Clarke CSS 300, 6470063 User guide

13" SCROLL SAW

Model No. CSS 300

Part No. 6470063

Operating and Maintenance

Instructions

0898

Thank you for purchasing this CLARKE 13" (330mm) Scroll Saw, designed for use by both professional
and DIY enthusiast.

Before operating this machine, please read this leaflet 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 Scroll Saw 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

Specifications ............................................................................................ 2

Safety Precautions General ..................................................................... 3

Additional precautions for Scroll Saws .................................................... 4

Electrical Connections ............................................................................. 5

Assembly .................................................................................................... 5

Installation .................................................................................................. 6

Bevel Alignment ........................................................................................ 6

Blade renewal............................................................................................ 7

Operating Characteristics ........................................................................ 8

Cutting Intricate patterns ......................................................................... 8

Parts list ....................................................................................................... 9

Parts Diagram .......................................................................................... 10

Maintenance ........................................................................................... 11

Trouble Shooting ...................................................................................... 11

SPECIFICATIONS

Motor

Voltage: 230V, 50Hz, 1 phase.

Power Rating: 75 Watts

Maximum thickness of cut: 40mm (1½")

Throat: 330mm (13")

Blade length: 125mm (5")

Strokes per minute: 1400

Stroke length: 8mm (5/16")

Table size: 305 x 190mm

Machine dimensions: 470x228x278mm

Table tilt: 0

Blade Type: Pin

Gross / Net weight: 16 / 15kg

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- 45O left

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SAFETY PRECAUTIONS

GENERAL SAFETY RULES FOR OPERATING MACHINERY

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, injury to the operator 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. 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.

3. 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.

4. DISCONNECT the MACHINE from the power supply before servicing and when changing
accessories such as blades or working on the machine.

5. KEEP GUARDS in place and in working order.

6. ALWAYS WEAR SAFETY GOGGLES, manufactured to the latest European Safety Standards.

Also use face or dust mask if cutting operation is dusty. Everyday eyeglasses do not have
impact resistant lenses, they are NOT safety glasses.

7. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents.

8. ALWAYS WEAR EAR PROTECTORS/DEFENDERS.

9. DON’T FORCE the Machine. It will do a better / safer job at the rate for which it was designed.

10. REMOVE ADJUSTING KEYS AND WRENCHES. Form the habit of checking to see that keys and
adjusting wrenches are removed from the machine before switching on.

11. DRUGS, ALCOHOL, MEDICATION. Do not operate machine while under the influence of drugs,
alcohol or any medication.

12. USE RECOMMENDED ACCESSORIES. The use of improper accessories could be hazardous.

13. NEVER LEAVE MACHINE RUNNING UNATTENDED. Turn power OFF. Do not leave machine until it
comes to a complete stop.

14. 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.

15. 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).

16. KEEP CHILDREN AWAY. All visitors should be kept a safe distance from the work area, especially
whilst operating the unit.

17. MAINTAIN MACHINE IN TOP CONDITION. Keep tools sharp and clean for the best and safest
performance. Follow maintenance instructions.

18. 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.

19. WEAR PROPER APPAREL. Loose clothing or jewellery may get caught in moving parts. Wear
protective hair covering to contain long hair.

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20. MAKE WORKSHOP CHILDPROOF. Cover the saw adequately when not in use, to prevent
children from damaging themselves by tampering with it.

21. 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.

22. HANDLE WITH EXTREME CARE Whenever transporting or installing machinery, and always
use a lifting tool.

23. AVOID ACCIDENTAL STARTING. Ensure the switch is OFF before plugging in to mains.

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

ADDITIONAL SAFETY INSTRUCTIONS FOR SCROLL SAWS

1. Wear safety goggles as protection against flying wood chips and saw 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. The scroll saw must be bolted securely to a stand or workbench. If the saw has a tendency to
move during certain operations, bolt the stand or workbench to the floor.

3. A solid wood workbench is stronger and more stable than a workbench with a plywood
table.

4. This scroll saw is for indoor use only.

5. Do not cut pieces of material which are to small to be held by hand.

6. Clear the work table of all objects except the workpiece (tools, scraps ,rulers etc.) before
turning the saw on .

7. Make sure the blades’ teeth are pointing down, toward the table, and that the blade tension
is correct.

8. When cutting a large piece of material, support it at the height of the table.

9. Do not feed the workpiece through the blade too fast. Feed only as fast as the blade will cut.

10. Keep your fingers away from the blade. Use a push stick as you near the end of the cut.

11. Take care when cutting a workpiece which is irregular in cross section. Moulding for example
must lie flat, and not ‘rock’ on the table as it is being cut. A suitable support must be used.

