Clarke CS 4-6D, 6500412 User guide

BELT & DISC SANDER

MODEL NO: CS4-6D

PART NO: 6500412

OPERATION & MAINTENANCE

INSTRUCTIONS

LS0816

INTRODUCTION

Thank you for purchasing this CLARKE product.

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.

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.

IN THE BOX

The following should be supplied inside the box. If any parts are missing, please
contact your local Clarke dealer.

• 1 x Belt/Disc Sander

• 1 x Sanding Table

• 1 x Tilting Work Table (Fitted)

• 1 x Lower Disc Guard

• 1 x Mitre Guide Assembly

• 1 x 6 mm Hexagon Key

• 1 x Sanding Belt

• 1 x Sanding Disc

• 1 x Fixings Pack

2

GENERAL SAFETY RULES

1. ALWAYS learn the machines applications, limitations and the specific
potential hazards. Read and become familiar with the entire operating
manual.

1. ALWAYS use a face or dust mask if the operation is particularly dusty.

2. AlWAYS check for damage before using the machine, check for alignment
of moving parts, breakage of parts, and any other condition that may
affect the machines operation. Damage should be properly repaired or
the part replaced. If in doubt, DO NOT use the machine. Consult your local
dealer.

3. ALWAYS disconnect the machine from the power supply before servicing
and when changing accessories.

4. ALWAYS wear safety goggles, manufactured to the latest European Safety
Standards. Everyday eyeglasses do not have impact resistant lenses, and
are not safety glasses.

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

6. ALWAYS ensure that adequate lighting is available. Ensure that lighting is
placed so that you will not be working in your own shadow.

7. ALWAYS keep children away. All visitors should be kept a safe distance from
the work area, especially when the machine is being used.

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

9. ALWAYS handle with extreme care and do not carry the tool/machine by its
electric cable, or pull on the cable to disconnect it from the power supply.

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

11. 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.

12. 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.

13. ALWAYS dress properly. Loose clothing or jewellery may get caught in
moving parts. Wear protective hair covering to contain long hair.

14. ALWAYS guard against electric shock. Avoid contact with earthed surfaces

- pipes, radiators etc.

3

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

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

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

18. NEVER use power tools in damp or wet locations or expose them to rain.
Do not use in an explosive atmosphere (around paint, flammable liquids
etc.). Avoid dangerous environments.

19. If the tool begins to make an abnormal noise, or produce excessive
vibrations, smoke or burning odour, turn the tool off immediately and do
not operate, until repaired.

EXTRA PRECAUTIONS FOR BELT/DISC SANDERS

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

2. ALWAYS wear a dust mask when using this machine. Be aware that harmful
or toxic dusts could be produced when sanding some woods.

3. ALWAYS use the table to support the workpiece.

4. ALWAYS check to ensure the table and attachments are secure before
starting.

5. ALWAYS maintain a clearance of 2-3mm between table and sanding disc.

6. ALWAYS hold the workpiece firmly so that it cannot be torn from your
hands.

7. ALWAYS feed the workpiece against the direction of rotation of the disc. i.e
the LEFT side of the disc.

8. 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.

9. ALWAYS use a dust extraction device, properly connected to the dust
extraction port.

10. ALWAYS ensure that nails or foreign objects have been removed from a
workpiece beforehand. Nails etc. will destroy the belt or disc.

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

12. NEVER sand pieces which cannot be held firmly by hand.

4

ELECTRICAL CONNECTIONS

Plug must be BS1363/A approved.

Always fit a 13 Amp fuse.

Ensure that the outer sheath of the cable is firmly held by the clamp

Neutral

(Blue)

Live

(Brown)

Earth

(Green and Yellow)

WARNING! Read these electrical safety instructions thoroughly
before connecting the product to the mains supply.

Before switching the product on, make sure that the voltage of your electricity supply is
the same as that indicated on the rating plate. This product is designed to operate on
230VAC 50Hz. Connecting it to any other power source may cause damage.

This product may be fitted with a non-rewireable plug. If it is necessary to change the
fuse in the plug, the fuse cover must be refitted. If the fuse cover becomes lost or
damaged, the plug must not be used until a suitable replacement is obtained.

If the plug has to be changed because it is not suitable for your socket, or due to
damage, it should be cut off and a replacement fitted, following the wiring instructions
shown below. The old plug must be disposed of safely, as insertion into a mains 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

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

• The wire which is coloured Blue must be connected to the terminal which is

marked N or coloured Black.

• The wire which is coloured Brown must be connected to the terminal which is

marked L or coloured Red.

• The wire which is coloured Yellow and Green must be connected to the

terminal which is marked E or or coloured Green.

We strongly recommend that this machine is connected to the mains supply via a Residual
Current Device (RCD)

If in any doubt, consult a qualified electrician. DO NOT attempt any repairs yourself.

