it. 2. EARTH ALL MACHINES. If the machine is equipped with three-pin plug, it should be plugged into a three-pin electrical socket. Never remove the earth pin. 3. ALWAYS ensure that ADEQUATE LIGHTING is available. A minimum intensity of 300 lux should be provided. Ensure that lighting is placed so that you will not be working in your own shadow. 4. CHECK for DAMAGE before using the machine. Any damaged part, such as a guard etc., should be checked to ensure that it will operate properly, and perform its intended function. Check for alignment of moving parts, breakage of parts, mountings, and any other condition that may affect the machines’ operation. Any damage should be properly repaired or the part replaced. If in doubt, DO NOT USE the machine. Consult your local dealer. 5. DISCONNECT the MACHINE from the power supply before servicing and when changing accessories such as blades, etc. 6. ALWAYS KEEP GUARDS IN PLACE and in working order. 7. ALWAYS WEAR SAFETY GOGGLES, manufactured to the latest European Safety Standards. Also use a face or dust mask if the cutting operation is dusty. Everyday eyeglasses do not have impact resistant lenses, they are NOT safety glasses. 8. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents. 9. ALWAYS WEAR EAR PROTECTORS/DEFENDERS. 10. DON’T FORCE THE MACHINE. It will do a better and safer job at the rate for which it was designed. 4

to see that keys and adjusting wrenches are removed from the machine before switching on. 12. Do not operate machine while under the influence of DRUGS, ALCOHOL OR ANY MEDICATION. 13. USE ONLY RECOMMENDED ACCESSORIES. The use of improper accessories could be hazardous. 14. NEVER LEAVE MACHINE RUNNING UNATTENDED. Turn power OFF. Do not leave machine until it comes to a complete stop. 15. ALWAYS DISCONNECT FROM THE MAINS SUPPLY when adjusting, changing parts, or working on machine. 16. AVOID DANGEROUS ENVIRONMENT. Don’t use power machines in damp or wet locations or expose them to rain. Keep your work area well illuminated. DO NOT USE in explosive atmosphere (around paint, flammable liquids etc.). 17. KEEP CHILDREN AWAY. All visitors should be kept a safe distance from the work area, especially whilst operating the unit. 19. MAINTAIN MACHINE IN TOP CONDITION. Keep tools sharp and clean for the best and safest performance. Follow maintenance instructions. 21. DON’T OVERREACH. Keep your proper footing and balance at all times. For best footing, wear rubber soled footwear. Keep floor clear of oil, scrap wood, etc. 22. WEAR PROPER APPAREL. Loose clothing or jewellery may get caught in moving parts. Wear protective hair covering to contain long hair. 23. MAKE WORKSHOP CHILDPROOF. Cover the saw adequately when not in use, to prevent children from damaging themselves by tampering with it. 24. NEVER STAND ON THE MACHINE. Serious injury could occur if the machine is tipped or if a cutting tool is accidentally contacted. Do not store materials above or near a machine, such that it is necessary to stand on the machine to reach them. 25. HANDLE WITH EXTREME CARE whenever transporting or installing machinery, and always use a lifting tool. 26. AVOID ACCIDENTAL STARTING. Ensure the switch is OFF before plugging in to mains. 27. ALWAYS CONCENTRATE ON THE JOB IN HAND, no matter how trivial it may seem. Accidents are frequently caused by carelessness due to familiarity. 5

