Clarke CSS 400, 6460100 User guide

400mm (16") SCROLL SAW

Model No. CSS 400

Part No. 6460100

Operating and Maintenance

Instructions

1200

Thank you for purchasing this CLARKE 400mm (16") 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

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

Installation .................................................................................................... 5

Bevel Alignment .......................................................................................... 5

Blade renewal ............................................................................................. 6

Saw Blade Notes ......................................................................................... 7

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

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

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

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

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

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

3

SAFETY PRECAUTIONS

GENERAL SAFETY RULES FOR OPERATING MACHINERY

WARN IN G:

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 may result.

✔ ALWAYS 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.

✔ 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.

✔ ALWAYS 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.

✔ ALWAYS disconnect the machine from the power supply before servicing and when changing

accessories such as blades, etc.

✔ ALWAYS keep guards in place and in working order.

✔ ALWAYS wear safety goggles, manufactured to the latest european safety standards and

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

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

✔ ALWAYS wear ear protectors/defenders.

✔ ALWAYS 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.

✔ ALWAYS use recommended accessories. The use of improper accessories could be hazardous.

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

✔ ALWAYS 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.

✔ ALWAYS 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).

✔ ALWAYS keep children away. All visitors should be kept a safe distance from the work area,

especially whilst operating the unit.

✔ ALWAYS maintain machine in top condition. Keep tools sharp and clean for the best and

safest performance. Follow maintenance instructions.

✔ ALWAYS wear proper apparel. Loose clothing or jewellery may get caught in moving parts.

Wear protective hair covering to contain long hair.

✔ ALWAYS make workshop childproof. cover the saw adequately when not in use, to prevent

children from damaging themselves by tampering with it.

✔ ALWAYS handle with extreme care whenever transporting or installing machinery, and always

use a lifting tool.

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

✔ ALWAYS 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.

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

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

✗ NEVER leave machine running unattended. Turn power off. Do not leave machine until it

comes to a complete stop.

✗ NEVER 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.

✗ 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.

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.

5

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.

FUSE RATING

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.

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PRINCIPAL PARTS OF THE SCROLL SAW

Fig. 1

ASSEMBLY (Numbers in brackets refer to the item numbers in the Parts List)

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 holes in the blade guard (33) and that in the air tube bracket (83), with the hole in the
end of the upper arm, and insert the bolt (90). Note that the air tube bracket should lie between
the blade guard and the upper arm. Thread on the washer and nut and tighten sufficiently so
that the guard is firm but capable of pivoting. Do not over tighten.

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 Scroll Saw is provided with 3 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.

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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 Loosen the tension on the blade by turning the blade

tension knob (17), two full turns anticlockwise.

2.2 Prise out the table insert (79), by pushing it from

beneath the table with your fingers.

2.3 Apply a slight downward pressure on the upper arm

whilst holding the blade firmly, allowing the pins at
the top of the blade to be disengaged from the
recesses in the upper blade holder (26) - see fig 2. It is
now a simple matter to disengage the blade pins from
the lower blade holder and lift the blade out through
the access hole in the table.

2.4 Remove the side cover (2), by unscrewing thethree

retaining screws, to give access to the lower holder.

2.5 Slacken off the single hex. socket head screws

securing the upper and lower blade holders, (see fig

3), so that the holders move freely, 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. 3.

Turn the strip, and therefore the blade holders, in
unison, so that it is in line with the table axis. Carefully
tighten each holder in turn, taking great care not to
alter their positions as you do so.

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

Fig. 2

Fig. 3

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 11 - Straight Line Cutting, for other causes of blade wander.

3. BEVEL ALIGNMENT (see fig. 4)

To align the bevel indicator, loosen the table bevel lock knob (57), and level the table until it is at
right angles to the blade. Use a small square to be sure that the angle between blade and table

o

.

is 90

NOTE: The metal strip may be used, in place of the blade, if
desired.

When the table is perpendicular to the blade, or metal
strip, tighten the bevel lock knob (57).

Loosen the screw holding the pointer (62), adjust the

O

pointer to 0

, then retighten the screw.

The bevel scale is a convenient indicator, but 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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Fig..4

4. BLADE INSTALLATION / RENEWAL

4.1 Standard Blade (with end pins)

4.1.1 Before installing or removing blades, turn OFF the saw and disconnect it from the
supply. Remove the blade as described in 2. 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 figs.
2 & 3). Cutting from the side is necessary when your workpiece is over 16" long.

IMPORTANT: Side cutting can only be performed when the bevel is set at 0O.

4.1.2 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
housing. Holding the blade firmly, apply downward pressure to the upper arm,
whilst slotting the upper end of the blade into the slot in the upper housing,
again, making sure the blade pins correctly engage in the recess in the housing.

4.1.3 Replace the Table Insert, and re-tension to the blade, by turning the tension

knob (17) clockwise until you feel the blade is firm. Check to ensure that the
blade pins are properly seated, top and bottom.

4.2 Plain Blades

A pair of holders is provided allowing the use of plain blades (see fig 5).

In order to install the blades with holders on to the machine, the holders must first be attached, as
follows.

4.2.1 Establish which direction of cut is required. (Normal in-line

or cross cut) This will determine which slots in the holder,
the ends of the blades are to be inserted.

