Clarke CMD300 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC1120 - rev 6
MILL DRILL
MODEL NO: CMD300
PART NO: 7610860

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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.
IMPORTANT
Please read all of the safety and operating instructions carefully before using
this product. Please pay particular attention to all sections of these instructions
that display warning symbols and notices.
GUARANTEE
This product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt which will be
required as proof of purchase. This guarantee is invalid if the product is found
to have been abused or tampered with in any way, or not used for the
purpose for which it was intended.
Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission. This guarantee does not effect your
statutory rights.
ENVIRONMENTAL PROTECTION
Through purchase of this product, the customer is taking on the
obligation to deal with Waste Electrical/Electronic Equipment (WEEE)
in accordance with the WEEE regulations in relation to the treatment,
recycling & recovery and environmentally sound disposal of the
WEEE. In effect, this means that this product must not be disposed of with
general household waste. It must be disposed of according to the laws
governing Waste Electrical and Electronic Equipment (WEEE) at a recognised
disposal facility.
WARNING: THIS SYMBOL IS USED THROUGHOUT THE INSTRUCTIONS
WHENEVER THERE IS A RISK OF PERSONAL INJURY. ENSURE THAT
THESE WARNINGS ARE READ AND UNDERSTOOD AT ALL TIMES.

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SPECIFICATION
Motor Supply 230Vac/ 50Hz / 1ph
Motor 470 W
Fuse link rating 5 Amp
Product Weight 51 kg
Operating temperature 0o- 40o
Sound Pressure Level 82 dB LpA
Max drill Capacity 13 mm
End mill capacity 16mm
Face mill capacity 30mm
Mill/Drill head angle -45 to +45o
Spindle Taper MT3
Table effective size 92mm x 400mm
Table cross travel 100mm
Table longitudinal travel 235mm
Spindle to Column 170mm
Overall dimensions 514 x 506 x 756mm
Spindle Speed Range 0-2500 rpm

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GENERAL SAFETY RULES
GENERAL SAFETY IN THE WORKPLACE
1. Always ensure that air can circulate around the machine and that the air
vents are unobstructed.
2. Always keep work area clean & tidy. Cluttered work areas and benches
invite accidents.
3. Never over-reach. Keep proper footing and balance at all times.
4. Never store equipment in a wet/damp environment or expose to rain.
5. Keep other persons away. Do not let persons, especially children, not
involved in the work, touch the tool or extension cable and keep them
away from the work area.
6. Never operate a machine when under the influence of alcohol, drugs or
medication.
7. Always ensure the workplace is well lit. Ensure that lighting is placed so that
you will not be working in your own shadow.
8. Do not use power tools in the presence of flammable liquids or gasses.
9. Stay alert, watch what you are doing, use common sense and do not
operate the machine when you are tired.
10. You should not operate this machine unless you are thoroughly familiar with
drilling machines and drilling techniques. If there is any doubt whatsoever
you should consult a qualified person.
CARE OF POWER TOOLS
1. Read this manual carefully. Learn the machines applications and
limitations, as well as the specific potential hazards peculiar to it.
2. Always keep guards in place and in working order. A guard or other part
that is damaged should be properly repaired or replaced by your Clarke
service department, unless otherwise indicated in this instruction manual.
3. Remove any adjusting keys or wrenches before starting. Form the habit of
checking to ensure that keys, wrenches and tools are removed from the
machine.
WARNING: WHEN USING ELECTRIC TOOLS, BASIC SAFETY PRECAUTIONS
SHOULD ALWAYS BE FOLLOWED TO REDUCE THE RISK OF FIRE, ELECTRIC
SHOCK AND PERSONAL INJURY INCLUDING THE FOLLOWING. READ ALL
THESE INSTRUCTIONS BEFORE ATTEMPTING TO OPERATE THIS PRODUCT
AND SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.