dust. In many cases, a full face shield is even better protection. A dust mask is also recommended to keep saw dust out of your lungs. 2. Use a solid wood workbench which will not move under load. 3. This saw is designed for use by DIY/Hobbyists, or tradesmen in a light commercial environment ONLY. 4. Clear the work table of all objects except the workpiece (tools, scraps, rulers etc.) before switching on the saw. 5. Keep your fingers well away from the blade. 6. Switch off the saw, and make sure the blade has come to a complete stop before clearing sawdust or off-cuts from the table. 7. Make sure there are no nails or foreign objects in the part of the workpiece to be sawn. 8. Set up the machine and make all adjustments with the power OFF, and disconnected from the supply. 9. DO NOT operate the machine with the guards removed. They must all be in place and securely fastened when performing any operation 10. Use ONLY approved replacement saw blades. Contact your local CLARKE dealer for advice. The use of inferior blades may increase the risk of injury. 11. DO NOT saw any material that does not have a flat surface on which to bear. 12. Do Not force the blade, lower it gently into the work. 13. Ensure you have complete control of the Cutting Head at all times. When a cut is completed, return it to its uppermost position gently. DO NOT allow it to snap back heavily under spring pressure. 14. Always clamp the work to the table...DO NOT perform freehand operations. 15. Ensure that the portion of the workpiece being cut bears firmly against the back fence. 16. Provide adequate support for long workpieces. 17. Never use solvents for cleaning plastic parts as this could cause damage to the material. A soft damp cloth only is required. ADDITIONAL SAFETY INSTRUCTIONS for MITRE SAWS 6

through an approved 13 amp BS 1363 plug, or a suitably fused isolator switch. WARNING! THIS APPLIANCE IS DOUBLE INSULATED IMPORTANT: The wires in the mains lead are coloured in accordance with the following code: Blue - Neutral Brown - Live As the colours of the flexible lead of this appliance may not correspond with the coloured markings identifying terminals in your plug proceed as follows: Connect BROWN cord to terminal marked with “L” or coloured RED. Connect BLUE cord to the terminal marked with “N” or coloured BLACK. If this appliance is fitted with a plug which is moulded onto the electric cable (i.e. non-rewirable) please note: 1. The plug must be thrown away if it is cut from the electric cable. There is a danger of electric shock if it is subsequently inserted into a socket outlet. 2. Never use the plug without the fuse cover fitted. 3. Should you wish to replace a detachable fuse carrier, ensure that the correct replacement is used (as indicated by marking or colour code). 4. Replacement fuse covers can be obtained from your local dealer or most electrical stockists. Fuse Rating The fuse in the plug must be replaced with one of the same rating -13amps and this replacement must be ASTA approved to BS1362. Cable Extension If a cable extension is needed, it is essential to ensure that the size of the conductors is at least the same size as those of the power cable supplied. 7

As its’ name implies, the machine is a Bevel/Mitre Saw, capable of straight cross cutting, and cutting bevels and mitres, or a combination of the two. The main arm, or Cutting Head, carries the motor and the tungsten carbide saw blade. It is allowed to swivel to produce mitre cuts and tilt to the left to produce bevel cuts. The maximum sizes of wood that may be cut in any of these processes is given on page 17. A dust extraction port is provided at the rear of the machine to which the dust bag (Q), is attached. If required, a vacuum extraction device may be used which will provide fast and efficient removal of sawdust. The extraction device may be used continuously or intermittently depending upon your requirements. The Cutting Head is locked in its lower position for transit purposes. To release it, pull out the Head Locking Pin, (C). It may be necessary to apply slight downward pressure to the head in order to do so, and allow the head to rise to its upper position gently, under control. The head will lock in its upper position, and is prevented from being lowered until the Head Release Lever (A) is moved sideways. A Cutting Head Release Lever B Trigger Switch (ON/OFF) C Cutting Head Locking Pin D Table Locking Knob E Work Clamp F Back Fence G Table Insert H Front Mounting Hole J Table Release Lever K Pointer L Stabiliser M Bevel Scale N Bevel Locking Knob O Head Return Spring Tension Adjuster P Cutting Head Stop Screw Q Dust Bag LEGEND 9