5

OVERVIEW

Sanding operations are inherently dusty. It is strongly recommended that users
use a dust-collection system when using this belt & disc sander. The use of a
mask or respirator is still recommended even when a dust-collection system is
in use.

6

ASSEMBLY

CAUTION: THE SANDER MUST ASSEMBLED BEFORE USE. DO NOT PLUG
UNIT INTO POWER SOURCE UNTIL THE UNIT HAS BEEN COMPLETELY
ASSEMBLED.

MOUNTING THE SANDER TO A WORKBENCH

Before attempting to use this sander, it should be properly mounted to a
workbench or stand

1. Position the sander on the
workbench where you intend to
use it.

2. Mark the workbench through the
mounting holes located in the
sander base. Drill holes in the
workbench at the marks.

3. Use long bolts, spring washers and
nuts (not supplied), to secure the
sander to the workbench as
shown.

MOUNTING THE TILTING WORK TABLE ASSEMBLY

1. Position table-support bracket so
that the "pivot pin" fits into the
corresponding hole on the sander
frame and the radius slot aligns
with the threaded hole in the
frame.

2. Place washer on threaded shaft of
knob, insert through radius slot,
and tighten into threaded hole.

3. Adjust table to angle desired for
sanding task.

4. To avoid trapping the workpiece or your fingers between the table and
disc, adjust the position of the table on it’s mounting bracket to maintain a
gap of no more than 2 mm.

7

INSTALLING THE BACKSTOP

1. Position the backstop against the
belt frame so that the slot aligns
with threaded hole in frame.

2. Secure the backstop to frame with
2 x socket head screws, washers as
shown. Do not overtighten.

• The gap between the sanding

belt and the backstop should
be no more than 2mm.

ATTACHING A DUST COLLECTION HOSE

This sander is equipped with a 2½" (60
mm) diameter dust port that can be
connected to a vacuum or dust­collection system.

1. Place a 2½” ID diameter hose over
the dust port.

Secure hose in place with a hose
clamp.

8

CHANGING THE SANDING DISCS

WARNING: TURN THE POWER OFF AND REMOVE THE PLUG FROM THE
OUTLET BEFORE CHANGING THE ACCESSORIES.

CAUTION: ‘HOOK & LOOP’ SANDING DISCS CANNOT BE USED WITH THIS
SANDER!

1. Remove mitre gauge and work
table assembly.

2. Remove the disc guard screws
and disc guard.

3. Remove sanding disc from disc
plate. Sanding discs are attached
to the plate using a pressure­sensitive adhesive

4. Ensure the disc plate is clean.

5. Peel backing away from the new
sanding disc.

6. Align perimeter of disc with plate
and press disc firmly into position
on plate, leaving no loose edges.

7. Replace the disc guard, disc
guard screws and work table.

CONSUMABLES

Sanding discs are available from your Clarke dealer.

Grit Part number

Fine 6502097

Medium 6500809

Course 6502102

9

CHANGING THE SANDING BELTS

CAUTION: CHECK THE INSIDE OF THE BELT FOR A "DIRECTION ARROW". IF
PRESENT, INSTALL THE BELT WITH THE ARROW POINTING IN THE SAME
DIRECTION AS THE DIRECTION INDICATOR ON THE HOUSING.

1. Loosen the socket head screw
using the 6 mm hex wrench
provided.

2. Raise the belt sanding arm as
shown.

3. Slide out one end of the tension
lever as shown to release belt
tension.

4. Remove the tray located on the
bottom of the belt sanding arm by
loosening the two screws on the
back of the belt sanding arm.

5. Slide the sanding belt off of the drive and idler drums.

6. Slide new sanding belt over the drive and idler drums. Ensure the belt is
centred on both drums and is the right way round.

7. Return the tension lever into its original positiom to apply tension to the belt.

8. Replace the tray and tighten the two screws on the back of the belt
sanding arm.

9. Lower the belt sanding arm and tighten the socket head screw using the
6mm hex wrench provided.

CONSUMABLES

Sanding Belts are available from your Clarke dealer.

Grit Part number

Fine 6502096

Medium 6500808

Course 6502101

10. Before using, check belt tracking as described in the next section and
adjust as necessary.

10

BELT TRACKING

The belt-tracking adjustment is set at the factory so that the abrasive belt will
run true on the drums. If, however, the belt should track to one side or the
other, an adjustment can be made by turning the tracking knob.

• Turning the knob clockwise will cause the belt to track to the right

(towards the disc sander).

• Turning the knob counter-clockwise will cause the belt to track to

the left side of the machine.

