Clarke CBM 2 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
MORTISING MACHINE
Model No. CBM 2
Part No. 6500010

Thank you for selecting this CLARKE CBM2 Mortising Machine.
Before operating the 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 machine 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
Safety Precautions 3
Additional precautions for Mortising Machines 5
Electrical Connections 6
Unpacking & Principal Parts 7
Assembly 7
Mounting the Chisel & Bit 8
Installation 9
Controls and Adjustments 9
Operation 11
Maintenance 12
Sharpening Drill Bit & Chisel 12
Specifications 13
Parts List & Accessories 14
Parts Diagram 15
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, personal injury to
the operator or damage to property, 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. 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.
3. 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

4. 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.
5. DISCONNECTtheMACHINE fromthe powersupply beforeservicing andwhen changing
accessories such as blades, etc.
6. KEEP GUARDS in place and in working order.
7. 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.
8. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents.
9. ALWAYS WEAR EAR PROTECTORS/DEFENDERS.
10. DON’T FORCE the Machine. It will do a better and safer job at the rate for which it was
designed.
11. 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.
12. DRUGS, ALCOHOL, MEDICATION. Do not operate machine while under the influence
of drugs, alcohol or any medication.
13. USE RECOMMENDED ACCESSORIES. The use of improper accessories could be
hazardous.
14. NEVER LEAVE MACHINE RUNNING UNATTENDED. Turn power OFF. Do not leave
machine until it comes to a complete stop.
15. ALWAYS REMOVE PLUG from electrical outlet when adjusting, changing parts, or
working on machine.
16. 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.).
17. KEEP CHILDREN AWAY. All visitors should be kept a safe distance from the work
area, especially whilst operating the unit.
18. MAINTAIN MACHINE IN TOP CONDITION. Keep tools sharp and clean for the best
and safest performance. Follow maintenance instructions.
19. 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.
20. WEAR PROPER APPAREL. Loose clothing or jewellery may get caught in moving
parts. Wear protective hair covering to contain long hair.
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.
4

22. HANDLE WITH EXTREME CARE Whenever transporting or installing machinery, and
always use a lifting tool wherever possible.
23. AVOIDACCIDENTAL 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 MORTISING
MACHINES
1. DO NOT USE until unit is completely assembled and installed according to these
instructions.
2. IF YOU ARE NOT thoroughly familiar with the operation of mortising machines, obtain
advice from a qualified person.
3. ENSURE the machine is secured to a workbench to prevent it from tipping over during
operation.
4. NEVER TURN MORTISING MACHINE ON before clearing the table of all objects (tools,
scrap pieces, etc.).
5. ALWAYS KEEP hands, fingers and hair away from the rotating bit.
6. DO NOTATTEMPT to mortise materials that do not have a flat surface, unless a suitable
support is used.
7. ALWAYS use ‘Hold Down’ to prevent the work from lifting when withdrawing the chisel.
8. ALWAYS SUPPORT workpiece securely against fence to prevent rotation.
9. ENSURE the drill bit is sharp, undamaged and properly secured in the chuck before use.
10. ENSURE the chuck key is removed before starting.
11. NEVER START the Machine with the drill bit or chisel pressed against the workpiece.
12. NEVER PERFORM LAYOUT, assembly or set-up work on the Machine with the cutting
tool rotating.
13. ALWAYS ADJUST DEPTH STOP to avoid drilling into the table.
14. ALWAYS STOP the machine before removing scrap pieces from the table.
15. SHUT OFF POWER, remove the drill bit and chisel and clean the table before leaving
the machine.
16. DO NOT WEAR gloves, neckties or loose fitting clothing. Long hair should be contained.
17. NEVER OPERATE the Machine if any part is damaged or broken.
18. NEVER PLACE YOUR FINGERS in a position where the drill or cutting tool could contact
them if the workpiece should shift unexpectedly.
19. ALWAYS DISCONNECT the machine from the electrical supply before changing the
chisel and bit, and before any cleaning or maintenance.
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 coverscan beobtainedfrom yourlocal dealer ormost electricalstockists.
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.
Important: If a cable extension is needed, it is essential to comply with the following data.
Voltage Extension length Cable section
230v Up to 20m 2.5mm2
230v From 20 to 50m 4mm2
6

