Clarke CS4-6E Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
LS0917
ORIGINAL INSTRUCTIONS
BELT & DISC SANDER
MODEL NO: CS4-6E
PART NO: 6500413

2
INTRODUCTION
Thank you for purchasing this CLARKE product.
Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safety of yourself
and that of others around you, and you can look forward to your purchase
giving you long and satisfactory service.
GUARANTEE
This product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt which will be
required as proof of purchase.
This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.
Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.
This guarantee does not effect your statutory rights.
IN THE BOX
The following should be supplied inside the box. If any parts are missing, please
contact your local Clarke dealer.
• 1 x Belt/Disc Sander
• 1 x Sanding Table
• 1 x Tilting Work Table (Fitted)
• 1 x Lower Disc Guard
• 1 x Mitre Guide Assembly
• 1 x 6 mm Hexagon Key
• 1 x Sanding Belt
• 1 x Sanding Disc
• 1 x Fixings Pack

3
GENERAL SAFETY RULES
1. ALWAYS learn the machines applications, limitations and the specific
potential hazards. Read and become familiar with the entire operating
manual.
1. ALWAYS use a face or dust mask if the operation is particularly dusty.
2. AlWAYS check for damage before using the machine, check for alignment
of moving parts, breakage of parts, and any other condition that may
affect the machines operation. Damage should be properly repaired or
the part replaced. If in doubt, DO NOT use the machine. Consult your local
dealer.
3. ALWAYS disconnect the machine from the power supply before servicing
and when changing accessories.
4. ALWAYS wear safety goggles, manufactured to the latest European Safety
Standards. Everyday eyeglasses do not have impact resistant lenses, and
are not safety glasses.
5. ALWAYS keep work area clean. Cluttered areas and benches invite
accidents.
6. ALWAYS ensure that adequate lighting is available. Ensure that lighting is
placed so that you will not be working in your own shadow.
7. ALWAYS keep children away. All visitors should be kept a safe distance from
the work area, especially when the machine is being used.
8. ALWAYS maintain machine in top condition. Keep tools/machines clean for
the best and safest performance. Follow maintenance instructions.
9. ALWAYS handle with extreme care and do not carry the tool/machine by its
electric cable, or pull on the cable to disconnect it from the power supply.
10. ALWAYS ensure the switch is off before plugging in to mains. Avoid
accidental starting.
11. ALWAYS concentrate on the job in hand, no matter how trivial it may seem.
Be aware that accidents are caused by carelessness due to familiarity.
12. ALWAYS keep your proper footing and balance at all times - don’t
overreach. For best footing, wear rubber soled footwear. Keep floor clear
of oil, scrap wood, etc.
13. ALWAYS dress properly. Loose clothing or jewellery may get caught in
moving parts. Wear protective hair covering to contain long hair.
14. ALWAYS guard against electric shock. Avoid contact with earthed surfaces
- pipes, radiators etc.

4
15. NEVER operate machine while under the influence of drugs, alcohol or any
medication.
16. NEVER leave machine running unattended. Turn power off. Do not leave
the machine until it comes to a complete stop.
17. NEVER force the machine, it will do a better and safer job at the rate for
which it was designed.
18. NEVER use power tools in damp or wet locations or expose them to rain. Do
not use in an explosive atmosphere (around paint, flammable liquids etc.)
Avoid dangerous environments.
19. If the tool begins to make an abnormal noise, or produce excessive
vibrations, smoke or burning odour, turn the tool off immediately and do
not operate until repaired.
EXTRA PRECAUTIONS FOR BELT/DISC SANDERS
1. ALWAYS wear ear protectors/defenders when using this machine.
2. ALWAYS wear a dust mask when using this machine. Be aware that harmful
or toxic dust could be produced when sanding some woods.
3. ALWAYS use the table to support the workpiece.
4. ALWAYS check to ensure the table and attachments are secure before
starting.
5. ALWAYS maintain a clearance of 2-3mm between table and sanding disc.
6. ALWAYS hold the workpiece firmly so that it cannot be torn from your
hands.
7. ALWAYS feed the workpiece against the direction of rotation of the disc. i.e
the LEFT side of the disc.
8. ALWAYS keep the mains cable well away from the machine and ensure an
adequate electrical supply is close at hand so that the operation is not
restricted by the length of the cable.
9. ALWAYS use a dust extraction device, properly connected to the dust
extraction port.
10. ALWAYS ensure that nails or foreign objects have been removed from a
workpiece beforehand. Nails etc. will destroy the belt or disc.
11. NEVER allow the ventilation slots in the motor to become blocked.
12. NEVER sand pieces which cannot be held firmly by hand.

