Clarke CON 1020, 6462026 User guide

PLANER

PLANER

Part No. 6460200

MODEL Nos. CON1020

Part No. 6462026

OPERATING & MAINTENANCE

INSTRUCTIONS

1

LS0610

SPECIFICATIONS

Model ...................................................................................... CON1020

Part No ...................................................................................... 6462026

Voltage ..................................................................................... 230VAC

Power Input .............................................................................. 1020Watts

No Load Speed ....................................................................... 16,000RPM

Plug Fuse Rating ....................................................................... 13Amps

Input Current Max. .................................................................. 4.5Amps

Max Cutting Depth ................................................................. 3mm

Max. Rebating Depth ............................................................. 20mm

Sound Power Level .................................................................. 101dB L

Vibration Emissions ................................................................... 3.847m/s**

Width of Cut ............................................................................. 82mm

Exhaust Port Dia. (Inner/Outer) .............................................. 35/40mm

Dimensions LxWxH .................................................................... 325x190x175mm

** See Notes on page 14 & 15

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 machines data bracket

WA

LIST OF PACKAGE CONTENTS

1. Planer

2. Dust bag

3. Rebate Fence

4. 2 x Securing knobs (one fitted with screw and washer)

5. Rebating Depth Gauge

6. Side fence Bracket

7. 1 x Drive Belt

8. Set of Carbon Brushes

9. Hex. Wrench - 3mm

PARTS & SERVICE CONTACTS

For Spare Parts and Service, please contact your nearest dealer,

or CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: [phone]

PARTS & SERVICE FAX: [phone]

or e-mail as follows:

PARTS: [e-mail]

SERVICE: [e-mail]

© Copyright CLARKE International. All rights reserved. April 2006

2

Please read these instructions carefully before operating the tool

Thank you for purchasing this CLARKE Planer designed for trade use.
Before using the device, please read this manual thoroughly and carefully follow all
instructions given. This is for your own safety and that of others around you, and is also to
help you achieve a long and trouble free service from your new tool.

CLARKE 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 affect your statutory rights.

CONTENTS Page

Specifications : .............................................................................................. 2

Carton Contents : ......................................................................................... 2

Parts and Service Contacts : ....................................................................... 2

Guarantee : ................................................................................................... 3

General Safety Precautions : ...................................................................... 4

Additional Precautions for Planers : ........................................................... 5

Electrical Connections : ............................................................................... 6

Unpacking and Carton Contents : ............................................................ 7

Operation : .................................................................................................... 8

Rebating : ...................................................................................... 9

Maintenance : ............................................................................................ 10

Replacing Cutter Blades : ......................................................... 10

Replacing Drive Belt : ................................................................. 11

Replacing carbon Brushes : ...................................................... 11

Parts Diagrams and Lists : ...................................................................... 12-13

Vibration Emissions : .................................................................................... 14

Declaration of Conformity : ...................................................................... 15

Vibration Emission Declaration : ............................................................... 15

3

GENERAL 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. ALWAYS Learn the machines’ applications, limitations and the specific potential
hazards peculiar to it. Read and become familiar with the entire
operating manual.

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

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

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

10. 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 .

11. ALWAYS ensure the switch is off before plugging in to mains. Avoid accidental
starting.

12. 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.

13. 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.

4

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

15. ALWAYS use recommended accessories, the use of improper
accessories could be hazardous and invalidate your
guarantee.

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.

21. DO NOT use in explosive atmosphere (around paint,
flammable liquids etc.). Avoid dangerous environment.

ADDITIONAL PRECAUTIONS FOR PLANERS

1. ALWAY S ensure the cutters are properly secured before use.

2. ALWAY S ensure the cutters are sharp, blunt cutters increase the risk of kick back.

3. ALWAY S switch the machine OFF immediately the task is completed.

4. ALWAY S use with a dust extraction device fitted.

5. ALWAY S allow the machine to reach full speed before commencing work.

6. DO NOT use the machine if the electric cable, plug or motor is in poor condition.

7. DO NOT allow the ventilation slots in the machine to become blocked.

8. DO NOT touch the cutter immediately after use, allow time for it to cool.

9. NEVER leave machine running unattended, A LWAYS ensure the machine is switched

off and come to a complete stop before leaving it.