TO TRACK THE SANDING BELT

1. Rotate the sanding arm to the
desired position and tighten
socket head screw to secure.

2. Turn power switch ON,

3. Note whether the belt tends to
wander off its track, and to which
side (left or right) of the sander.

• If the sanding belt does not

move to either side, it is tracking properly.

• If the sanding belt moves to the right (disc side of the sander), turn

the tracking knob counter clockwise ¼ turn.

• If the sanding belt moves to the left (away from the disc), turn the

tracking knob clockwise ¼ turn.

4. Readjust tracking knob another ¼ turn, as necessary.

11

OPERATION

WARNING: NEVER TOUCH THE SANDING DISC OR BELT WHILE IT IS
MOVING, DO NOT TOUCH THE WORK PIECE AFTER SANDING, IT COULD BE
VERY HOT.

WARNING: ALWAYS WEAR SAFETY GLASSES WHEN OPERATING THE
SANDER

CAUTION: ALWAYS MAKE SURE THE WORK TABLE AND BACKSTOP ARE
PROPERLY ADJUSTED AND SECURE BEFORE USE.

ON/OFF BUTTONS

The On/Off buttons are located on the front of the sander.

1. Press the GREEN button (I) to turn
the sander on.

2. Press the RED button (0) to turn the
sander off.

• If the power supply is

interrupted for any reason, the
unit will automatically switch off.
When power is restored, simply
press the GREEN button to
resume work.

BELT SANDING

HORIZONTAL AND VERTICAL SANDING

The sanding belt can be used in the
vertical or horizontal position,
depending on operator needs and
the workpiece.

To change from one position to the
other:

1. Loosen the socket head screw
using the 6 mm hex wrench
provided.

2. Manually move the sanding belt to the desired angle and retighten the
socket head screw.

12

SURFACE SANDING ON THE BELT

When sanding flat broad surfaces on
the belt hold the workpiece firmly on
the surface of the belt and against
the backstop, keeping fingers away
from the sanding belt. Consider using
a push or hold-down stick.

• Use extra caution when sanding

very thin pieces, and when
sanding extra long pieces,
remove the backstop.

NOTE: When using the sander without the backstop, ensure that you you

have a firm hold on the workpiece at all times and take extra
care.

• Apply only enough pressure to allow the sanding belt to remove

material.

SANDING CURVED PIECES

When sanding inside-curves on the
belt sander, always sand on the idler
drum end of the belt.

1. Hold the workpiece firmly, keeping
fingers away from the sanding
belt. Keep the curve pressed firmly
against the idler drum, moving the
work evenly back and forth across
the drum.

SANDING DISC

SANDING OUTSIDE CURVES

Always sand outside curves using the
sanding disc and moving the
workpiece from the left side of centre,
as shown. Keep the curve pressed
firmly against the sanding disc,
moving the work evenly from the left
side of the sanding disc. Be sure to
hold the workpiece firmly against the
surface of the table.

13

MITRE GAUGE - DISC SANDER

A mitre gauge can be used on the
work table, as shown. The mitre
gauge head can be set anywhere up

o

to 60

(right or left) by loosening the
lock-knob, setting the mitre gauge
head to the desired angle, and
tightening the lock-knob.

SANDING SMALL SURFACES USING THE MITRE GAUGE

Use of the mitre gauge is recommended for sanding small end surfaces on the
sanding disc.

NOTE: Always move the workpiece across the left side (dust chute end

of machine) of the sanding disc and be sure to hold the
workpiece down tightly onto the table surface.

MAINTENANCE

WARNING: ALWAYS DISCONNECT TOOL FROM POWER SOURCE BEFORE
MAKING ANY ADJUSTMENTS, INSTALLING OR PERFORMING
MAINTAINENCE.

CAUTION: TOOL SERVICE MUST BE PERFORMED ONLY BY QUALIFIED
REPAIR PERSONNEL. SERVICE OR MAINTENANCE PERFORMED BY
UNQUALIFIED PERSONNEL COULD RESULT IN A RISK OF INJURY. WHEN
SERVICING A TOOL, USE ONLY IDENTICAL REPLACEMENT PARTS. FOLLOW
INSTRUCTIONS IN THE MAINTENANCE SECTION OF THIS SERVICE MANUAL.
USE OF UNAUTHORISED PARTS OR FAILURE TO FOLLOW MAINTENANCE
INSTRUCTIONS MAY CREATE A RISK OF ELECTRIC SHOCK OR INJURY.

1. Clean the machine, belt and disc after each use.

2. Keep the machine dry, clean and free from oil and grease.

3. Store the tool in a safe and dry place, out of reach of children.

4. During normal use, sanding belts and disc can become loaded with

sanding debris. Use a stick belt cleaner (available at most hardware stores)
to remove build-up.