On receipt inspect the machine to ensure that all parts are accounted for and that no damage was incurred during transit. Any deficiency or damage should be reported to your CLARKE dealer immediately. The main body of the saw is fully assembled and adjusted at the factory. It is necessary only to fit the accessories supplied as follows: 1. Mount the machine on a firm solid base that will not move under load. Ensure there is an appropriate electrical supply, and adequate lighting, so that you will not be working in your own shadow. 2. Four holes are provided in the base, one of which is shown at H, so that the machine may be bolted permanently to a workbench for added stability. Alternatively it may be bolted to a piece of plywood with a thickness of 5/8” minimum. If this method is preferred, the plywood support should be clamped to a solid base or workbench whenever the saw is being used. 3. The Work Clamp may be slipped into one of the sockets provided for the purpose, as shown at ‘E’. 4. Slide the Work Supports into their mountings, one on either side of the base. 5. Screw the Table Locking Knob into the Locking Mechanism as shown at D. To move the table, first ensure the Locking Knob is slackened off completely, i.e. turned anticlockwise one or two turns, then, whilst grasping the Locking Knob, depress the Table Release Lever, and keep depressed whilst turning the table. Release the Locking Lever and Knob at the desired position, as indicated on the scale, and lock in position by screwing the Locking Knob IN until it is firm. 6. Attach the dust bag to the dust extraction outlet with its spring clip. 7. Finally, pull out the rear stabiliser for added stability, if mounted loosely. Fig.3 Fig.4 10

First, set the work in place. Clamp it firmly against the table and back fence. Check the security of the Bevel Locking Knob (N) and tighten if necessary, also ensure the table is locked using the Table Locking Knob (D). NOTE: If the workpiece is not entirely straight, ensure that the portion at either side of the intended cut rests firmly against the table and back fence. It is important to ensure that one end of the workpiece is completely free to move i.e. NOT clamped or held in any way. This will normally be the off-cut or shorter end. When satisfied, make a final check to ensure that all safety precautions are being complied with, then pull the Trigger - B, to start the motor. Allow the blade to reach full speed. If any unusual sounds or vibrations occur, release the trigger immediately and investigate the cause. When satisfied, move the Head Release Lever (A), sideways with the thumb of your right hand, and gently lower the head so that the blade comes into contact with the workpiece. Do not force the blade, a light pressure is all that is required. You will notice that to provide maximum safety, the blade is not exposed at any time, and the guard rises automatically as the blade is lowered. Nevertheless, NEVER treat the machine with indifference, and NEVER be casual with your approach. To switch off, release the Trigger whilst still maintaining full control of the head. NOTE: The Head should rise under spring pressure, gently. If the movement is too rapid or conversely, too sluggish, spring tension needs to be adjusted. Refer to ‘Adjustments’ on page 16. B. Mitre Cutting This is a cross cutting operation, except that the saw blade is set at an angle to the work, but remains perpendicular to the table. The head is mounted on the table which is free to rotate by up to 45O, to the left and right. To set the required mitre angle, rotate the table (and hence the Cutting Head) using the procedure described on page10, to the desired position, lining up the angle on the scale, with the pointer (K). Lock the Table in position by screwing in the Locking Knob firmly. The procedure for cutting is the same as that for cross cutting. For convenience, positive stops are provided at various angles. These are: Zero (90O), 15O, 22.5O, 30O and 45O Mitre Cut at 45O Fig.5 11

As with Mitre Cutting, this is a cross cutting operation, except that the blade is not perpendicular to the table (see illustration) Ensure the table is set so that the table pointer lines up with the zero on the scale on the bed. Slacken off the Bevel Locking Knob (N), and swing the Head to the side. Set the head to the required angle according to the scale (M). Lock the head in position by retightening the Bevel Locking Knob. The 45O adjuster is factory set so that when the Head is tilted to its fullest extent the blade will cut 45O bevel. The procedure for cutting is the same as that for cross cutting. If the angle is critical, use a small angle gauge on the table to check the angle of the blade to table. Assistance will be required to carry out this task. D. Compound Mitre and Bevel Cutting. Having determined the angles you require, first set the Bevel angle, using the procedure described above, and then the Mitre angle. The procedure for cutting is the same as that for cross cutting. Fig.7 Fig.6 12

the motors’ carbon brushes, maintaining adjustments, and ensuring that after use, any sawdust or wood chips are cleaned away, with a low pressure air line or brush, paying particular attention to the motor air vents which should be kept clear at all times. Should the motor not function normally, it is possible that it has become clogged with saw dust, in which case, it will be necessary to disassemble the motor in order to clean the various components. Contact your CLARKE dealer for advice. 2. Changing the Saw Blade IMPORTANT: Exercise extreme care when handling the saw blade. The tips are extremely sharp, and careless handling could result in severe personal injury. 1. With the machine disconnected from the mains supply, and the Cutting Head in the raised position, remove the Blade Guard Arm Link Pin, arrowed in Fig. 8, and retain. 2. Slacken the Blade Guard Bracket securing screw, shown at ‘A’ in Fig. 9, and REMOVE the screw ‘B’. (Leave Screw ‘A’ in place.) This will allow the Lower Blade Guard to be removed completely. Take great care from this point, not to come into contact with the saw blade teeth. Fig.10 Fig.9 Fig.8 13 3. Remove the two screws securing the left hand lower plastic guard, arrowed in Fig. 10, and remove the guard.