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4. Don’t force the machine and use the correct power tool. It will do the job
better and safer, at the rate for which it was intended.
5. Always disconnect the machine from the power supply before carrying out
any servicing or changing of accessories.
6. Before further use of the power tool, it should be carefully checked to
determine that it will operate properly and perform its intended function.
Check for alignment of moving parts, binding of moving parts, breakage of
parts, mounting or other condition that may affect its operation.
7. Have defective switches repaired by your Clarke service department. Do
not use a power tool if the switch does not turn it on and off.
8. Always check for any damage or any condition that could affect the
operation of the machine. Damaged parts should be properly repaired.
9. Never remove the cover panel unless the machine is disconnected from
the power supply, and never use the machine with cover panels removed.
10. Have your tool repaired by a qualified person. This tool complies with the
relevant safety rules. Repairs should only be carried out by qualified
persons using original spare parts, otherwise this may result in considerable
danger to the user.
11. Never use this product for any other purpose than that described in this
booklet.
12. Never abuse the power cable by yanking the cable to disconnect it from
the socket. Keep the cable away from heat, oil or sharp edges.
13. Guard against electric shock. Avoid body contact with earthed or
grounded surfaces.
14. If the tool should be used outdoors, use only extension cables intended for
outdoor use and marked accordingly.
15. Avoid accidental starting by making sure the power switch is off before
plugging in the power cable.
ADDITIONAL SAFETY RULES FOR DRILLS
1. Always use clamps or a drill vice bolted to the table, to hold the work. It
should never be held with bare hands.
2. Always shut off the power before leaving the machine.
CAUTION: 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.

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3. Always make all adjustments with the power off.
4. Always use the correct speeds for the bit size and the type of material
being worked.
5. Never leave the machine unattended whilst it is running. Turn the machine
OFF and do not leave until it has come to a complete stop.
6. Always remove and store the bits when you have finished work.
7. Never attempt to drill into a workpiece that does not have a flat surface
unless a suitable support is used.
8. Always stop the machine before removing workpieces, work supports or
swarf from the table.
9. Keep bits sharp and clean for best and safest performance. Follow
instructions for changing accessories.
10. Adjust the table or depth stop to avoid drilling into the table surface.
11. Always be sure that the bit is securely locked in the chuck.
12. Never assemble or set up any work on the table while the machine is
running.
13. Keep handles dry, clean and free from oil and grease.
14. Always keep hands and fingers away from the bit.
PROTECTIVE CLOTHING
1. Dress properly. Loose clothing or other jewellery may get caught in moving
parts. Non-slip footwear is recommended. Wear protective hair covering to
contain long hair.
2. Always wear safety glasses. (Everyday glasses are not safety glasses)
3. Wear a face mask if drilling into any material which produces dust.
4. Never wear gloves when operating rotating equipment.
WARNING: DUST GENERATED FROM CERTAIN MATERIALS CAN BE
HAZARDOUS TO YOUR HEALTH. ALWAYS OPERATE IN A WELL VENTILATED
AREA. USE A DUST COLLECTION SYSTEM IF POSSIBLE.
WARNING: THE USE OF ANY ACCESSORY OR ATTACHMENT OTHER THAN
ONE RECOMMENDED IN THIS INSTRUCTION MANUAL MAY PRESENT A RISK
OF PERSONAL INJURY.

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ELECTRICAL CONNECTIONS
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.
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.
•TheBlue wire must be connected to the terminal marked Nor
coloured Black.
•TheBrown wire must be connected to the terminal marked Lor
coloured Red.
•TheYellow and Green wire must be connected to the terminal
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.
WARNING! READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE
MAINS SUPPLY.
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
Plug must be BS1363/A approved.
Always fit a 5 Amp fuse.
Ensure that the outer sheath of the cable is firmly held by the clamp
Neutral
(Blue)
Live
(Brown)
Earth
(Green and Yellow)

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PARTS INVENTORY (LOOSE ITEMS)
1. Double-ended open spanner 8/10mm AF
2. Double-ended open spanner 14/17mm AF
3. Double-ended open spanner 17/19mm AF
4. 2 x T-nuts
5. Set hex wrenches, 3, 4, 5 & 6mm
6. Drill chuck with tapered shank
7. Chuck key
8. 3 x Levers/handles
9. Tommy bar
10. Drawbolt for taper shank
11. Peg spanner
12. Open ended spanner - 36mm AF
13. 2 x Handles for wheel adjusters
14. Oil bottle
15. Chuck guard
Not shown:-1 spare fuse