5
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.
• The wire which is coloured Blue must be connected to the terminal which is
marked Nor coloured Black.
• The wire which is coloured Brown must be connected to the terminal which is
marked Lor coloured Red.
• The wire which is coloured Yellow and Green must be connected to the
terminal which is marked E or or coloured Green.
We strongly recommend that this machine is connected to the mains supply via a Residual
Current Device (RCD)
If in any doubt, consult a qualified electrician. DO NOT attempt any repairs yourself.
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 13 Amp fuse.
Ensure that the outer sheath of the cable is firmly held by the clamp
Neutral
(Blue)
Live
(Brown)
Earth
(Green and Yellow)

6
OVERVIEW
Sanding operations are inherently dusty. It is strongly recommended that users
use a dust-collection system when using this belt & disc sander. The use of a
mask or respirator is still recommended even when a dust-collection system is
in use.

7
ASSEMBLY
MOUNTING THE SANDER TO A WORKBENCH
Before attempting to use this sander, it should be properly mounted to a
workbench or stand
1. Position the sander on the
workbench where you intend to
use it.
2. Mark the workbench through the
mounting holes located in the
sander base. Drill holes in the
workbench at the marks.
3. Use long bolts, spring washers and
nuts (not supplied), to secure the
sander to the workbench as
shown.
MOUNTING THE TILTING WORK TABLE ASSEMBLY
1. Position the table-support bracket
so that the “pivot pin” fits into the
corresponding hole on the sander
frame and the radius slot aligns
with the threaded hole in the
frame.
2. Place a washer on the threaded
shaft of the knob, insert through
radius slot, and tighten into
threaded hole.
3. Adjust the table to the angle desired for the sanding task.
4. To avoid trapping the workpiece or your fingers between the table and
disc, adjust the position of the table on it’s mounting bracket to maintain a
gap of no more than 2 mm.
CAUTION: THE SANDER MUST BE ASSEMBLED BEFORE USE. DO NOT PLUG
THE SANDER INTO A POWER SOURCE UNTIL IT HAS BEEN COMPLETELY
ASSEMBLED.

8
INSTALLING THE BACKSTOP
1. Position the backstop against the
frame so that the slot aligns with
threaded hole in the frame.
2. Secure the backstop to the frame
with 2 x socket head screws and
washers as shown.
• Do not overtighten.
• The gap between the sanding
belt and the backstop should
be no more than 2 mm.
ATTACHING A DUST COLLECTION HOSE
This sander is equipped with a 2½” (60
mm) diameter dust port that can be
connected to a vacuum or dust-
collection system.
1. Place a 2½” ID diameter hose over
the dust port.
Secure the hose in place with a hose
clamp.

9
CHANGING THE SANDING DISCS
1. Remove the mitre gauge and
work table assembly.
2. Remove the disc guard screws
and disc guard.
3. Remove the sanding disc from the
disc plate.
• Sanding discs are attached to
the plate using a pressure-
sensitive adhesive
4. Ensure the disc plate is clean.
5. Peel the backing away from the
new sanding disc.
6. Align perimeter of the disc with the
plate and press the disc firmly into
position on the plate, leaving no
loose edges.
7. Replace the disc guard, disc
guard screws and work table.
CONSUMABLES
Sanding discs are available from your Clarke dealer.
WARNING: TURN THE POWER OFF AND REMOVE THE PLUG FROM THE
POWER OUTLET BEFORE CHANGING THE ACCESSORIES.
CAUTION: ‘HOOK & LOOP’ SANDING DISCS CANNOT BE USED WITH THIS
SANDER!
Grit Part number
Fine 6502097
Medium 6500809
Coarse 6502102