12. Take care when ‘backing off’ a workpiece from the blade, as the blade may bind in the ‘kerf’.
In this event, switch OFF the machine and disconnect from the supply. Wedge open the kerf,
and withdraw the workpiece.

13. Switch off the saw, and make sure the blade has come to a complete stop before clearing
sawdust or off-cuts from the table.

14. Make sure there are no nails or foreign objects in the part of the workpiece to be sawn.

15. Be extra cautious with very large or small, or irregularly shaped workpieces.

16. Set up the machine and make all adjustments with the power OFF, and disconnected from
the supply.

17. DO NOT operate the machine with the covers off. They must all be in place and securely
fastened when performing any operation

18. Be sure to use the correct blade size and type.

19. Use ONLY approved replacement saw blades. Contact your local CLARKE dealer for advice.
The use of inferior blades may increase the risk of injury.

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ELECTRICAL CONNECTIONS

Connect the mains lead to a standard, 230 Volt (50Hz) electrical supply through an approved 13
amp BS 1363 plug, or a suitably fused isolator switch.

WARNING! THIS APPLIANCE MUST BE EARTHED

IMPORTANT: The wires in the mains lead are coloured in accordance with the following code:

Green & Yellow - Earth

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 GREEN & YELLOW coloured cord to plug terminal marked with a letter “E” or Earth
symbol “ ”or coloured GREEN or GREEN & YELLOW.

Connect BROWN coloured cord to plug terminal marked with a letter “L” or coloured RED.

Connect BLUE coloured cord to plug terminal marked with a letter “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.

5. The fuse in the plug must be replaced with one of the same rating (5 amps) and this
replacement must be ASTA approved to BS1362.

PRINCIPAL PARTS OF THE SCROLL SAW

Fig. 1

ASSEMBLY

Your Scroll Saw is fully assembled, except for the Blade Guard, and the Air tube. To attach these
components, proceed as follows:

Line up the slotted hole in the blade guard and that in the air tube bracket, with the hole in the
upper arm casing, and insert the bolt supplied. Note that the air tube bracket should lie between
the blade guard and the upper arm, as shown in fig. 1. Thread on the washer and nut and tighten
sufficiently so that the guard is firm but capable of movement. Do not over tighten.

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INSTALLATION

Plan your installation. Ensure adequate space is available, with good lighting and ventilation, and
an adequate electrical supply is close at hand.

1. MOUNTING YOUR SAW

Your Scroll Saw is provided with 4 mounting holes, and it is strongly recommended that you mount
the machine on a solid surface. A pad between the saw and the workbench is further
recommended. The best dimensions being - 24" x 12" x ½”. Ensure you use flat washers between
the bolt head and the mounting hole, and do not over tighten the bolts.

2.BLADE HOLDER ALIGNMENT

It is important that the blade holders are checked for alignment before use. Misaligned holders
will cause the blade to wander, and reduce the blades’ life expectancy.

To check the alignment,

2.1 Remove the side cover, by unscrewing the three retaining screws, (including the screw
securing the table angle pointer),to give access to the lower holder.

2.2 Loosen the tension on the blade by turning the blade tension knob (see fig.1).

2.3 Remove the table insert, by squeezing the the two lugs, one either side of the
slot, together, from beneath the table, whilst pushing upwards.

2.4 Disengage the blade pins from the upper blade holder,
then the lower blade holder and pull the blade through
the access hole in the table.

2.5 Slacken off the single hex. socket head screw securing
lower blade holder, using the hex socket wrench
supplied.

2.6 A metal strip is provided which should be inserted into
the blade slots in both holders, thereby replacing the
blade as shown in fig. 2.

With the steel strip in place and the holders therefore
aligned, tighten the lower blade holder hex. socket
head securing screw.

On completion, replace the side cover, table insert and blade by reversing the procedure above.

NOTE: If the blade tends to wander during use, re-check this adjustment as it may take one or
two attempts to get it right. Also see page 8 - Straight Line Cutting, for other causes of blade
wander.

Fig. 2

3. TABLE ALIGNMENT (see fig. 3)

To ensure the table is correctly aligned, i.e. is at right angles
to the blade, loosen the table securing knob, and level
the table by bringing a small square up to the blade, as
illustrated in fig.3. to ensure the table is at 90

When the table is perpendicular to the blade, tighten
thetable securing knob.