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UNPACKING
Thank you for purchasing this CLARKE Milling/Drilling Machine, designed for
drilling, deep milling and face milling of small workpieces with maximum
dimensions of 300mm x 200mm x 200mm.
IMPORTANT: Careful consideration is required when choosing the location
for the machine with regard to table movement, Mill/Drill head movement
and location of the power supply. Additionally, the workbench should be
firm, flat and level. Avoid installing in damp or very dusty locations and
ensure that adequate light is provided.
Your new machine is delivered fully assembled (except for handles which are
contained in a bag of loose parts), and should be bolted to a board with four
bolts. Various tools and accessories are also contained in the bag of loose
parts - see Fig.1.
To remove the machine from the case, carefully lay the carton on its side and
break the seal at the bottom. Fold the three flaps back and gently turn the
carton so that it is upright. Tilt the carton in order to fold back the remaining
flap then lift the carton from the machine and packing materials.
1. Remove all polystyrene packaging material, then, with assistance, lift the
machine onto a workbench. DO NOT attempt to do this single handedly.
2. Unbolt the machine from the board - 4 nuts with countersunk screws and
washers, and with assistance, carefully slide or lift into position on your
workbench.
3. Before drilling the bench in order to secure the machine, ensure:
• the head can be raised to its full height - 755mm from the table
surface,
• the head can be pivoted in either direction through 45º without
fouling,
• adequate clearance is available for the longitudinal travel of the
cross slide.
4. Once satisfied, drill four holes corresponding with those in the machine
base, and bolt the machine securely to the workbench using M10 nuts
bolts and washers, (not supplied).
5. Alternatively, the Mill/Drill may be mounted centrally on a board of at least
20mm (3/4”) thickness, and of minimum size, 455x455mm (18”x18”).
This allows the Mill/Drill to be moved to somewhere more convenient when not
in use, in a small workshop. The board may then be clamped securely (with
‘G’ clamps to a workbench when required for use.
6. Screw the three handles into the head raise/lower hub.

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PARTS IDENTIFICATION

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7. Screw a handle to each of the table cross feed and longitudinal feed
handle and secure with the locknuts provided.
8. If using the Drill chuck, attach the clear plastic chuck guard to its mount,
using the single screw provided.
9. Any preservative must be cleaned off thoroughly using a solvent, then
dried and a thin film of machine oil applied to all untreated surfaces. Take
great care when using the solvent, do not to allow it to get into the motor
or electrical components - switches etc.
10. Lightly lubricate all moving parts, handwheel threads etc., with machine
oil.
11. Check to ensure the post is secure by attempting to tighten the post
securing nut at the rear of the machine using the 36mm spanner provided.
Your Mill /Drill is now ready for use.
OPERATION
Ensure the work area is clean and tidy and all tools and accessories etc., are
removed and stored safely, before plugging the machine into the power
supply.
Switch the power on. The green indicator lamp on the switch panel on the
front of the machine will illuminate, indicating that power is being supplied to
the machine.
When first using the machine,
use the following procedure.
1. Select LOW range by
moving the lever, adjacent
to the Emergency Stop,
fully to the ‘L’ position.
2. Push the emergency OFF
switch cover button (fig.2)
upwards in direction of
arrow. This will allow the
cover to spring outwards,
releasing the OFF button.
3. Start the machine by turning the rotary ON/OFF, variable speed switch,
slowly clockwise to mid position and allow to run for a minute or two before
winding up to full speed, then allow to run for a further two minutes.

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4. Switch OFF by turning the rotary switch fully
anticlockwise, then move the Hi-Lo range lever to
the ‘H’ - high position, and repeat the process.
NOTE: In case of emergency, hit the switch cover
quickly. The cover will latch down and the
motor will be switched OFF.
The machine will not start when the emergency switch
cover is closed.
If the emergency switch is used to switch OFF, when the
rotary ON/OFF switch in the ON position, the machine
will not start again when the emergency switch is released. The amber
warning lamp will also illuminate.
The rotary switch must first be turned OFF then turned ON again to start the
machine.
Once the machine has been ‘run up’ check to ensure that it is secure on the
bench or board, and check again to ensure the post is secure by attempting
to tighten the post securing nut at the rear of the machine using the 36mm
spanner provided.
DRILLING
The machine is provided with a drill chuck and morse
taper shank - Fig.4.
1. Insert the taper shank up into the spindle, sharply.
CAUTION: TAKE EXTREME CARE NOT TO DAMAGE THE TAPER
IN ANY WAY. ANY BURR OR IRREGULARITY WILL RENDER IT
UNSERVICEABLE UNTIL IT IS PROPERLY REPAIRED USING A
GRIND STONE. PROFESSIONAL ADVICE SHOULD BE SOUGHT.
2. Pull off the spindle draw bolt cover from the head
(see Parts ID, Fig-C on page 10.) and insert the draw
bolt. Screw it into the end of the taper shank and
tighten using the spanner provided - see Fig.5

