Clarke CCS 2, 6462040 User guide

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185MM CIRCULAR SAW

MODEL No. CCS2

Part No. 6462015 Part No. 6462040

OPERATING & MAINTENANCE

INSTRUCTIONS

0704

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Thank you for purchasing this CLARKE Circular Saw, designed for cutting wood ONLY.

Before attempting to use the machine, please read this manual thoroughly and follow the instructions carefully. In doing so you will ensure the safety of yourself and that of others around you, and you can look forward to the saw giving you long and satisfactory service.

Guarantee

This product is guaranteed against faulty manufacture for a period of 12 months from the date of purchase. Please keep your receipt which will be required 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.

Specifications

Mains Supply ..................................................................................... 230V 50Hz 1ph

Power Rating .................................................................................... 1300W

Fuse Rating ....................................................................................... 13amp

No Load Speed ................................................................................ 4,800 RPM

Guaranteed Sound Power Level (Under Load) .......................... 108.6dBL

Weight ............................................................................................... 6kg

Cutting Capacity @ 90º .................................................................. 60mm

Cutting Capacity @ 45º .................................................................. 45mm

Blade/Bore Diameter/Type ............................................................ 185/20mm/TCT

Dimensions ........................................................................................ 353x250x290mm

Part Number ..................................................................................... 6462040

Declared vibration emission value in accordance with

EN12096

Measured vibration emission value -

Uncertainty value -

<2.5m/s

0.99m/s

Highest measured reading in a single plane 4.56m/s

Values determined according to EN28622-1

This product Confirms to 98/37/EEC Regulations

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.

Parts List

No. Description Part No. No. Description Part No.

1 Screw TMCCCS201 2 Back Cover TMCCCS202 3 Screw TMCCCS203 4 Plate TMCCCS204 5 Brush Holder TMCCCS205 6 Carbon Brush TMCCCS206 7 Carbon Brush Cap TMCCCS207 8 Handle TMCCCS208

9 Housing TMCCCS209 10 Stator TMCCCS210 11 Screw TMCCCS211 12 End Plate TMCCCS212 13 Bearing Sleeve TMCCCS213 14 Bearing 609 TMCCCS214 15 Armature TMCCCS215 16 Bearing TMCCCS216 17 Case TMCCCS217 18 Spring TMCCCS218 19 Self-locking Bolt TMCCCS219 20 Button TMCCCS220 21 Upper Blade Guard TMCCCS221 22 Screw TMCCCS222 23 Bracket TMCCCS223 24 Brace TMCCCS224 25 Washer TMCCCS225 26 Nut TMCCCS226

27 Ring TMCCCS227

28 Bevel Locking Lever TMCCCS228 29 Washer TMCCCS229 30 Screw TMCCCS230 31 Long Rivet TMCCCS231 32 Spindle TMCCCS232 33 Screw TMCCCS233 34 Base TMCCCS234 35 Screw TMCCCS235

36 Depth Plate w/scale TMCCCS236 37 Rivet TMCCCS237

38 Handle TMCCCS238

PARTS & SERVICE TEL: 020 8988 7400

or e-mail as follows:

PARTS: [email protected]

SERVICE: [email protected]

39 Screw TMCCCS239 40 Cord Clamp TMCCCS240 41 Screw TMCCCS241 42 Rubber Handle TMCCCS242 43 Cable Gland/protector TMCCCS243 44 Capacitor TMCCCS244 45 Switch TMCCCS245

46 Handle Cover TMCCCS246

47 Screw TMCCCS247 48 Locking Lever TMCCCS248 49 Ring TMCCCS249 50 Depth Locking Lever TMCCCS250 51 Washer TMCCCS251

52 Screw TMCCCS252 53 Cable complete TMCCCS253 54 Needle Bearing TMCCCS254 55 Gear TMCCCS255 56 Woodruff Key TMCCCS256 57 Spindle TMCCCS257 58 Round Plate TMCCCS258