UNPACKING
Unpacktheshipping carton, and
lay out the components so that
they can be clearly identified.
Check them off as follows:
A. Morticing Machine
B. Hydraulic Cylinder
D. Handle
E. 3/4” Chisel Bush
F. 5/8” Chisel Bush
G. Fence Locking Handle
I. Chuck Key
J. Allen Key - 4mm
K. Allen Key - 5mm
L. Table
M. Hold Down
N. Fence
O. Screw (2 off)
Not Shown
1. 13mm Mortice Chisel set.
2. 1/2” Chuck (Fitted)
ASSEMBLY.
WARNING: For your own safety, do not connect the Mortising Machine to a power
source until it is fully assembled, and you have read and understood all safety and
operational instructions.
CAUTION: Do not allow brake fluids, gasoline, penetrating oils, etc., to come in contact with
plastic parts. These solutions contain chemicals that can damage and/or destroy plastics.
1. Screw the Handle (D) into the hole on
the pinion shaft. (see fig.2)
2. Use the handle to raise the head to the
top of its’ travel, and hold in place.
3. Secure the Hydraulic Cylinder to its’two
fittings by pushing on the spherical
housings until they click into place. One
fitting is located on the column and one
on the side of the head. The head will
now be held in position, (see fig 3).
4. You may now want to reposition the
handle. To do this see “Raising and
lowering the Head” on page 9.
Fig. 2
Fig. 1
7

5. Assemble the Table to the base using
the two screws provided.
6. Insert the bar of the Fence assembly
through the hole in the column and
secure with the Fence Locking Handle.
7. Assemble the ‘Hold Down’ on the
verticalpost ofthe fenceassembly, and
secure with the set screw, using the
Allen Key provided. (see fig. 4)
CHISELAND BIT
WARNING: Makesure switchis in OFF
position and power cable is unplugged
beforeperforming checks, adjustments,
or setup procedures.
1. Loosen the two cover securing knobs on the
head and remove the cover, to expose the
chuck.
Ensure the chuck is firmly secured to the
spindle,byholdingthe spindle withanappro-
priatespannerusing the flatsadjacent tothe
top edge of the chuck, and screwing the
chuck on tightly.
2. NOTE: There are two different size chisel
bushes provided. Determine which size fits
the chisel to be used, and store the other
one in a safe place for future use.
Insert the chisel bush up through the hole in
thehead, ensuring theround holein the side
of the bush faces the front of the machine.
The chisel securing screw, on the front of
the head, must pass through this hole to
secure the chisel. Screw in the screw a few
turns, to temporarily hold the bush in
position.
Fig. 5
Fig.3
Fig. 4
8

NOTE: The screw should not become tight at this point. If it does, loosen it and retry,
making certain that the round hole in the side of the bush is lined up with the screw.
3. Insert the bit into the chisel, and insert chiseland bit up through the bush.
NOTE: The opening in the side of the chisel should always be to the right or left, never to
the front or rear. The opening allows chips to escape during operation.
4. Push the chisel up as far as possible into the head, and nip up the screw to temporarily
hold it in this position. You can lower the drill bit gently, and allow it to rest on the base
whilst carrying out this operation.
5. Push the drill bit up through chisel, and into the opened jaws of the chuck , as far as it will
go, then back off approx. 1/16”, and secure the drill bit in this position, by tightening the
jaws using the chuck key provided.
6. Loosen the chisel securing screw and lower the chisel until it contacts the end of the drill
bit, then raise it 1/16”, and secure it in this position by tightening the securing screw,
ensuring the opening on the side of the chisel is on one side, not facing the front.
NOTE: The chisel should be adjusted so that flat portion of the drill bit is at least 1/16"
from the bottom of the chisel. For certain types of wood, it may be necessary to increase
this distance up to a maximum of 3/16". This ensures having proper clearance between
the cutting lips of the bit and the points of the chisel.
INSTALLATION
IMPORTANT:
Before using the Machine, ensure it is bolted
down to a firm and stable workbench to prevent
it from tipping during operation. Two holes are
suppliedinthe centre ofthebasefor thispurpose.
CONTROLSAND ADJUSTMENTS
WARNING: Make sure the switch is in
the OFF position and power cable is
unplugged before performing checks,
adjustments, or setup procedures.
The ON-OFF switch is located on the motor and has operating positions clearly marked. Push
switch up to turn tool ON and down to turn it OFF. The switch has a Switch Key that, when
removed, allows the switch to be locked in OFF position. To activate locking feature, push the
switch to OFF and pull Switch Key out of the switch.
RAISING AND LOWERING THE HEAD
A handle is provided to raise and lower the head. This handle may be adjusted for maximum
leverage and comfort during operation. To do this loosen the large hex nut located on the
pinion shaft, just enough to allow interlocking teeth to pass one another. Reposition the handle
to the desired location, and re-tighten the hex nut.
ADJUSTING FENCE
The fence can be moved in or out, by loosening the locking handle on the column, sliding the
fence to the desired position and re-tightening the locking handle.
Fig. 6
9