10
CHANGING THE SANDING BELTS
1. Loosen the socket head screw
using the 6 mm hex wrench
provided.
2. Raise the belt sanding arm as
shown.
3. Slide out one end of the tension
lever as shown to release belt
tension.
4. Remove the tray located on the
bottom of the belt sanding arm by
loosening the two screws on the
back of the belt sanding arm.
5. Slide the sanding belt off of the drive and idler drums.
6. Slide new sanding belt over the drive and idler drums. Ensure the belt is
centred on both drums and is the right way round.
7. Return the tension lever into its original position to apply tension to the belt.
8. Replace the tray and tighten the two screws on the back of the belt
sanding arm.
9. Lower the belt sanding arm and tighten the socket head screw using the
6 mm hex wrench provided.
CONSUMABLES
Sanding Belts are available from your Clarke dealer.
10. Before using, check belt tracking as described in the next section and
adjust as necessary.
CAUTION: CHECK THE INSIDE OF THE BELT FOR A “DIRECTION ARROW”. IF
PRESENT, INSTALL THE BELT WITH THE ARROW POINTING IN THE SAME
DIRECTION AS THE DIRECTION INDICATOR ON THE HOUSING.
Grit Part number
Fine 6502096
Medium 6500808
Coarse 6502101

11
BELT TRACKING
The belt-tracking adjustment is set at the factory so that the abrasive belt will
run true on the drums. If, however, the belt should track to one side or the
other, an adjustment can be made by turning the tracking knob.
• Turning the knob clockwise will cause the belt to track to the right
(towards the disc sander).
• Turning the knob counter-clockwise will cause the belt to track to
the left side of the machine.
TO TRACK THE SANDING BELT
1. Rotate the sanding arm to the
desired position and tighten
socket head screw to secure.
2. Turn power switch ON,
3. Note whether the belt tends to
wander off its track, and to which
side (left or right) of the sander.
• If the sanding belt does not
move to either side, it is tracking properly.
• If the sanding belt moves to the right (disc side of the sander), turn
the tracking knob counter clockwise ¼ turn.
• If the sanding belt moves to the left (away from the disc), turn the
tracking knob clockwise ¼ turn.
4. Readjust tracking knob another ¼ turn, as necessary.

12
OPERATION
ON/OFF BUTTONS
The On/Off buttons are located on
the front of the sander.
1. Press the GREEN button (I) to turn
the sander on.
2. Press the RED button (0) to turn the
sander off.
• If the power supply is
interrupted for any reason, the unit will automatically switch off.
When power is restored, press the GREEN button to resume work.
RESET BUTTON
The machine is fitted with a thermal overload protector. If the motor stops
running or fails to start:
1. Wait 5 minutes and then press the reset button.
• If the reset button continually activates contact your CLARKE dealer.
BELT SANDING
HORIZONTAL AND VERTICAL SANDING
The sanding belt can be used in the
vertical or horizontal position,
depending on operator needs and
the workpiece.
To change from one position to the
other:
WARNING: NEVER TOUCH THE SANDING DISC OR BELT WHILE IT IS
MOVING, DO NOT TOUCH THE WORK PIECE AFTER SANDING, IT COULD BE
VERY HOT.
WARNING: ALWAYS WEAR SAFETY GLASSES WHEN OPERATING THE
SANDER
CAUTION: ALWAYS MAKE SURE THE WORK TABLE AND BACKSTOP ARE
PROPERLY ADJUSTED AND SECURE BEFORE USE.