Finally, zero the pointer by loosening the securing screw,
adjusting it so that it points to 0O, then retightening the
securing screw.

o

.

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Fig. 3

4.BLADE INSTALLATION / RENEWAL

1. Before installing or removing blades, turn OFF the saw and disconnect it from the supply.

Remove the blade as described in ‘Blade Holder Alignment’, above.

NOTE:

Whilst the blade is out of the housings, look at the blade housings closely. You will observe that the
blade slots and pin recesses are made so you can position the blade for cutting from the front, or
from the side (see fig. 2 ). Cutting from the side is necessary when your workpiece is over 13" long.

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IMPORTANT: Side cutting can only be performed when the table is set at 0

2. With the blade teeth pointing DOWNWARDS, slot the new blade into the lower housing so
that the pins on the end of the blade, engage in the recess in the holder.

3. Hook the upper blade pins into the slots in the upper holder.

4. Apply tension the the blade by screwing the tension knob clockwise.

.

NOTES ON SAW BLADES IMPORTANT: ALWAYS USE GOOD QUALITY BLADES

BLADES BREAK FOR FIVE PRINCIPAL REASONS:

1. Too much tension or too little tension on the blade.

2. Overworking the blade by feeding the workpiece too fast.

3. Twisting or bending the blade by feeding the workpiece off-centre.

4. Over use - the blade has reached the end of its useful life.

5. Feeding too much material into the saw, - more than the maximum 40mm (1½”) depth
for which it was designed.

HOW TO DETERMINE THE RIGHT BLADE FOR THE JOB

This scroll saw accepts a wide variety of blade widths and thicknesses. The width of the blade ,
the thickness of the blade, and the number of teeth per inch (TPI) are determined by the type of
material and size of the radius being cut. Here are several examples:

TPI WIDTH THICKNESS MATERIAL

10 2.8mm 0.5mm Medium curves on 1/4" to 1-1/2" wood, wallboard,

0.11" 0.020" hardboard.

15 2.8mm 0.5mm Same as above, plus wood 1/8" to 1-1/4" thick

0.11" 0.020"

18 2.4mm 0.25mm Extra thin cuts on soft woods to 1/4" and parquetry

0.095" 0.011

As a general rule, select the narrowest blades recommended for intricate curve cutting and
widest blades for straight and large curve operations.

BEVEL CUTTING

When cutting bevels, set the table to your desired angle using the pointer as an indicator.

It should be remembered however that the bevel scale is a convenient indicator only, it is not
guaranteed to be 100% accurate. Where absolute accuracy is required, always double check
with a protractor before starting a cut.

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SCROLL SAW OPERATING CHARACTERISTICS

The scroll saw’s unique ability is cutting intricate curves which other saws cannot do. A scroll saw
can also be used for straight line cutting such as cross cuts, ripping and bevels,
The following is a list of points to remember when using a Scroll Saw.

1. The saw does not cut wood by itself. You feed the workpiece into the blade, letting the blade
cut the wood as you move the piece ahead.

2. You must guide the wood into the blade SLOWLY, because the teeth are very small, and cut
ONLY on the down stroke. If you push the wood into the blade too rapidly, you can easily
break the blade.

3. Although the capacity of the saw accepts wood up to 40mm thick, better results are obtained
with wood no more than 20mm thick. For wood thicker than 20mm, you must guide the wood
into the blade very slowly, taking care not to bend or twist the blade.

4. The teeth on the blade will wear out sooner or later. The blade must therefore be replaced
often to obtain the best cutting results. A blade will stay sharp for ½ hour to 2 hours of
continuous running, depending on the material being cut.

5. Be aware that the blade has a tendency to follow the grain of the wood - the line of least
resistance. You can compensate for this by watching the grain carefully and guiding the
wood past the saw blade.

6. If you are not familiar with scroll saws, there will naturally be a learning period - a period to
learn the saw itself, and a period to learn how the wood and saw work together. Expect
some blade breakages, Scroll Saw blades are fairly fragile - not the same types of blade you
find on a handsaw or circular saw.

STRAIGHT LINE CUTTING

A little practice will be necessary in order to create a straight line cut. This is due to the very
design and nature of the machine itself. The saw blade is quite fragile and due to several different
influences, will tend to wander off line. These influences include the following:

1. Blade tension. A slack blade will naturally wander off line.

2. Condition of the blade. A dull blade requires a greater effort to guide it through the work.
thereby tending to force it off line.

3. Blade holders misaligned. The holders are secured with a single hex. socket head screw.
Slacken the screw and adjust the holder so as to align correctly. The blade should be in line
with the table, and not twisted.

