Clarke CLS 405, 3401997 User guide

405MM CIRCULAR LOGSAW

MODEL NO: CLS405

PART NO: 3401997

ASSEMBLY &

OPERATING INSTRUCTIONS

ORIGINAL INSTRUCTIONS DL1221 - rev 1

INTRODUCTION

Thank you for purchasing this CLARKE Circular Log Saw.

Before attempting to use this product, 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 your purchase
giving you long and satisfactory service.

When unpacking, check for damage or shortages etc. Any found should be
reported to your CLARKE dealer where the product was originally purchased.

Please keep these instructions in a safe place for future reference.

OVERVIEW

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SPECIFICATIONS

Model Number CLS405

Cutting Length Min/max 250 -1000 mm

Cutting Capacity (min/max dia) 30 - 140 mm

Wood Weight Max 11 kg

Operating Voltage 230V / 50Hz

Motor Power 2200 W

IP Rating IP54

No load blade Speed 2800 rpm

Duty Cycle S2 / 15 minutes

Blade Diameter 405 mm

Internal Bore Diameter 30 mm

Teeth Thickness (Kerf) 3.2 mm

No of Saw Teeth 32 HW

Sound Pressure Level 101 dB LpA

Guaranteed Sound Power Level 115 dB LWA

Product Dimensions: (L x W x H) 755 x 736 x 1046 mm

Weight 36.3 kg

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SAFETY WARNINGS

WORK AREA

1. Keep the work area clean and well lit. Cluttered and dark areas invite
accidents.

2. DO NOT operate power tools in explosive atmospheres such as in the
presence of flammable liquids, gasses or dust. Power tools create sparks
which may ignite dust or fumes.

3. Keep children and bystanders away while operating any power tool.
Distractions can cause you to lose control.

ELECTRICAL SAFETY

1. Power tools must match the power outlet. Never modify the plug in any
way. Do not use adaptor plugs with earthed (grounded) power tools.

Correct plugs and outlets will reduce the risk of electric shock.

2. DO NOT expose power tools to rain or wet conditions. Any water entering
power tools will increase the risk of electric shock.

3. DO NOT abuse the electrical cable. Never use the cable for pulling or

unplugging the power tool. Keep the cable away from sources of heat, oil,
sharp edges or moving parts. Damaged or tangled cables increase the risk

of electric shock.

4. Use outdoor extension leads. If working outdoors, 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.

5. When using a cable reel, always unwind the cable completely. We strongly
recommend that this machine is connected to the mains supply via a
Residual Current Device (RCD).

PERSONAL SAFETY

1. Stay alert, watch what you are doing and use common sense when you
are operating a power tool. Do not operate a power tool when you are

tired, ill or under the influence of alcohol, drugs or medication. A moment
of inattention may result in personal injury.

2. Wear personal protective equipment including eye protection. Safety
equipment such as a dust mask, non-skid shoes or hearing protection used
for appropriate conditions will reduce personal injuries. Use a face or dust
mask if operation is particularly dusty. Wear ear protectors/defenders as
the noise level of this machine can exceed 85dB (A).

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3. DO NOT over-reach. Keep your proper footing and balance at all times.
This enables better control of the power tool in unexpected situations.

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

5. Avoid accidental starting of the machine. Ensure the switch is in the off
position before plugging the machine in to the power supply. Plugging in
power tools that are switched on invites accidents.

6. Dress properly. Do not wear loose clothing or jewelry which may get
caught in moving parts. Wear protective hair covering to contain long hair.
For best footing, wear protective footwear. Keep floor clear of oil, scrap
wood, etc.

7. Wear gloves while handling saw blades and always store them in the
protective packing provided. A dust mask should be warn to reduce the
inhalation of harmful dust.

8. Always remove and stack cut timber in a suitable place, well away from
the saw operator.

9. Switch the machine OFF immediately after the task is completed.

POWER TOOL USE AND CARE

1. DO NOT force the power tool. Use the correct accessories for your
application. The power tool will do a better and safer job at the rate for
which it was designed.

2. DO NOT use the power tool if the switch does not turn it on and off. Any
power tool that cannot be controlled with the switch is dangerous and
must be repaired.

3. Disconnect the power tool from the power supply before making any
adjustments or storing the tool. These measures will reduce the risk of the
power tool starting accidentally.