10. NEVER proceed unless the workpiece has been thoroughly checked to ensure it is

completely free of nails, screws, staples etc.

11. AVOID accidental starting, by switching off and isolating from the main electrical

supply by removing the plug from the socket. Never load the tool so much that the
motor comes to a standstill.

12. IMPORTANT! This machine develops considerable noise when in use. ALWAYS wear

Ear Defenders

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

5

ELECTRICAL CONNECTIONS

Connect the mains lead to a domestic, 230 volt (50Hz) electrical supply through a fused
good quality 13 amp BS 1363 plug, or a suitable fused isolator switch.

THIS PRODUCT 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 conductor insulation of this appliance may not correspond with the coloured
markings identifying terminals in your plug, you should proceed to connect as follows:

• The BROWN conductor to the terminal marked “L” or coloured RED.

• The BLUE conductor to the terminal marked “N” or coloured BLACK.

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).

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.

6

UNPACKING AND CARTON CONTENTS

1. Planer

2. Dust bag

3. Rebate Fence

4. 3 x Securing knobs (one fitted with screw and washer)

5. Rebating Depth Gauge

6. Side fence Bracket

7. 1 x Drive Belt

8. Set of Carbon Brushes

9. Hex. Wrench - 3mm

Fig.1

When unpacking, check to ensure that no transit damage has been incurred. Please contact
your Clarke dealer immediately should any damage be apparent.

7

OPERATION

A. Lock - OFF switch

B. ON/OFF switch

C. Planing Depth Adjuster knob

D. Adjustable plate

E. Rebate Fence Assembly

F. Drive Gear Cover

G. Dust Bag

H. Rebate Depth Gauge

Fig.2

• Ensure the workpiece is securely clamped.

• To switch the tool ON, press the lock-off button (A) fully and pull the ON/OFF switch (B).

To switch the tool OFF, release the ON/OFF switch.

• Set the planing depth (Fig. 1) by turning the adjustment knob (C) until the desired

planing depth is reached.

The planing depth can be read from the scale arounf the knob.

• Hold the machine with both hands using both grips. This ensures optimum control over

the machine.

• Ensure the cutters have reached full speed before they touch the workpiece.

• Guide the machine at a constant speed across the material to be worked. Do not

move too quickly - allow the machine enough time to plane the workpiece.

• For large surfaces it is recommended to make several shallow cuts at a smaller planing

depth.

• Remove the machine completely from the workpiece after use before switching off.

• Lay the machine on its side when placing down.

8

Rebating

Rebates (see Fig.4) may be produced using the rebate fence in conjunction with the depth
gauge. The maximum rebate depth is 20mm.

Attach the depth gauge (5, Fig. 1) to the machine in the manner shown at H, Fig.2, using
the securing knob provided.

Attach the Rebate Fence as follows:

Fig.3

• Attach the bracket 6, Fig 1 to
the machine, using the securing
knob provided.

• Attach the Fence to the
bracket in the manner shown
in Fig. 3, again using the
securing knob with screw and
washer provided.

Fig.4

Set the depth of rebate using depth gauge, having first of all set the depth of cut using the
large adjuster knob.

9

CLEANING AND MAINTENANCE

The machine does not require any special maintenance except for ensuring it is kept
perfectly clean, including the motors ventilation slots.

It may be necessary however to replace the cutter blades, drive belt and motor carbon
brushes from time to time. These actions are described below.

Replacing the cutters (fig. 5)

1. Place the machine on a table with the
planing base towards you.

2. Rotate the cylinder until the first cutter
is visible.

3. Turn the three securing screws (C, Fig.7)
fully, in the direction shown in Fig.5.

This will loosen the cutter block assembly
from the cylinder.