the blade. If necessary give the blade a gentle tap to dislodge it from the inner flange. 7. Reassemble in reverse order, ensuring the tips of the blade point downwards at the front, as shown in Fig. 13. 4. Remove the screw securing the upper plastic guard, arrowed in Fig.11, and pull away the guard. 5. Unscrew and remove the Blade securing screw using the claw and box spanners provided, taking great care to avoid damaging your hand on the saw blade teeth. IMPORTANT: The securing screw has a LEFT HAND THREAD, i.e. turn it CLOCKWISE to undo. Hints and Tips. 1. When replacing the upper plastic blade guard (para 4 above), take care not to overtighten the securing screw. 2. To replace the Lower Blade Guard Bracket (para.2 above), centralise the guard about the blade, then position the bracket so that screw ‘A’ engages with the slotted hole in the bracket. Tighten screw (A). Using the screw as a pivot move the bracket until the other screw hole, in the Upper Blade Guard, and the hole in the bracket are aligned. Enter the screw and tighten. Fig.13 Fig.11 Fig.12 14

Eventually, the motors’ carbon brushes will need replacing. This task may be carried out quickly and easily as follows. 1. Remove the two cross head screws, securing the motors’ end cover, and pull off the cover. 2. Disconnect the spade connector, shown in Fig. 15, then pull out the brush carrier, complete with brush, as shown in Fig. 14. The cable is located on a plastic peg, shown in Fig. 15 and will simply pull away as you remove the brush. 4. Replace in reverse order. To locate the brush carrier, (which houses the brush), correctly, position the brush so that it bears on the commutator then push down gently and evenly on the brush carrier so that the carrier can be pushed on to its runners, with the brush sitting snugly on the commutator. Ensure the spade connector is secure and the cable is mounted on the locating peg before replacing the end cover. 15 Fig.15 Fig.14

It may be necessary from time to time, to check various settings and make appropriate adjustments. a. Squareness of Blade It is most important to check that the blade is exactly perpendicular to the table. To do this, place a small square on the table and bring it up to the blade, checking to see if it is square. If an adjustment is required, first slacken the Bevel Locking Knob, then slacken off the adjuster locknut T, screw the adjuster (S) in or out, as the case may be until the blade is exactly square, keeping light pressure on the head to keep it in contact with the adjuster screw. When completely satisfied, lock the adjuster with the lock nut, and with the head resting against the stop, tighten the Bevel Locking Knob. NOTE: It simplifies matters if assistance is used during this process. Check the position of the pointer in relation to the scale. If necessary zero the pointer by slackening off the pointer securing screw, moving the pointer accordingly and retighten the securing screw. b. 45O Bevel Stop Slacken off the Bevel Locking Knob, and tilt the Head to its maximum. Lower the Blade and with a small 45O gauge between the bed and blade, check for trueness of angle. If an adjustment is required, slacken the locknut which secures the adjuster shown at U in Fig.16. and is found beneath the table. Turn the adjuster in or out as the case may be, using an appropriate Hex. wrench, to acquire the correct angle. When satisfied, lock the adjuster with the locknut. c. Squareness of Backfence Place a square flat on the table with its base resting on the Backfence. If it is not square with the edge of the slot in the table, slacken off the two backfence securing screws R, Fig.2, using an appropriate Hex. wrench, sufficient to be able to move the fence until it is square. When satisfied, tighten the securing screws. d. Cutting Head Spring Tension To increase the Cutting Head spring tension, screw the adjuster (O, Fig.2), ‘IN’ using an appropriate Hex. wrench, until the required tension is achieved. Fig.16 16