4. Store power tools out of the reach of children and do not allow persons
unfamiliar with these instructions to operate this product. Power tools are
potentially dangerous in the hands of untrained users.

5. Maintain power tools in top condition. Check for misalignment or binding of
moving parts, broken parts, or any condition that may affect the
machine’s operation. If damaged, have the machine repaired before use.
Many accidents are caused by poorly maintained power tools.

6. Check the power tool for damage before use. Any damaged part should
be inspected to ensure that it will operate properly and perform its
intended function. Any damage should be properly repaired or the part
replaced. If in doubt, DO NOT use the machine. Consult your local dealer.

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SERVICING

1. When necessary, have your power tools serviced or repaired by a qualified
person using identical replacement parts. This will ensure that the safety of

the power tool is maintained.

PRECAUTIONS SPECIFIC TO CIRCULAR SAWS

1. ALWAYS wear ear protectors/defenders during continuous use as the noise
level of this machine can exceed 85dB (A).

2. ALWAYS keep the mains cable well away from the saw and ensure an
adequate electrical supply is close at hand so that the operation is not
restricted by the length of the cable.

3. ALWAYS use only the correct blade for this saw and ensure the blade is fully
tightened before use. The blade must always be rated to operate at a
rotational speed equal to, or greater than that of the machine.

4. Beware of foreign objects. When cutting pre-used wood, ensure all nails
have been removed beforehand. Nails will damage the saw blade.

5. When switching off, remember that the blade will continue to rotate for a
short time after the stop button has been pressed to stop the saw.

6. NEVER operate the saw without the blade guards being installed correctly.

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

8. DO NOT use the saw if the power cable, plug or motor is in poor condition.

9. ALWAYS ensure the workpiece is held securely when cutting by placing
securely in the log cradle to avoid loss of control.

10. ALWAYS hold the cradle handles with both hands to keep hands well away
from the saw blade.

12. DO NOT attempt to saw very small logs including those which cannot be
properly secured. Logs sizes are stated in the Specification on page 3.

CHANGING BLADES

1. Unplug the saw from the power supply before changing the blade and
take care to prevent entrapment of the fingers between the blade and
the inner guard. Ensure the blade is secure before use.

2. Use the appropriate saw blade for this saw. Correct blades are available
from your CLARKE dealer Part No 3401991

3. ONLY use saw blades in good working condition. Discard and replace
cracked or bent saw blades.

4. ALWAYS secure the blade using the wrenches supplied.

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SAFETY SYMBOLS & PICTOGRAMS

Please read all of the safety and operating instructions carefully before using
this product.

The following safety symbols are found on the product.

Refer to instruction
manual before use.

Never reach into the
running saw blade.

Wear eye protection Wear a breathing mask

Wear ear protection Do not use in the rain

Wear protective gloves Keep hands away from

the blade or serious per­sonnel injury could result.

Wear safety footwear Disconnect mains power

cable prior to any repair,
cleaning or
maintenance.

Keep children and
bystanders away

Never attempt to cut
more than one log at a
time.

Inspect the log cutter for
damage before use.

Avoid accidents by
keeping work space
tidy.

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ELECTRICAL CONNECTIONS

Plug must be BS1363/A approved.

Always fit

make sure that the outer sheath of

Neutral

(Blue)

Live

(Brown)

Earth

(Green and

the cable is firmly held by the clamp

Yel low)

a 13 Amp
fuse

WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS
SUPPLY.

Connect the mains lead to a standard, 230 Volt (50Hz) electrical supply
through an approved 13 amp BS1363 plug, or a suitably fused isolator switch.

If the plug has to be changed because it is not suitable for your socket or
because of damage, it must be removed and a replacement fitted, following
the wiring instructions shown below. The old plug must be discarded safely as

insertion into a power socket could cause an electrical hazard.

WARNING: THE WIRES IN THE POWER CABLE OF THIS PRODUCT ARE
COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE:
BLUE = NEUTRAL BROWN = LIVE YELLOW AND GREEN = EARTH.

The If the colours of the wires in the power cable do not correspond with the
markings on the terminals of your plug, proceed as follows.

• Connect the blue wire

to the terminal which
is marked N.

• Connect the brown

wire to the terminal
which is marked L.