4. Hold down the safety device with your
thumb as shown in Fig. 6, and slide the
cutter assembly in the direction shown
to remove it from the cylinder.

5. Tap the cutter block assembly gently in
order to free the cutter blade, which
will either slide out, or the clamping
plate - ‘B’, Fig.7 will become detached
from the clamping block ‘A’ Fig.7,
allowing the blade to be removed.

Note: The cutter has two cutting edges.
When both cutting edges are worn, the
cutter must be replaced.

6. Turn the cutter so that the new cutting
edge is facing upwards or take a new cutter
and place it between the block - A and
the clamping plate - B, ensuring the locating
lugs of the clamping plate engage with the
clamping block correctly.

7. Slide the cutter block assembly back
into the cylinder

8. Secure the cutter block by screwing the
screws C, Fig.7 OUT until each one just
touches the side of the recess in the
cylinder, then tighten the two outer
screws first followed by the centre screw.

Fig.5

Fig.6

Fig.7

Adjusting a cutter

With the planing depth set to zero, place a straight edge along the bottom face of the
machine. The cutter blade should just touch the straight edge.

If adjustment is necessary, screw the hex. socket head screws - D, Fig 7, (and also shown
in Fig. 5), in or out as required, until the cutter blade just touches the straight edge, along
its entire length. i.e. the blade must be parallel across the base of the machine.

10

Replacing the Drive Belt

Should the cutter bind in the workpiece, it is probable that the drive belt needs changing.
Should this be the case, please proceed as follows:

• Remove the three securing screws, arrowed in Fig. 8 and pull off the cover.

• Pull off the old belt by turning the larger pulley whilst pulling the belt towards you in the

middle of its run, so that it gradually eases of the pulleys - take care not to trap your
fingers between the belt and pulley.

• Replace the new belt in a similar manner, turning the large pulley whilst pushing the

belt over the ridges in the pulleys.

Fig.8

Ensure the belt is fully engaged on both pulleys - see Fig. 9

• Finally, replace the cover.

Replacing the Carbon Brushes

• Unscrew and remove the side cover - three securing screws.

• VERY carefully prise out the carbon brush

holders as indicated in Fig. 10. DO NOT USE
FORCE. This can be a little tricky, but once
the holder is part way out, use a small
screwdriver to prise the holder away from
the brush end.

• Disassemble the holder, taking care to

retain the plastic end cap.

• Replace the carbon brush and slide the

spade connection on to the end of the
brush and hold in place with the plastic end cap,

• Replace the holder carefully back into place, again DO NOT USE FORCE to

avoid damaging the brush.

Fig.9

Fig.10

11

PARTS DIAGRAM

12

PARTS LIST

No. Description Qty Part No.

1 Baffle 1 KPCON102001

2 Spring 1 KPCON102002

3 Capacitor 0.22µF 1 KPCON102003

4 Right Housing 1 KPCON102004

5 Dustproof gasket 1 KPCON102005

6 Adjustable base 1 KPCON102006

7 Dowel 1 KPCON102007

8 Join cover 1 KPCON102008

9 Dustproof gasket 1 KPCON102009

10 Adjusting screw 1 KPCON102010

11 Washer 1 KPCON102011

12 Pin 1 KPCON102012

13 Adjusting knob 1 KPCON102013

14 Dial 1 KPCON102014

15 Adjusting knob base1 KPCON102015

16 Washer 1 KPCON102016

17 Screw 1 KPCON102017

18 Adjustable knob lid 1 KPCON102018

19 Blade holder 1 KPCON102019

20 Blade 2 KPCON102020

21 Blade Support 2 KPCON102021

22 Fixing block 2 KPCON102022

23 Screw 4 KPCON102023

24 Screw 6 KPCON102024

25 Spring 1 KPCON102025

26 Steel ball 1 KPCON102026

27 Left housing 1 KPCON102027

28 Bearing 1 KPCON102028

29 Bearing cover 1 KPCON102029

30 Screw 4 KPCON102030

31 Large Pinion 1 KPCON102031

32 Nut 1 KPCON102032

33 Belt 1 KPCON102033

No. Description Qty Part No.