The holder is provided with two slots, at right angles to each
other, and one, hex. socket head grub screw, used for
securing the end of the blade in the slot. It will be necessary
to remove the grub screw from the tapped hole in one
slot, and replace it in the tapped hole in the slot you intend
to use. (Fig. 5 shows a blade prepared for normal ‘in line’
cutting).

4.2.2 Remove the side cover (2) by removing the 3 screws securing it

4.2.3 With the two blade holders secured to the blade, and the table insert removed,

lower one end of the blade through the access hole in the table.

Ensure the blades’ teeth point DOWNWARDS and FORWARDS. Slot the holder
over the lip on the end of the lower housing, and, applying downward pressure
on the upper arm, slot the upper holder over the lip on the upper housing.

Fig. 5

Fig. 5

NOTE: Easy access to the lower housing is provided when the side cover is removed.

4.2.4. Replace the table insert, and the side cover, and re-tension the blade by turning

the blade tension knob (17) two full turns clockwise.

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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 2" 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 1-3/4" wood, wallboard,

0.11" 0.020" hardboard.

15 2.8mm 0.5mm Same as above, plus wood 1/8" to 1-1/2" 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.

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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 2" thick, better results are obtained
with wood no more than 1" thick. For wood thicker than 1", 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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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. After every 50 hours of use, lubricate the upper and lower arm bushes with SAE 20 oil, by

removing the hex. socket head screws (item 8)

C. 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

instructions (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 excesive 3. Renew Blade and correctly

force to be used at workpiece tension.

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PARTS DIAGRAM

13

PARTS LIST

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

1 Base 1 SD40001 45 Eccentric 1 SD40045
2 Side cover 1 SD40002 46 Hex. socket set screw 1 SD40046
3 Cap head screw 11 SD40003 47 Motor 1 SD40047
4 Body 1 SD40004 48 Switch 1 SD40048
6 Label 1 SD40006 49 Hex. socket head bolt 1 SD40049
7 Cap head screw 6 SD40007 50 spring compression 1 SD40050
8 Socket head screw 1 SD40008 51 Flat washer 2 SD40051

8A Socket head screw 1 SD40008A 53 Table 1 SD40053

10 Label 1 SD40010 54 Hex. socket head bolt 1 SD40054
11 Label 1 SD40011 55 Bracket-tilt 1 SD40055
13 Bush 1 SD40013 57 Knob 1 SD40057

13A Bush 1 SD40013A 58 Cap. head screw 2 SD40058

14 Bolt tensioning 1 SD40014 62 Indicator 1 SD40062
15 Bolster threaded 1 SD40015 63 Support table 1 SD40063
16 Bolster 1 SD40016 64 Spring washer 9 SD40064
17 Blade tension knob 1 SD40017 65 Hex. head bolt 4 SD40065
18 Spring pin 1 SD40018 66 Hex. head bolt 2 SD40066
19 Spring 1 SD40019 68 Hex. head bolt 3 SD40068
20 Retainer 2 SD40020 70 Label warning 1 SD40070
21 Hex. socket head bolt 2 SD40021 71 Plug 1 SD40071
22 Spring bushing 2 SD40022 75 Plain blade holder 2 SD40075
23 Upper arm 1 SD40023 77 Steel housing 1 SD40077
24 Hex. socket head bolt 2 SD40024 78 Right housing 1 SD40078
25 Star washer 2 SD40025 79 Table insert 1 SD40079
26 Upper blade holder 1 SD40026 82 Windpipe 1 SD40082
27 Blade 1 SD40027 83 Windpipe clamp 1 SD40083
28 Hex. soc. head bolt 1 SD40028 84 Balloon seat 1 SD40084
33 Blade guard 1 SD40033 85 Bushing 2 SD40085
34 Lower arm 1 SD40034 86 Bellows 1 SD40086
35 Spring washer 1 SD40035 87 Plastic tube 1 SD40087
36 Ball bearing 2 SD40036 88 Nut 1 SD40088
37 Spring washer 7 SD40037 89 Spring bolt 3 SD40089
38 Hex. nut. 1 SD40038 90 Hex. head bolt 1 SD40090
39 Hex.socket head bolt 1 SD40039 91 Cap. head screw 1 SD40091
40 Link 1 SD40040 92 Flat washer 2 SD40092

40A Link cover 1 SD40040A 93 Spring washer 1 SD40093

41 Bushing 1 SD40041 94 Tapping screw 1 SD40094
44 Lower blade holder 1 SD40044

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

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SPECIFICATIONS

Motor Voltage: ................................................................ 230V, 50Hz, 1 phase.

Rating: .................................................................. 90 Watts

Maximum thickness of cut: ......................................................... 50mm (2")

Throat: ............................................................................................ 400mm (16")

Blade length: ................................................................................. 125mm (5")

Strokes per minute: ...................................................................... 1400

Stroke length: ................................................................................ 20mm (3/4")

Table size: ...................................................................................... 375 x 200mm

Machine dimensions: ................................................................... 540x265x360mm

Table tilt: ........................................................................................ 0O - 45O left

Base size: ....................................................................................... 400 x 215mm

Blade Type: ................................................................................... Pin (plain type optional)

Gross / Net weight: ....................................................................... 22 / 20kg

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

machine’s data plate

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]

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