13
1. Loosen the socket head screw using the 6 mm hex wrench provided.
2. Manually move the sanding belt to the desired angle and retighten the
socket head screw.
SURFACE SANDING ON THE BELT
When sanding flat broad surfaces on
the belt hold the workpiece firmly on
the surface of the belt and against
the backstop, keeping fingers away
from the sanding belt. Consider using
a push or hold-down stick.
• Use extra caution when sanding
very thin pieces, and when
sanding extra long pieces,
remove the backstop.
NOTE: When using the sander without the backstop, ensure that you
have a firm hold on the workpiece at all times and take extra
care.
• Apply only enough pressure to allow the sanding belt to remove
material.
SANDING CURVED PIECES
When sanding inside-curves on the
belt sander, always sand on the idler
drum end of the belt.
1. Hold the workpiece firmly, keeping
fingers away from the sanding
belt. Keep the curve pressed firmly
against the idler drum, moving the
work evenly back and forth across
the drum.
SANDING DISC
SANDING OUTSIDE CURVES
Always sand outside curves using the
sanding disc and moving the
workpiece from the left side of centre,
as shown. Keep the curve pressed
firmly against the sanding disc,
moving the work evenly from the left
side of the sanding disc. Be sure to
hold the workpiece firmly against the
surface of the table.

14
MITRE GAUGE - DISC SANDER
A mitre gauge can be used on the
work table, as shown. The mitre
gauge head can be set anywhere up
to 60o(right or left) by loosening the
lock-knob, setting the mitre gauge
head to the desired angle, and
tightening the lock-knob.
SANDING SMALL SURFACES USING THE MITRE GAUGE
Use of the mitre gauge is recommended for sanding small end surfaces on the
sanding disc.
NOTE: Always move the workpiece across the left side (dust chute end
of machine) of the sanding disc and be sure to hold the
workpiece down tightly onto the table surface.
MAINTENANCE
1. Clean the sander, belt and disc after each use.
2. Keep the sander dry, clean and free from oil and grease.
3. Store the sander in a safe and dry place, out of reach of children.
4. During normal use, sanding belts and discs can become loaded with
sanding debris. Use a stick belt cleaner (available at most hardware stores)
to remove build-up.
WARNING: ALWAYS DISCONNECT THE SANDER FROM POWER SOURCE
BEFORE MAKING ANY ADJUSTMENTS, INSTALLING BELTS/DISCS.
CAUTION: SERVICING MUST BE PERFORMED ONLY BY QUALIFIED REPAIR
PERSONNEL. SERVICE OR MAINTENANCE PERFORMED BY UNQUALIFIED
PERSONNEL COULD RESULT IN A RISK OF INJURY. WHEN SERVICING A
TOOL, USE ONLY IDENTICAL REPLACEMENT PARTS. FOLLOW
INSTRUCTIONS IN THE MAINTENANCE SECTION OF THIS SERVICE MANUAL.
USE OF UNAUTHORISED PARTS OR FAILURE TO FOLLOW MAINTENANCE
INSTRUCTIONS MAY CREATE A RISK OF ELECTRIC SHOCK OR INJURY.

15
REPLACING THE DRIVE BELT
1. Using a cross head screwdriver,
remove the screw located in the
middle of the cover.
2. Remove the cover.
3. Loosen (3) screws to allow the
pulleys to move enough to pass
the belt around them. Pass the
belt around the motor pulley and
drive pulley as shown.
4. Slightly tighten (3) screws. Adjust
the tension of the belt by putting a
flat blade screwdriver into the
adjusting hole. Push up on the
screwdriver to increase the tension
between pulleys.
5. Tighten screws fully, being careful
not to disturb the belt.
6. Test belt tension by placing fingers
on either side of belt and squeeze.
• There should be about a 1/4”
give to the belt.
NOTE: Excessive tension on the pulley belt may cause increased noise
and over load the motor. Excessive looseness may cause the belt
to fail prematurely.
7. Replace the pulley cover and position it inside the relief edges of the pulley
housing.
8. Using a cross head screwdriver, refit and tighten the flat head screw.