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3. In order to hold the spindle,
insert the tommy bar into
the hole in the side of the
head so that it locates in
the hole in the spindle, see
Fig. 5. Hold the spindle still
whilst nipping up the draw
bolt.
4. Place the drill chuck on to
the end of the taper shank
with a sharp upward
movement.
5. The drill is lowered using the
levers on the right side of the machine,
however, in order to do so, it is first of all
necessary to disconnect the Dog
Clutch, shown in Fig. 6. Simply pull back
on the hub to disconnect.
6. Now by turning the handles, the drill
head may be lowered.
7. In order to ensure the drill chuck is firmly
secured on the spindle, place a piece
of wood on the table then lower the drill
head so that the nose of the drill chuck
comes into contact with it. Pull down
sharply one time.
8. When drilling using a mill/drill machine, it must be remembered that without
care, the drill bit could easily come into contact with the surface of the
table.
9. Drill head travel must always be restricted therefore before proceeding to
drill, otherwise damage to the table and/or drill bit could occur.
10. A limiting device is provided, mounted on the
post slide, shown in Fig. 7.
11. When through drilling, wind the drill head, with
drill bit installed, down to the maximum depth
required, and hold in place whilst sliding the
limit device up to meet it. Lock the limit device
in place using its locking lever.
• The limit device is also used if you wish to drill
to a predetermined depth.

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12. Bring the drill bit down to touch the workpiece surface and note the
reading on the scale on the post.
13. Move the workpiece away from the drill bit, using the longitudinal or cross
slide handles, then lower the head once again to the depth previously
noted, plus the depth of hole required. At this point, bring the limit device
up to the head and lock firmly in place. Your drill depth is now set.
14. The workpiece must ALWAYS be firmly secured. This will normally be with the
use of a vice which is securely clamped to the table. Alternatively, clamps
may be used. A suitable vice and a ‘T’ nut and clamp set designed
specifically for this machine, are available from your Clarke dealer. Please
refer to Accessories on page 25.
15. The table, carrying the workpiece, is manoeuvred using the longitudinal
and cross slide adjusting handles. Once the workpiece is positioned, any
further movement is avoided by locking both longitudinal and cross slides
in place using the locking levers provided - see parts identification Fig-B, on
page 10.
Drill speeds are effected by using either the High or Low ranges together with
the variable speed rotary switch. See notes on cutting speeds on page 16.
Never attempt to change ranges until the machine has come to a complete
stop.
MILLING
Vertical milling is similar to drilling, except that instead of the workpiece being
held stationary, it may be moved in 3 directions - A. vertically, and B.
horizontally in both axis. Milling cutters are capable of cutting with their ends
and their faces.
Several broad categories of end and face milling tools exist, such as centre
cutting versus non-centre cutting (whether the mill can take plunge cuts), and
categorisation by number of flutes, by helix angle, by material, and by coating
material. Each category may be further divided by specific application and
special geometry.
Please note that It is not within the scope of this manual to advise on types of
cutter, it is assumed that the user is familiar with milling applications, cutters
and techniques.
This machine is also capable of milling at any angle from vertical - 90º, to 45º
left or right of vertical.
INSTALLING THE CUTTER
If the chuck is installed, proceed as follows:
1. Insert the tommy bar into the hole in the side of the head so that it locates
in the hole in the spindle.

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2. Remove the draw bolt cover and with the spindle being held, undo the
draw bolt by two complete turns only, using the spanner provided.
3. Strike the head of the draw bolt sharply with a soft faced mallet, or by
placing a piece of wood on the head and striking the wood with a
hammer. The taper shank will disengage, thereby allowing the draw bolt to
be fully unscrewed and the drill chuck and taper shank to be withdrawn.
NOTE: It is possible that when the head of the draw bolt is struck, the
chuck could become disengaged with the taper shank and drop
on to the bed, with possible resultant damage. It is strongly
advised therefore, that the operator holds the chuck with one
hand whilst striking the head of the draw bolt, or a substantial
piece of cloth is placed beneath the chuck, in order to avoid
damage when it drops.
With the taper shank removed, the cutter may be installed in a similar manner
to the drill chuck, please see the notes on pages 12/13.
Please note that a range of accessories, including collet sets and collet chuck
sets which are used to secure the cutter, are available from your Clarke dealer
- see Accessories on pages 25-27.
USING THE MICRO FEED
For Milling, the micro feed should always
be used.
In order to use this device, it is first of all
necessary to engage the dog clutch on
the raise/lower hub assembly. Simply turn
the raise/lower handles until the cutter is
as near the workpiece as possible and
the dogs become aligned, then push the
hub IN fully.
In this mode, the handles cannot be used
to raise or lower the head, only by turning
the micro adjuster knob, will this be
effected.
A scale on the adjuster sleeve may be used to determine the depth of cut.
Turn the adjuster so that the cutter just touches the workpiece, then zero the
scale by holding the adjuster knob whilst grasping the knurled rim of the scale
and turning until the zero on the scale lines up with the pointer. Back off slightly
and start the machine.
Turn the adjuster once again until the zero mark lines up with the pointer and
double check that the cutter is just touching the work - if not, make the
necessary adjustment. Any further movement of the adjuster will commence
cutting.