59 Bearing TMCCCS259 60 Front Cover TMCCCS260 61 Screw TMCCCS261

62 Riving Knife Bracket TMCCCS262 63 Nut TMCCCS263

64 Riving Knife TMCCCS264 65 Screw TMCCCS265 66 Rod TMCCCS266 67 Rivet TMCCCS267 68 Plastic Ring TMCCCS268 69 Lower Blade Guard TMCCCS269 70 Lever TMCCCS270 71 Screw TMCCCS271 72 Ring TMCCCS272 73 Inner Flange TMCCCS273 74 Blade See Dealer 75 Outer Flange TMCCCS275 76 Screw TMCCCS276

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Parts Diagram

Safety Precautions

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. ALWAY S learn the machines’ applications, limitations and the specific potential hazards peculiar to it. Read and become familiar with the entire operating manual.

2. ALWAY S use a face or dust mask if operation is particularly dusty.

3. ALWAYS check for damage. Before using the machine, any damaged part, 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.

4. ALWAYS disconnect the tool/machine from the power supply before servicing and when changing accessories.

5. ALWAY S wear safety goggles, manufactured to the latest European Safety Standards. Everyday eyeglasses do not have impact resistant lenses, they are not safety glasses.

6. ALWAYS keep work area clean. Cluttered areas and benches invite accidents.

7. A LWAYS 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.

8. ALWAY S keep children away. All visitors should be kept a safe distance from the work area, especially whilst operating the machine.

9. ALWAY S use CLARKE replacement blades. The use of improper parts/accessories could be hazardous.

10. ALWAYS maintain machine in top condition. Keep tools/machines clean for the best and safest performance. Follow maintenance instructions.

11. ALWAYS handle with extreme care do not carry the tool/machine by its’ electric cable, or yank the cable to disconnect it from the power supply .

12. ALWAYS ensure the switch is off before plugging in to mains. avoid accidental starting.

13. ALWAYS concentrate on the job in hand, no matter how trivial it may seem. Be aware that accidents are caused by carelessness due to familiarity.

14. ALWAYS keep your proper footing and balance at all times don’t overreach. For best footing, wear rubber soled footwear. Keep floor clear of oil, scrap wood, etc.

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15. ALWAYS wear proper apparel. Loose clothing or jewellery may get caught in moving parts. Wear protective hair covering to contain long hair.

16. ALWAYS remove plug from electrical outlet when adjusting, changing parts, or working on the machine.

17. NEVER operate machine while under the influence of drugs, alcohol or any medication.

18. NEVER leave machine running unattended. Turn power off. Do not leave the machine until it comes to a complete stop.

19. NEVER force the machine, it will do a better and safer job at the rate for which it was designed.

20. NEVER use power tools 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.). Avoid dangerous environment.

Additional Precautions For Circular Saws

1. ALWAYS wear ear protectors/defenders when using this machine.

2. ALWAYS use the appropriate saw blade for the material being cut.

3. ALWAYS keep the mains cable well away from the machine and ensure an adequate

electrical supply is close at hand so that the operation is not restricted by the length of the cable.

4. ALWAYS ensure the Riving Knife is in place and directly in line with the blade.

5. ALWAYS allow sufficient clearance beneath the work to ensure the blade does not

come into contact with the work bench or any other object.

6. ALWAYS ensure the blade is fully tightened before use.

7. ALWAYS use a rip fence or guide when ripping.

8. ALWAYS check blade guard has returned FULLY before putting saw down.

9. ALWAYS ensure that nails have been removed from a workpiece beforehand. Nails will

damage the saw blade.

10. NEVER operate the saw when the blade guard is not working properly. The Guard

should be checked for correct operation before each use.

11. NEVER use abrasive disks with this machine, it is designed to cut wood ONLY

12. NEVER start the saw when the blade is in contact with the work.

13. NEVER allow the ventilation slots in the motor to become blocked.

14. NEVER use the machine if the electric cable, plug or motor is in poor condition.

15. NEVER reach beneath the workpiece whilst cutting

16. If the blade binds whilst cutting, or cutting is interrupted, hold the saw firmly, release

the trigger and allow the blade to stop completely. NEVER attempt to remove the saw when the blade is in motion, otherwise kickback will occur.