14

REMOVING PULLEY COVER AND INSTALLING DRIVE BELT

1. Using a cross head screwdriver,

remove the screw located in the
middle of the cover.

2. Remove the cover.

3. Loosen (3) screws to allow pulleys

to move enough to place the belt
around them. Place belt around
the motor pulley and drive pulley
as shown.

4. Slightly tighten (3) screws. Adjust

tension of belt by putting blade
screwdriver in adjusting hole. Push
up on screwdriver to tighten
tension between pulleys.

5. Tighten screws fully, being careful

not to disturb the belt.

6. Test belt tension by placing fingers

on either side of belt and squeeze.

• There should be about a 1/4"
give to the belt.

NOTE: Excessive tightness on pulley belt may cause increased noise and

over load motor. Excessive looseness on pulley belt may cause
belt to fail prematurely.

7. Locate the pulley cover and position it inside the relief edges of pulley
housing.

8. Using a cross head screwdriver, reinstall and tighten the flat head screw.

15

SPECIFICATIONS

For Parts & Servicing, 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]

Motor 230V, 50Hz, 1ph

Input Power 370 Watts

Fuse Rating 13A

Sanding Disc Diameter 6” (150 mm)

Sanding Belt Size (W x L) 4” x 36” (914 x 100 mm)

Sanding Belt Speed 450m/min

Sanding Table Dimensions (L x W) 225 x 160 mm

Table Angle Range 0-45 degrees

Mitre Guide Angle Range 0-60 degrees

Net Weight 18.65 kg

Dimensions (LxWxH) 447 x 363 x 255 mm

Sound Pressure Level dB L

Sound Power Level dB L

Vibration

Part No 6500412

pA

WA

91.1 dB (A)

79.9 dB (A)

3.34 m/s

2

PARTS AND SERVICING

16

EXPLODED DIAGRAM & PARTS LIST

17

EXPLODED DIAGRAM & PARTS LIST

NO DESCRIPTION

1 Philips Screw M4x6

2Flat Washer D4

3Base Cover

4 Philips Screw St4.2x10

5 Toothed Lock Washer D4

6Disc Cover

7Disc Paper

8 Hex Socket Round Head

Screw M6x16

9 Toothed Lock Washer D6

10 Disc

11 Sanding Disc Guard

12 Phillips Screw M5x8

13 Spring Washer D5

14 Flat Washer D5

15 Toothed Lock Washer

D5

16 Disc Rotation Label 5x10

17 Base

18 Phillips Screw St4.2x20

19 Wire Connection Box

Cover

20 Phillips Screw St2.9x28

21 Relay

22 Wire Connection Box

23 Phillips Screw M5x10

24 Power Switch

25 Phillips Screw M6x8

26 Spring Washer D6

27 Hex Nut,type I M5

28 Capacitor

29 Capacitor Support

30 Phillips Screw M5x12

31 Hex Bolt M6x12

32 Big Flat Washer D6

33 Work Table Support

Angle Plate

34 Miter Gauge Knob

35 Work Table

NO DESCRIPTION

36 Cotter Pin

37 Miter Gauge Knob

38 Mitre Gauge

39 Cotter Pin

40 Tension Spring

41 Bushing

42 Joint Lever

43 Screw Bushing D12

44 Bearing 101

45 Idler Roller

46 Idler Shaft

47 Phillips Screw M5x20

48 Bushing

49 Connecting Rod

50 Tension Spring

51 Tension Knob

52 Big Flat Washer D5

53 Hex Nut,type I M6

54 Phillips Screw M5x16

55 Adjust Knob

56 Flat Washer D6

57 Rubber Washer

58 Adjust Spring

59 Belt Support

60 Limiting Plate

61 Driving Roller

62 Hex Socket Round Head

Screw M8x12

63 Driving Shaft

64 Bearing Cap

65 Support Cover

66 Phillips Screw M5x10

67 Cog Belt Guard Cover

68 Phillips Screw M5x16

69 Special Locked Washer

70 Cog Belt

71 Driven Pulley

72 Phillips Screw M5x25

NO DESCRIPTION

73 Bearing Base

74 Phillips Screw M6x25

75 Hex Socket Round Head

Screw M8x25

76 Belt Cover

77 Square Nut

78 Motor Arbor Wheel

79 Phillips Screw M5x6

80 Belt Protection Plate

81 Motor Assy

82 Cord

83 Cord Clip

84 Dust Hood

85 Bracket Support

86 Belt

87 Flat Washer D8

88 Hex Cylinder Screw

M8x16

89 Tension Pole

90 Roll Pin 5x8

91 Capacitor

92 Capacitor Support

93 Nut M8

Quote Part number
AWNCS46D + Diagram
number.

e.g Tension spring is
AWNCS46D50

18

DECLARATION OF CONFORMITY

19