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GENERAL NOTES ON MILLING
Set up the workpiece in a similar manner to that for drilling.
• Slowly bring the cutter into contact with the work piece and start
machining.
• DO NOT attempt to make too bigger cuts than the cutter and
machine are capable of, it is much better and safer to make several
small passes.
• Always use an appropriate cutting/cooling fluid whilst machining,
which can be applied with a small brush etc, NOT FINGERS.
• DO NOT allow swarf to build up in the cutting area. Stop the
machine and remove using a suitable implement, (brush etc).
• When finished turn the machine OFF, return the cutter to its highest
position and allow it to come to a complete stop before attempting
to remove the work piece or tool.
• Always finish by cleaning and drying the machine, and storing all
tools and accessories etc, safely.
CUTTING SPEEDS
In order to drill, and particularly mill satisfactorily, it is most important that the
correct cutting speed is used,
Cutting speed is the speed at which the cutting edge of the tool passes over
the work. This is usually expressed in feet per minute or metres per minute.
For a given material there will be an optimum cutting speed for a certain set of
machining conditions, and from this speed the spindle speed (RPM) can be
calculated. Factors affecting the calculation of cutting speed are:
• The material being machined (steel, brass, aluminium etc. - see
table below)
• The material the cutter is made from i.e. Carbon steel, High speed
steel (HSS), carbide or ceramics.
Material type Meters per min feet per min
Steel (tool) 15 - 18 50 - 60
Mild steel 30 - 38 100 - 125
Cast iron (medium) 18 - 24 60 - 80
Bronze 24 - 45 80 - 150
Brass (soft) 45 - 60 150 - 200
Aluminium 75 - 105 250 - 350

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A good rule of thumb is, the smaller the hole or depth of cut, and the softer the
material to be machined etc, the faster the speed.
Please note that It is not within the scope of this manual to provide a tutorial
on cutting speeds or the methods used to determine spindle speeds (RPM), for
your particular application. It is assumed that the operator is familiar with these
practices.
MAINTENANCE
The amount of maintenance depends on the amount of use the machine
gets. However, it is important to carry out routine maintenance to prevent
premature wear and shortening the life of the machine.
1. Inspect and clean all non painted surfaces. Lubricate using a light
machine oil. Do Not over lubricate. Oil can be applied to the work table
and column etc., using a soft oil soaked cloth.
2. Inspect and clean all moving parts. Lubricate using machine oil. Check for
smooth operation.
3. Inspect the machine for signs of wear or damage. Any faults should be
rectified before continuing.
4. Check all nuts and bolts are tight.
SLIDE ADJUSTMENTS
With use, play may develop in the cross, longitudinal and the post slides. It is
possible to adjust these components in order to eradicate any unnecessary
movement.
Before making any adjustments, clean all friction surfaces. It is necessary to
move the table and cross slide to both extremes to carry out the cleaning
process correctly.
When finished cleaning, re-lubricate using a light machine oil.
Return both the table and cross slide to their central positions.
Adjustment is effected by means of
Jib Strips. These are precision
machined steel strips, positioned
between the mating surfaces as
shown in Fig.9. The strips are
adjustable so as to apply pressure on
these surfaces, sufficient for the parts
to slide easily about each other

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without unnecessary slackness. The longitudinal slide for example carries four
adjusters, shown in Fig.10.
To adjust, first ensure that the slides are lubricated with a thin film of machine
oil as described previously.
Slacken off all adjuster locknuts
using the hex wrench provided,
and back off each adjuster by half
a turn.
Screw IN each adjuster in turn until
a slight resistance is felt.
Wind the slide through its full travel
to check that there are no high
spots and travel is smooth
throughout.
If the slide moves smoothly and all
slack has been eliminated, hold the adjuster still and tighten all lock nuts.
Finally, wind the slide through its full length once again to double check. If
there is any slack or tightness, readjust as described above.

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COMPONENT PARTS

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COMPONENT PARTS