17. NEVER use the saw with the blade guard jammed open.

Note : The guard is operating correctly when it moves freely and readily returns to closed position

Additionally, please keep these instructions in a safe place for future reference.

Kickback

Kickback is when the saw is driven back fiercely into the hands of the operator, and may be caused by the following:

a. The blade becoming twisted or misaligned in the cut. b. Dull Blades...ALWAYS use a sharp, perfectly serviceable blade. d. Workpiece not properly secured, or held down adequately e. Wet, warped, green or pressure treated timber. f. Riving Knife misaligned. g. Sawing into knots, nails etc. h. Forcing the tool. i. Using improper saw blades.

j. Depth setting too great....do not exceed 3-4mm.

Always hold the saw firmly so as not to loose control should kickback occur.

Maintenance

The Saw is generally maintenance free, except for occasionally changing the saw blade, described below, and maintaining in a clean condition, ensuring the motor vents are clear at all times. Do not use solvents to clean body parts

Changing the Saw blade

Ensure the saw is isolated from the mains supply, by removing the plug from the socket. Press the Spindle Locking Knob (N, Fig. 1) in order to hold the blade securely, then, using the

special wrench, (supplied), unscrew (anticlockwise) and remove the Blade Centre Bolt and washer, followed by the Outer Flange.

Retract the Lower Blade Guard all the way up into the Upper Guard, and slide the blade off the spindle and down through the slot, taking great care not to damage hands on the saw’s teeth.

Replace in reverse order, ensuring the blade is the correct way round...i.e. The teeth should be pointing FORWARDS at the bottom. Ensure also, the blade sits snugly on its registration on the spindle before replacing the outer flange, washer and centre bolt, which should then be tightened but taking care not to overtighten.

Riving Knife Adjustment

It is vital that the Riving knife is perfectly in-line with the blade at all times with a gap of no more than 5mm exsisting between the blade and knife.

Should it be necessary to adjust the Knife, ensure the tool is disconnected from the mains, then lower the Guide Plate so that the blade depth is zero using the locking lever, O Fig. 1, to reveal the two Riving Knife securing screws - A, Fig.4. Slacken the screws sufficient for the knife to be adjusted, ensuring the gap between blade and knife - B, is no more than 5mm, and constant along the length of the knife.

Additionally, the blade should not extend more than 5mm below the end of the riving knife.

Ensure the securing screws are tight before use.

NOTE: It may be necessary to bend the knife slightly to ensure it is directly in-line with the blade.

Fig. 4

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4. Starting

Place the leading edge of the Guide Plate on the top face of the workpiece, ensuring the saw blade IS NOT making contact.

(See ‘General Notes’, which follow, for

more detailed information Re: marking the workpiece and accurate cutting etc.)

Hold the saw FIRMLY with both hands, then press the Interlock Button ‘M’ Fig. 1 and pull up the ON/OFF switch.

The saw will start. Proceed to feed the saw into the work firmly and at a slow rate. Do not force it.

Be aware that sawdust will be emitted from the dust extractor outlet. Suitable precautions should be taken to protect property etc.

5. Stopping

Release the ON/OFF switch and allow the saw blade to stop completely before

withdrawing the saw from the cut. NEVER attempt to remove the saw with the blade rotating and NEVER attempt to stop the blade by lateral pressure..

General Notes

1. Always support work as near as possible to the cut.

2. Support work so that the off-cut will be on your right hand side.

3. Clamp workpiece so that it will not move during the cut.

4. Side on which finished appearance is important should be face down.

5. Before beginning a cut, draw a guide line along the desired line of cut, then

place the front edge of the Guide Plate on that part of the work that is solidly

supported.....NEVER on the part of the work that will become the off-cut.

The notch on the front of the Guide Plate is marked 45 guideline with the 0O mark.

IMPORTANT! When marking your guideline, you must take into account the thickness of the saw blade. This must be added to your desired width.