• Connect the yellow

and green wire to the
terminal which is

marked E or .

We strongly recommend that this machine is connected to the mains supply
via a Residual Current Device (RCD). If you are not sure, consult a qualified
electrician. DO NOT try to carry out any repairs yourself.

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INVENTORY

1Motor 11Saw Blade

2 Base Frame 12 Limit Plate

3 Log Carriage Extension 13 Handle

4 Pivoting Log Carriage 14 Top Guard

5 Inner Saw Blade Cover 15 Back Plate 1

6 Blade Guard 2 16 Back Plate 2

7 Outer Saw Blade Cover 17 Guide Tube with Return Spring

8 Blade Guard 18 Cross Brace

9 Front Clamping Disc 19 Blade Wrench, Face Wrench, Spanner

10 Rear Saw Blade Disc 20 Hardware Bag

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ASSEMBLY

This log saw was partially
assembled at the factory. To
complete your saw follow the
instructions below.

SAW BLADE GUARDS

1. Place the back plate 1,
against the outside of the
connecting part of the log
carriage and align its two
holes with the upper two holes
of the connecting part as Fig

A, step 1.

2. Fix the back plate 1 to the
table with one M8 x12 bolt, flat
washer and nut as Fig A, step

2.

3. Put the saw blade guard 1
against the inner side of the
same connecting part, align
the holes and bolt the saw
blade guard 1, connecting
part and back plate, together
with three M8 x 20 bolts,
washers and nuts.

4. Repeat the same assembly
steps on the other side for
back plate 2 and saw blade
guard 2 as Fig A steps 3 & 4.

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HANDLE

Attach the handle to the back of the log carriage. Secure it with two M8x25
bolts and lock nuts as Fig B. Screw the wing bolt M5 x 20 into the hole at the
upper right corner.

ON/OFF SWITCH

Fix the switch to the motor plate
with two M4 x 55 bolts as Fig C.

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RETURN SPRING

Fix one end of the guide pipe with
return spring on the left leg with
M8 x 55 bolts, washers and lock
nut as Fig D.

CONNECTING PIVOTING LOG CARRIAGE AND BASE FRAME

Lay the pivoting log carriage on
the ground with legs inside the
base frame, and put one end of
the cross brace outside as shown
in Fig E. Fasten them together with
M8 x 40 bolts, washers and lock
nuts on both sides.

Fix the other end of the cross
brace from the inner side of the
base frame with M8 x 70 bolts,
washers and lock nuts on both
sides.

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INNER SAW BLADE COVER

Slide the shaft through the centre
hole of the inner saw blade cover
and align its other holes with those
on the motor plate as Fig F. Secure
it with three M8 x 20 bolts, washers
and lock nuts on the upper side
and one M8 x 45 bolt, washer and
lock nut on the lower.

SAW BLADE

Slide the rear saw blade retaining
disc onto the motor shaft. Place
the saw blade together with the
front retaining disc onto the shaft
and touching the rear disc.
Secure it with the nut M20 as Fig
G, step 1.

NOTE: The arrow on the blade

must point in the direction
of the operating side.

NOTE: The teeth must point in

the direction of rotation
as shown when viewed
from the exposed side.

Tighten the nut using the saw
blade wrench. Hold the front
retaining disc with the face
wrench as Fig G, steps 2 & 3.

Never use a cracked, blunt or
otherwise damaged blade.

Ensure the blade is rated at least
equal to the speed/performance
of the machine.

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IMPORTANT: Keep the two special wrenches in a safe place.

CAUTION: INSTALLING THE BLADE THE WRONG WAY ROUND WILL RESULT
IN DAMAGE TO THE BLADE. THE ARROW MUST POINT TOWARDS THE
DIRECTION OF ROTATION.

OUTER SAW BLADE COVER

Tighten the outer saw blade cover
to the inner cover with four M5 x
10 cross head screws and flat
washers as Fig H.

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FIXING RETURN SPRING/CHAIN AND GUARD PLATE

Take the cotter pin and washer
from the guiding pipe with spring
as Fig I step 1. Push the log
carriage to the base frame until
the open end of the guiding pipe
is inserted into the angle part of
the base frame as Fig I step 2.

Secure the pipe with the washer
and cotter pin as Fig I step 3.