Running Current........................................ 6.5Amps Power Rating: ............................................ 1400 Watts Speed: ....................................................... 3900RPM Fuse Rating .............................................................. 13Amps Dimensions: (Head Lowered) ................................ 445x490x365mm Dimensions: (Head Raised) ................................... 445x490x520mm Blade size (Fitted): .................................................. 250mm, 36T, 16mm Bore Noise level (Lw)....................................................... 101.9dB(A) at 1M Vibration Level ........................................................ <2.5m/s² (Normal Load) Weight (packed/unpacked) ............................... 17.2/15kg Part Number ............................................................ 6500768 ACCESSORIES Replacement Saw Blades Tungsten Carbide Tipped 24 Tooth ........ 6490110 40 Tooth ........ 6490120 60 Tooth ........ 6490130 Please note that the details and specifications contained herein, are correct at the time of going to print. However, CLARKE International reserve the right to change specifications at any time without prior notice. Always consult the machine’s data plate Type of Cut Depth Thickness Cross (90°) 70mm 120mm Mitre (at 45°) 70mm 90mm Bevel (at 45°) 40mm 120mm Compound (at 2x 45°) 40mm 90mm MAXIMUM CUTTING SIZES 17 Part Number

TMCCMS2512 5 Back Fence TMCCMS25105 6 Work Support TMCCMS25106 7 M5 hex screw TMCCMS25107 10 Bracket TMCCMS25110 11 Base TMCCMS25111 12 M5 screw TMCCMS25112 13 M8 Self Locking Nut TMCCMS25113 15 M8x25 hex skt hd screwTMCCMS25115 16 Crank TMCCMS25116 17 Table Locking Knob TMCCMS2517 20 Spring Plate w/handle TMCCMS25120 21 Pointer TMCCMS25121 24 M4x8 cross head screw TMCCMS25124 25 Plate TMCCMS25125 26 Work Clamp Screw TMCCMS25126 27 Locating Block TMCCMS25127 28 Work Clamp plate TMCCMS25128 29 Table TMCCMS25129 30 Table insert TMCCMS25130 31 M4x8 flat head screw TMCCMS25131 32 Pointer TMCCMS25132 33 Trunnion TMCCMS25133 34 Spring Brg Block TMCCMS25134 35 Head Mtg Bracket TMCCMS25135 36 Locating Pin Head TMCCMS25136 37 Locating Pin TMCCMS25137 38 Dust Cover TMCCMS25138 39 Clamping Pin TMCCMS25139 40 M16 Self Locking Nut TMCCMS25140 41 Head TMCCMS25141 42 Sleeve TMCCMS25142 43 Spring TMCCMS25143 44 Arm TMCCMS25144 45 Bolt TMCCMS25145 46 Link Arm TMCCMS25146 47 M6 square-neck screw TMCCMS25147 48 Spring Retaining Cover TMCCMS25148 49 Blade Guard TMCCMS25149 50 Spring TMCCMS25150 51 Plate TMCCMS25151 52 Lower Plastic Guard TMCCMS25152 55 Head Clamping Knob TMCCMS25155 56 Dust Bag TMCCMS25156 57 Dust Bag Clamp TMCCMS25157 58 Screw TMCCMS25158 59 Spring TMCCMS25159 60 Bracket TMCCMS25160 61 Head Release Lever TMCCMS25161 63 Upper Plastic Guard TMCCMS25163 64 Screw TMCCMS25164 67 Motor Mtg. Screw TMCCMS25167 68 Motor TMCCMS25168 69 L.H. Lower Plastic Gd. TMCCMS25169 70 Inner Flange TMCCMS25170 71 Outer Flange TMCCMS25171 72 Blade Securing Nut TMCCMS25172 80 Blade see Accessories No. Desciption Parts List No. Desciption Parts List PARTS & SERVICE TEL: 020 8988 7400 PARTS & SERVICE FAX: 020 8558 3622 or e-mail as follows: PARTS: [email protected] SERVICE: [email protected] For Spare Parts and Service, please contact your nearest dealer, or CLARKE International, on one of the following numbers. PARTS & SERVICE CONTACTS 18