Since the blade thickness may vary, always test on a scrap piece first to determine how much, if any, the guideline must be offset to produce your desired width.

Parallel Cut

Making a parallel cut using the Parallel Stop. Position the face of the Stop firmly against the edge of the workpiece, this makes

a true cut without pinching the blade. The guiding edge of the workpiece must be straight for your cut to be straight. Use

caution to prevent your blade from binding in the cut.

and 0O. Line up your

Electrical Connections

This product is provided with a standard 13 amp, 230 volt (50Hz), BS 1363 plug, for connection to a standard, domestic electrical supply. Should the plug need changing at any time, ensure that a plug of identical specification is used.

WARNING

This appliance is Double Insulated, and the two wires in the mains lead should

be wired up in accordance with the following colour code:

BLUE - NEUTRAL

BROWN - LIVE

•

Connect the BLUE coloured cord to the plug terminal marked a letter “N”

• Connect the BROWN coloured cord to the plug terminal marked a letter “L”

If this appliance is fitted with a plug which is moulded on to the electric cable (i.e. nonrewireable) 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 Clarke dealer or most electrical stockists.

FUSE RATING

The fuse in the plug must be replaced with one of the same rating (13 amps) and this replacement must be ASTA approved to BS1362.

If in doubt, consult a qualified electrician. Do not attempt any electrical repairs yourself.

CABLE EXTENSION.

Always use an approved cable extension suitable for the power rating of this tool (see specifications), the conductor size should also be at least the same size as that on the

machine, or larger. When using a cable reel, always unwind the cable completely.

Bevel Cut

The angle of cut of your saw can be adjusted from 0º and 45º, there is a cutting indication notch in the sole plate to assist in lining up the line of cut.

Align your line of cut with the inner guide on the sole plate, (45º), when making full 45º bevel cuts, make a test cut on a scrap piece first, again to determine how much offset, if any, is needed in order to produce your desired width.

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Features

Operation

Fig. 1

WARNING! This appliance should not be used by anyone not fully trained in the use and operation of Power Tools

IMPORTANT!

Before use, ensure the workpiece is perfectly secure, and there is sufficient clearance BENEATH the workpiece so that there is no possibility of the saw blade coming into contact with any other object.

Fig. 2

1. Set the blade depth

.... so that the blade just breaks through the underside of

the workpiece. This is achieved as follows:

Raise the Lower Blade Guard using the lever ’D’ Fig. 1, and lay the saw alongside the workpiece so that the blade guard is supported by the top surface of the workpiece.

Unlock the Blade Depth Locking Lever ‘O’ by pulling it upwards.

Hold down the Guide Plate whilst raising the saw, and push downthe locking lever when the blade is just of the workpiece, as illustrated. The saw blade should never extend by more that 3- 4mm.

Failure to set the depth correctly will result in the Lower Blade Guard not operating correctly and fouling the workpiece during the cutting process.

A - Saw Blade Centre Bolt

B - Saw Blade Outer Flange

C - Riving Knife

D - Lower Blade Guard Lever

E - Dust Extraction Outlet

F - Guide Plate (Bevel) Locking Lever

G - Blade Bevel Gauge

H - Guide Plate

I - Parallel Stop Locking screw

J - Parallel Stop

K - Lower Blade Guard

L - ON/OFF Switch

M - ON/OFF Switch Interlock Button

N - Spindle Lock

O - Blade Depth Locking Lever

P - Blade Depth Gauge

2. Set the blade angle

If Accuracy is required, use a protractor against the saw blade and Guide Plate.

Unlock the Guide Plate using the locking lever ‘F’, adjust accordingly then re-lock the Guide Plate.

For general use, a scale is provided, shown at ‘G’ Fig. 1.

The illustration shows the blade set at 45

Fig. 3

3. Safety

Check that all parts are secure, including the saw blade and Riving Knife, which must be directly in line with the blade...if it is not, it MUST be realigned before use.

Adjust the parallel stop if required. Ensure the mains cable is well away from the saw blade and not looped under the workpiece, then plug into the mains supply.