34 Belt cover 1 KPCON102034

35 Label 1 N/A

36 Screw 5 KPCON102036

37 Screw 13 KPCON102037

38 Small pinion 1 KPCON102038

39 Bearing cover 1 KPCON102039

40 Bearing 1 KPCON102040

41 Base Plate 1 KPCON102041

42 Armature 1 KPCON102042

43 Fan guide 1 KPCON102043

44 Screw 2 KPCON102044

45 Stator 1 KPCON102045

46 Handle cover 1 KPCON102046

47 Switch 1 KPCON102047

48 Bearing 3 KPCON102048

49 Retaining ring 1 KPCON102049

50 Axis Pin 1 KPCON102050

51 Power cable 1 KPCON102051

52 Cable Sheath 1 KPCON102052

53 Cable Retainer 1 KPCON102053

54 Cover 2 KPCON102054

55 Carbon brush 2 KPCON102055

56 Brush holder 2 KPCON102056

57 Side Cover 1 KPCON102057

58 Screw 1 KPCON102058

59 Depth Guide 1 KPCON102059

60 Thumb Nut 1 KPCON102060

61 Washer 1 KPCON102061

62 Distance Guide 1 KPCON102062

63 Angle Piece 1 KPCON102063

64 Screw 1 KPCON102064

65 Screw 1 KPCON102065

66 Spanner 1 KPCON102066

13

HAND-ARM VIBRATION

Employers are advised to refer to the HSE publication “Guide for Employers”.

All hand held power tools vibrate to some extent, and this vibration is transmitted to the operator
via the handle, or hand used to steady the tool. Vibration from about 2 to 1500 herz is potentially
damaging and is most hazardous in the range from about 5 to 20 herz.

Operators who are regularly exposed to vibration may suffer from Hand Arm Vibration Syndrome
(HAVS), which includes ‘dead hand’, ‘dead finger’, and ‘white finger’. These are painful
conditions and are widespread in industries where vibrating tools are used.

The health risk depends upon the vibration level and the length of time of exposure to it……in
effect, a daily vibration dose.

Tools are tested using specialised equipment, to approximate the vibration level generated under
normal, acceptable operating conditions for the tool in question. For example, a grinder used at
45° on mild steel plate, or a sander on soft wood in a horizontal plane etc.

These tests produce a value ‘a’’, expressed in metres per second per second, which represents the
average vibration level of all tests taken, in three axes where necessary, and a second figure ‘K’,
which represents the uncertainty factor, i.e. a value in excess of ‘a’, to which the tool could
vibrate under normal conditions. These values appear in the declaration on page 7.

You will note that a third value is given in the specification - the highest measured reading in a
single plane. This is the maximum level of vibration measured during testing in one of the axes,
and this should also be taken into account when making a risk assessment.

‘a’ values in excess of 2.5 m/s2 are considered hazardous when used for prolonged periods. A
tool with a vibration value of 2.8 m/s2 may be used for up to 8 hours (cumulative) per day,
whereas a tool with a value of 11.2 m/s2 may be used for ½ hour per day only.

The graph below shows the vibration value against the maximum time the respective tool may be
used, per day.

The uncertainty factor should also be
taken into account when assessing a
risk. The two figures ‘a’ and ‘K’may
be added together and the resultant
value used to assess the risk.

It should be noted that if a tool is
used under abnormal, or unusual
conditions, then the vibration level
could possibly increase significantly.
Users must always take this into
account and make their own risk
assessment, using the graph as a
reference.

Some tools with a high vibration value, such as impact wrenches, are generally used for a few
seconds at a time, therefore the cumulative time may only be in the order of a few minutes per
day. Nevertheless, the cumulative effect, particularly when added to that of other hand held
power tools that may be used, must always be taken into account when the total daily dose rate
is determined.

14

DECLARATION OF CONFORMITY

15