Install the guard plate of the inner
saw blade cover on the saw
blade guard with an M5 nut and
two flat washers as Fig I step 5.

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LIMIT PLATE

Mount the limit plate and fasten
with two M5 x 10 screws, washers
and spring washers as in Fig J.

TOP GUARD

Mount the top guard with four M5
x 10 bolts and locknuts as Fig K.

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LOG CARRIAGE EXTENSION

Loosen the wing bolt M5 x 20 on
the back of the log carriage until
the carriage extension can be
inserted into the opening.

Slide the carriage extension into
the channel and align it correctly.
Secure it with the wing bolt.

MOUNTING THE SAW TO THE FLOOR

The foot of each leg is provided
with an 8mm bolt hole for fixing
the log saw to a suitably level floor
or platform. Choose a suitable
position close to a convenient
power supply and bolt or screw
the stand securely in position.
(fixings not supplied).

SET THE LOG RULER

Loosen the wing bolt M5 x 20 to
allow the log ruler to be pulled out
freely. Set the desired length on
the scale. Turn it clockwise as
shown in the illustration step 3,
and secure by tightening the wing
bolt.

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OPERATION

1. Check that all component parts are secure. If the log saw is not fixed to the
floor, ensure that it is placed in a steady position on firm ground.

2. Ensure the power cable is well away from the saw and the workpiece, then
plug into the mains supply.

3. Check that any previously used timber being sawn does not contain any
nails or other metal objects which would damage the blade.

4. ALWAYS check that the saw guard and cradle move freely and spring back
when released.

5. The maximum log diameter that can be cut is 140 mm/ 11 kg.

USING THE SAW

1. Turn on the motor switch

• Once motor switch is set to ON the blade starts rotating.

2. Open the top guard, place the log to the cutting position on the log
carriage and close the guard. Position the log so that it will not move while
cutting.

3. If the length of the log is greater than the length of the carriage, extend
the adjustable log support carriage and set it's position to suit with the
securing knob.

4. Grip the handle at the left side of log carriage and push it towards the saw
blade cover.

• The movable saw blade guard will open and expose the saw blade.

5. Keep pushing with even pressure until the log on the log carriage is cut.
Avoid putting unnecessary pressure on the blade and avoid applying
lateral pressure. Let the blade work naturally.

6. Stop pushing and the log carriage will retract to its original position. Move
the rest of log to the cutting position and continue next cycle until the work
is accomplished.

7. Regardless of the diameter of the wood, only one piece should be placed
on the carriage for cutting at anyone time. Do not attempt to saw multiple
pieces of timber at once.

8. If logs of equal length are required, set the log stop bar to the required
distance using the ruler. Measure this against the scale on the carriage and
lock in position with the wing bolt provided.

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9. ALWAYS control the carriage, keeping both hands on the handles
provided. When pushing the logs into the saw, take care that the motor
speed does not drop.

10. To stop the saw press the OFF switch. Always switch off before unplugging
and never leave the saw running unattended.

11. NEVER try to re-start the saw if the blade becomes jammed in the log.
Switch off and release the jammed log first.

MAINTENANCE

1. ALWAYS inspect the saw before use and ensure it is in top condition.

2. Ensure that the guard can spring freely back to its closed position and
clean out any debris lodged behind it.

3. Check the power cable to ensure it is sound and free from cracks, bare
wires etc.

4. After use, clean all dust and wood chippings from the saw and its hinged
parts and guards.

5. Ensure motor air vents are clear of debris, (use compressed air to clean the
machine if possible). If using compressed air always wear goggles and a
dust mask.

6. For any problems requiring the dismantling and overhaul of the saw,
contact your CLARKE International Service Department on 020-8988-7400.

STORAGE

1. Store in a clean, dry environment protected from the weather and away
from children and untrained users.

CHANGING THE SAW BLADE

CAUTION: ONLY USE SAW BLADES WITH THE CORRECT FITTING AS
SUPPLIED. ALWAYS ENSURE THE SAW IS DISCONNECTED FROM THE
POWER SUPPLY BEFORE INSTALLING/REMOVING THE BLADE.

1. Ensure the saw is disconnected from the power supply. Take care that the
saw blade has cooled down before touching if it has just been in use.