CUTTING INTRICATE PATTERNS

One capability a scroll saw has that other saws do not, is cutting intricate patterns inside a
workpiece. To do this, you should adopt the following procedure.

1. Drill a 1/4" hole in the middle of the workpiece, in a area which will not be a part of the
finished object.

2. Switch off and unplug the machine from the supply.

3. Remove the blade from the machine.

4. Place the workpiece on the table, with the 1/4" hole over the access hole in the table.

5. Replace the blade, through the hole in the workpiece, (teeth downwards), and Re-tension
the blade.

6. Plug the saw back in. Check to ensure that the workpiece is not touching the blade before
switching ON.

When you are finished doing the work inside the workpiece, turn the saw off, unplug it, remove the
blade, remove the workpiece, reinstall the blade, and plug the saw back in.

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PARTS LIST

No. Description Part No.

1. Left Frame HTSS300001

2. Screw HTSS300002

3. Rubber Block HTSS300003

4. Label HTSS300004

5. Copper Cover HTSS300005

6. Arm HTSS300006

7. Screw HTSS300007

9. Spring Washer HTSS300009

10. Screw HTSS300010

11. Connecting Screw HTSS300011

12. Roller HTSS300012

13. Roller Washer HTSS300013

14. Star Washer HTSS300014

15. Screw HTSS300015

16. Protecting Plate HTSS300016

17. Warning Label HTSS300017

18. Right Frame HTSS300018

19. Tension Knob HTSS300019

20. Washer HTSS300020

21. Spring Washer HTSS300021

22. Screw HTSS300022

23. Cam HTSS300023

24. Screw HTSS300024

No. Description Part No.

25. Square Bolt HTSS300025

26. Spring HTSS300026

27. Blade Holder Upper HTSS300027

28. Screw HTSS300028

29. Blade Holder Lower HTSS300029

30. Base HTSS300030

32. Bolt HTSS300032

33. Bolt HTSS300033

34. Blade Guard HTSS300034

35. Washer HTSS300035

36. Nut HTSS300036

37. Motor HTSS300037

38. Nut HTSS300038

39. Pointer HTSS300039

40. Screw HTSS300040

41. Hex. Screw HTSS300041

42. Table HTSS300042

43. Screw HTSS300043

44. Bevel Scale Housing HTSS300044

45. Table Securing Knob HTSS300045

46. Base Plate HTSS300046

47. Blade Insert HTSS300047

PARTS AND SERVICE

For Spare Parts and Servicing, please contact your nearest dealer, or

CLARKE International, on one of the following numbers.

PARTS - 0181 558 6696 SERVICE - 0181 556 4443

PARTS & SERVICE FAX - 0181 558 3622

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.

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PARTS DIAGRAM

MAINTENANCE

A. Apply a thin coat of paste wax on the work table from time to time. This will help the wood

glide across the table more smoothly.

B. The motor is permanently lubricated. Do not try to oil the motor bearings or service any

internal parts of the motor. If the power cord is worn, frayed, cut or damaged, replace it.

Do not try to patch it up with electrical tape this could lead to more trouble.

TROUBLESHOOTING

PROBLEM PROBABLE CAUSES SUGGESTED REMEDY

Breaking Blades. 1. Incorrect tension. 1. Adjust blade tension.

2. Overworked (worn out) blade. 2. Reduce feed rate or replace
blade.

3. Wrong blade being used. 3. Use narrow blades for thin
wood, wider blades for
thicker wood.

4. Twisting blade in wood. 4. Avoid side pressure on blade.

Motor Will Not Run. 1. Defective cord, plug or outlet. 1. Unplug saw, replace

defective parts.

2. Defective motor. 2.Repairs MUST be made by a
qualified technician. Call
Clarke Service dept. for
advice.

Excessive Vibration 1. Improper mounting of saw. 1. See proper mounting instr (p5)

(Some vibration is 2. Unsuitable mounting surface. 2. Replace plywood
inevitable when the workbench surface with solid
saw and motor are lumber surface.

running) 3. Loose table or table rubbing 3. Tighten table adjuster knob.

against motor.

4. Motor mount is loose. 4. Tighten motor mount screws.

Blade Runout 1. Blade holders not aligned. 1. Loosen screws holding

blade holder to rocker arms.
Adjust position of blade
holders. Use metal strip

to verify alignment. Retighten
holder screws

2. Insufficient Blade tension 2. Increase Blade tension

3. Dull Blade causing excessive 3. Renew Blade and correctly

force to be used at workpiece tension.

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