ADJUSTING HOLD DOWN
The purpose of the hold down in to prevent the workpiece from lifting as the chisel is raised up,
out of the hole. The hold down should be adjusted so it just touches the top of the workpiece
and allows the workpiece to slide left or right. The hold down can be turned upside down to
accommodate thicker workpieces. To adjust the hold down, loosen the set screw (A) with the
Allen key provided, position the hold down, and re-tighten set screw (A).
ADJUSTING DEPTH STOP ROD
A depth stop rod is provided to limit the
depth of the chisel cut. To adjust the depth
stoprod,loosen thesetscrew (B) andlower
the head until the bottom of the chisel is at
thedesired depth. Lowerthe depthstop rod
until it contacts base and re-tighten screw
(B, Fig. 7).
ADJUSTING CHISEL PARALLEL TO
WORKPIECE
The chisel can be adjusted parallel to
theworkpieceby loosening thesecuring
screw and rotating the chisel until the
back surface of the chisel is flat against
the workpiece. Then re-tighten the
screw.
ADJUSTING SLIDING FIT BETWEEN HEAD AND COLUMN (Ref fig. 9)
Two bolts are provided on the rear of the head, to ensure a good sliding fit between head and
column when the head is raised and lowered. Adjustment is made by loosening or tightening
these two bolts. NOTE: Correct adjustment is when a good snug sliding fit is obtained without
any side movement between the head and column. The adjustment should not be too tight
that it restricts the sliding movement, or too loose that it affects accuracy. There are also two
set screws, located on the side of the head, which can be adjusted. These two screws keep
the head and column in good alignment. If there is excessive movement in this area:
1. Loosen the lock nut, securing the set screw.
2. Screw the set screw in, until movement is eliminated.
3. Secure the set screw in this position by re-tightening the lock nut ,whilst holding the set
screw to prevent it from turning.
Fig 8
Fig 7
10

OPERATION
1. Position the motor assembly at a suitable height on the column according to the depth of
the workpiece.
2. Set the machine fence to suit the position of the mortise on the workpiece. Make sure the
fence and chisel are square to each other, and tighten in place.
3. Set the depth stop to the required depth of cut.
4. Lower the Hold Down (B, Fig. 10), so that it
rests gently on the surface of the workpiece,
but not so tight as it prevents the workpiece
from moving, and lock into position.
When working on long workpieces, support
the timber along its length.
5. Clamp the workpiece firmly against the fence,
switch on the machine, and feed the chisel
and bit steadily into the workpiece by pulling
down on the operating handle.
NOTES: We recommend that you check the
position, and depth of cut, on a piece of scrap
before cutting your workpiece.
The rate of penetration of the chisel must be fast
enough to prevent burning at the tip of the bit, but
notso fastas to cause the machine to slowor stall.
With experience you will find suitable feed rates to
suit various types of timber.
You may encounter smoke from the bit or material
once the chisel has engaged the material. The
smoke created is a natural operating occurrence
Fig. 9
Fig. 10
11

in hollow chisel mortising and is caused by material chip friction and the resins in the stock
being burned off. Bluing of the chisel after initial use is not indicative of a dull chisel, but a
combination of friction and resin buildup on the cutting faces of the chisel.
A dull chisel can be detected by the amount of excess force required to complete a cut.
After the first cut, the workpiece must be moved along in the correct direction relative to the
slot in the chisel, to allow chips to clear freely. Move the workpiece so that the chisel slot is
releasing chips into the already cut part of the mortise (see fig. 11). Do not have the slot
against the blind end of the mortise, as the chips will not be able to clear from the chisel. This
will cause overheating and possible breakage to the chisel or bit.
When cutting deep mortises, make the cut in several stages of approximately 25mm each, to
allow chips to clear.
When performing a through mortise, a piece of wood should be placed between the workpiece
and the table. This prevents the wood from splintering when breaking through the bottom of
the mortise and also prevents damage to the table.
Always switch the mortising machine off after use. Never leave the machine running
unattended.
MAINTENANCE
WARNING: For your own safety, turn OFF power and disconnect tool from power
source before performing any maintenance.
Periodically clean dust accumulation from the machine. Apply a light coat of paste wax to the
base surface. This will help keep it clean and rust free.
All of the ball bearings are packed with grease at the factory and require no further lubrication.
A light machine or penetrating oil should be used to periodically lubricate necessary points.
Open the cover and apply a light coat of oil on drill bit shaft where it passes through the chisel,
but not on its cutting edge. Also oil rack and pinion gear teeth, column, and pinion shaft.
12
Move timber in
thisdirection
Chisel slot
on left
Chisel slot
on right
Move timber in
thisdirection
Fig. 11