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SAW BLADE CHANGE

2. Remove the limit plate by
unfastening the M5 x 10 screws
and washers.

3. Support the carriage and pull
the cotter pin and washer from
the return guide tube.

4. Remove the M8 x 50 bolt,
washers and nut securing the
chain.

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5. Lower the log carriage
towards the ground.

6. Remove the four M5 x 10
screws and washers from the
blade guard and from the
outer blade cover.

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7. Use the blade locking wrench
to prevent the blade from
turning and remove the blade
retaining nut using the open
wrench provided. as shown on
page 14.

8. Remove the washer and outer
retaining disc and remove the
blade while deflecting the
inner guard by hand. Brush
away any dust and debris from
the spindle before fitting the
new blade.

9. Replace all components in
reverse order

CAUTION: INSTALLING THE BLADE THE WRONG WAY ROUND WILL RESULT
IN DAMAGE TO THE BLADE.

SHARPENING THE BLADE

The saw blade can be sharpened several times without removing it from the
machine. Use a fine cut square bladed file of 8-12” for sharpening.

When sharpening manually, only file the front rake of each tooth over a
distance of about 5-7mm.

ALWAYS keep the original shape of the tooth. Take care not to make sharp
notches at the root of the tooth with your file.

Check the blade carefully for cracks

NOTE: Replacement blades are available from your CLARKE dealer as

Part No 3401991.

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FAULT FIN DIN G

Problem Cause Solution

Machine will not
operate.

Motor becomes
hot.

Heavy internal
sparking.

Excessive vibration Blade not mounted

Burns showing on
the cut timber.

No power supply. Check supply and rectify.

Switch is faulty. Consult your CLARKE dealer.

Fuse in plug has blown. Check and replace.

Motor is faulty. Consult your CLARKE dealer.

Unduly heavy use. Reduce the force applied to

the saw. Let the machine do
the work.

Air vents have become
blocked.

Low supply voltage. Ensure supply voltage is

Motor fault such as worn
brushes.

correctly.

Saw motor bearings worn. Return to your CLARKE

Incorrect or blunt saw
blade.

Clean out air vents using
compressed air or clean
with a dry cloth.

correct. If an extension
cable is used, ensure it is of
the correct rating and is fully
unwound.

Return to your CLARKE
dealer for repair.

Check seating of blade and
securing discs, and tightness
of retaining nut.

dealer for repair.

Replace blade with the
correct CLARKE
replacement. Check and
tighten blade as necessary.

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PARTS L IST

NO Description NO Description

1 Screw M5 x 10 30 Saw blade guard 2

2 Washer 5mm 31 Bolt M8 x 55

3 Flat washer 5mm 32 Flat washer

4 Inner saw blade cover 33 Return spring

5 Outer saw blade cover 34 Bolt M8 x 70

6Switch 35Base frame 2

7 Motor 36 Cross brace

8 Rear Retaining disc 37 Locking chain

9 Saw blade 38 Cotter pin 3mm

10 Nut M20 x 1.5 39 Bolt M8 x 40

11 Front retaining disc 40 Plug for 30mm section

12 Screw st 4.2 x 9.5 41 Bolt M8 x 50

13 Plastic wearstrip 42 Bolt M8 x 30

14 Locknut M5 43 n/a

15 Blade guard 1 44 Top guard

16 Plastic bar 1 45 n/a

17 Plastic bar 2 46 n/a

18 Back plate 1 47 Back plate 2

19 Bolt M8 x 12 48 Screw M4 x 55

20 Wing screw M5 x 20 49 Base frame

21 Screw M8 x 25 50 Guard plate

22 Handle 51 Screw M8 x 20

23 Pivoting log carriage 52 Screw M5 x 20

24 Log ruler 53 Closing plate

25 Log carriage extension 54 Guide tube

26 Plug for 25mm section 55 Screw M8 x 45

27 Bolt M8 x 20 56 Wing screw M5 x 12

28 Washer 8 mm 57 Bolt M8 x 45

29 Locknut M8

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COMPONENT PARTS

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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.

ENVIRONMENTAL RECYCLING POLICY

Through purchase of this product, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the WEEE.

In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing
Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal
facility.

If disposing of this product or any damaged components, do not dispose of
with general waste. This product contains valuable raw materials. Metal
products should be taken to your local civic amenity site for recycling of metal
products.

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DECLARATION OF CONFORMITY

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