16
SPECIFICATIONS
PARTS AND SERVICING
Motor 230V, 50Hz, 1ph
Input Power 370 W
Fuse Rating 13A
Sanding Disc Diameter 6” (150 mm)
Sanding Belt Size (W x L) 4” x 36” (914 x 100 mm)
Sanding Belt Speed 450 m/min.
Sanding Table Dimensions (L x W) 225 x 160 mm
Table Angle Range 0-45 degrees
Mitre Guide Angle Range 0-60 degrees
Net Weight 18.65 kg
Dimensions (LxWxH) 447 x 363 x 255 mm
Sound Pressure Level dB LpA 91.1 dB (A)
Sound Power Level dB LWA 79.9 dB (A)
Vibration 3.34 m/s2
Part No 6500413
For Parts & Servicing, please contact your nearest dealer, or
CLARKE International, on one of the following numbers.
PARTS & SERVICE TEL: [phone]
PARTS & SERVICE FAX: [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [e-mail]

17
EXPLODED DIAGRAM & PARTS LIST

18
EXPLODED DIAGRAM & PARTS LIST
NO DESCRIPTION
1 Phillips Screw + Flat
Washer M4x6
2Baseboard
3 Phillips Screw M4x8
4 Lock Washers 4
5 Phillips Screw St4.2x10
6DiscCover
7 Disc Paper 150mm-80#
8 Socket Head Screw +
Lock Washer M6x16
9Disc
10 Wheel Box
11 Switch Box
12 Phillips Screw M5x8
13 Phillips Screw + Spring
Washer M5x25
14 Tension Lever Assy
15 Bush
16 Phillips Screw + Lock
Washer + Big Flat Washer
M5x16
17 Base
18 Phillips Screw M4X20
19 Connecting Box Cover
20 Phillips Screw St2.9x30
21 Relay 220v-240v
22 Tension Spring
23 Cotter Pin 1.6x10
24 Roll Pin 5x10
25 Phillips Screw + Spring
Washer + Flat Washer
M5x8
26 Phillips Screw M4x12
27 Hex Flange Nut M4
28 Capacitor 100uf/250v
29 Capacitor Support
30 Phillips Screw-plate
M4x12
31 Hex Head Bolt + Big Flat
Washer M6*12
32 Big Flat Washer 6
33 Work table Support
34 Miter Gauge Handle
35 Work table
36 Miter Slide
37 Miter Gauge Pointer
38 Miter Gauge
39 Switch Kjd20-2
40 Pressure Spring
41 Guard
42 Guide Shelf
43 External Circlip D12
44 Bearing 6001-2rs
45 Driven Roller
46 Driven Shaft
47 Phillips Screw M5*25
48 Capacitor Support
49 Capacitor 10uf/450v
50 Hex Nut-plate M8
51 Sanding Belt 100*915mm
52 Socket Head Screw +
Flat Washer M8x16
53 Support
54 Phillips Screw M5x16
55 Bearing Base
56 Belt Adjusting Handle
57 Rubber Washer
58 Adjusting Spring
59 Support Assy
60 Backstop
61 Drive roller
62 Inner Hex Lock Screw
M8x12
63 Drive Shaft
64 Bearing Cap
65 Support Cover
66 Phillips Screw M5x10
67 Belt Cover
NO DESCRIPTION
Quote Part Number
AWNCS46E + Diagram
number. e.g Tension
spring is AWNCS46E22
68 Phillips Screw + Special
Shaped Lock Washer
M5x16
69 Motor Shaft Wheel
70 Drive Belt
71 Driven Wheel
72 Phillips Screw + Spring
Washer + Flat Washer
M6x25
73 Socket Head Bolt M8x25
74 Belt Cover
75 Hex Nut M8
76 Anti Bending Tail Sleeve
77 Plate 150l
78 Cable Clamp
79 Phillips Screw M5*20
80 Dust Collecting Cover
81 Front End Housing
82 Phillips Screw - Plate
M6*113
83 Retainer 90#
84 Bearing 6003-2rs
85 Stator Wire Package
86 Rotor
87 Wave Spring Washer 35
88 Rear End Cover
89 Spring Washer
90 Hex Nut-plate M6
91 Hex Bolt + Spring Washer
M6x20
92 External Circlip D17
93 Power Cable
94 Protection Plate
95 Socket Head Wrench
M6x90x32
NO DESCRIPTION

19
DECLARATION OF CONFORMITY