SHARPENING THE DRILL BIT & CHISEL
For best performance the chisel and bit need to be kept sharp. Blunt cutting edges will give
untidy and inaccurate mortises, and can cause overheating and breaking of the chisel and
bit.
Sharpen the bit by using a small smooth file, following
the original shape of the bit. File the inside edge of the
spur, the sides of the brad point, and the cutting edge
inwards towards the flutes of the bit to restore
sharpness. Do not file the outside edge of the spur as
this will affect the diameter of the bit.
Fig. 12
Fig. 14
Removeinner
corners
Triangular
File
13
SPECIFICATIONS
Motor 230VAC 50Hz 1Ph
Power Rating 370 Watts
Speed 2800RPM
Current Rating 2.5Amps
Fuse Rating 5 Amps
Chuck Capacity 3/8”
Chisel Capacity 5/8”, 3/4” Shank Dia.
‘Hold Down’ Capacity 4.25”
Head Travel (Chisel installed) 4.75”
Fence Size 1.56”x13.75”
Base Size 5.88”x13.50”
Overall Dimensions 30.24”Hx13.75”Wx13.38”D
Net Weight 44.8lbs
Use a mortice chisel cutter with the
correct size pilot to sharpen the
chisel. Two or three turns of the
cutter in a carpenters hand brace
should be enough to sharpen the
chisel. Use a small triangular smooth file to relieve the
inner corners of the chisel, and remove any burrs from
the outside of the chisel with a fine oilstone.
Chisels and bits will need replacing when they become
badly worn and difficult to sharpen.
Fig. 13

PARTS LIST
Item Description Qty Part No. Item Description Qty Part No.
1 Base 1 FMHM120S01 25 Hydraulic Cylinder 1 FMHM120S25
2 Spring Washer M8 3 FMHM120S02 26 Left Adj. Gear 1 FMHM120S26
3 Screw M8x20 3 FMHM120S03 27 Spring Pin 1 FMHM120S27
4 Column 1 FMHM120S04 28 Hex. Nut M16 1 FMHM120S28
5 Set Screw M8x10 2 FMHM120S05 29 Right Adj. Gear 1 FMHM120S29
6 Head 1 FMHM120S06 30 Upper Sph Hd Fitting 1 FMHM120S30
7 Depth Stop Rod 1 FMHM120S07 31 Handle 1 FMHM120S31
8 Motor 1 FMHM120S08 32 Handle Grip 1 FMHM120S32
9 Rack 1 FMHM120S09 33 Screw M5x16 3 FMHM120S33
10 Screw M6x12 2 FMHM120S10 35 Chuck 1 FMHM120S35
11 Hex. Nut M8 2 FMHM120S11 36 Chisel & Bit 13mm 1 FMHM120S36
12 Hex. Screw M8 2 FMHM120S12 37 Bush (5/8” & 3/4”) 2 FMHM120S37
13 Table 1 FMHM120S13 38 Cap 1 FMHM120S38
14 Fence 1 FMHM120S14 39 Flat Hd Screw M6x20 2 FMHM120S39
15 Hold Down 1 FMHM120S15 40 Chuck Cover 1 FMHM120S40
16 Fence Lock. Handle 1 FMHM120S16 41 Knob 2 FMHM120S41
17 Brass Screw M8x25 1 FMHM120S17 42 Switch Base 1 FMHM120S42
18 Set Screw M6x6 1 FMHM120S18 43 Switch Cover 1 FMHM120S43
19 Pinion Shaft 1 FMHM120S19 44 Switch 1 FMHM120S44
20 Key 5x5x14 1 FMHM120S20 45 Brass Pin 2 FMHM120S45
21 Collar 1 FMHM120S21 46 Spring 2 FMHM120S46
22 Gear 1 FMHM120S22 47 Set Screw M10x20 2 FMHM120S47
23 Lower Sph. Hd Fitting 1 FMHM120S23 48 Hex. Nut 2 FMHM120S48
24 Cylinder Head 2 FMHM120S24 49 Screw 2 FMHM120S49
ACCESSORIES
In addition to the 13mm (1/2”) Hardened Steel, Hollow Mortise Chisel supplied with your
machine, the following sizes are available from your CLARKE dealer.
Mortise Size Bit Shank Size Part No.
1. 6mm (1/4”) 5mm 6500025
2. 9mm (3/8”) 6mm 6500026
14

PARTS DIAGRAM
15