Clarke Woodworker CS4-6C Instruction Manual

0607
MODEL NO: CS4-6C
PART No: 6500401
BELT/DISC SANDER
BELT/DISC SANDER
OPERATION & MAINTENANCE
INSTRUCTIONS

2
When disposing of his produc , do no dispose of wi h general was e. I mus be disposed of according o he laws
governing Was e Elec rical and Elec ronic equipmen , a a recognised disposal facili y.
CONTENTS
For Spare Par s and Service, please con ac your neares dealer,
or CLARKE In erna ional, on one of he following numbers.
PARTS & SERVICE TEL: [phone]
PARTS & SERVICE FAX: [phone]
or e-mail as follows:
PARTS: Par s@clarkein erna ional.com
SERVICE: Service@clarkein erna ional.com
PARTS & SERVICE CONTACTS
Specificatio s......................................................................................3
Safety Precautio s..............................................................................4
Electrical Co ectio s.......................................................................6
Pre-Assembly Check..........................................................................7
Assembly I structio s..........................................................................8
Getti g to k ow your Belt Sa der...................................................13
Operati g I structio s......................................................................15
Mai te a ce....................................................................................18
Troubleshooti g.................................................................................19
Parts Diagram...................................................................................20
Parts List.........................................................................................21-22
Declaratio of Co formity...............................................................23

Thank you for purchasing his CLARKE Bel and Disk Sander designed for hobby/
DIY, indoor use, and for sanding wood or wood produc s ONLY.
Before attempti g to use the sa der, please read this ma ual thoroughly a d
follow the i structio s carefully. I doi g so you will e sure the safety of yourself
a d that of others arou d you, a d you ca look forward to the sa der givi g you
lo g a d satisfactory service.
These i structio s should be retai ed a d used for refere ce by all those who use
the equipme t.
CLARKE GUARANTEE
This CLARKE product is guara teed agai st faulty ma ufacture for a period
of 12 mo ths from the date of purchase. Please keep your receipt as proof
of purchase.
This guara tee is i valid if the product is fou d to have bee abused or
tampered with i a y way, or ot used for the purpose for which it was
i te ded.
Faulty goods should be retur ed to their place of purchase, o product
ca be retur ed to us without prior permissio .
This guara tee does ot effect your statutory rights.
SPECIFICATIONS
Motor................................................ 230V, 50Hz, 1ph
Motor Power.................................... 440Watts
Motor Speed.................................... 2900RPM
Fuse Rati g...................................... 5Amp
Sa d Disk Size................................. 5 i ch(127mm)
Belt Disk Size....................................4 x36 i ch (100x914mm)
Belt Speed........................................ 8.5M/s
Dust Extractio Port OD................... 62mm
Net Weight....................................... 19.2kg
Dime sio s (LxWxH)........................480x350x280mm
Part No:............................................6500401
3

SAFETY PRECAUTIONS
WARNING:
As wi h all machinery, here are cer ain hazards involved wi h heir opera ion
and use. Exercising respec and cau ion will considerably lessen he risk of
personal injury. However, if normal safe y precau ions are overlooked or
ignored, personal injury o he opera or or damage o proper y, may resul .
1. ALWAYS Lear the machi es applicatio s, limitatio s a d the
specific pote tial hazards peculiar to it. Read a d become familiar
with the e tire operati g ma ual.
2. ALWAYS use a face or dust mask if operatio is particularly dusty.
3. ALWAYS check for damage. Before usi g the machi e, a y
damaged part, should be checked to e sure that it will operate
properly a d perform its i te ded fu ctio . Check for alig me t
of movi g parts, breakage of parts, mou ti gs a d a y other
co ditio that may affect the machi es operatio . A y damage should be properly
repaired or the part replaced. If i doubt, DO NOT use the machi e. Co sult your
local dealer.
4. ALWAYS disco ect the machi e from the power supply before servici g a d whe
cha gi g accessories.
5. ALWAYS wear safety goggles, ma ufactured to the latest Europea Safety Sta dards.
Everyday eyeglasses do ot have impact resista t le ses, they are ot safety
glasses.
6. ALWAYS keep work area clea . Cluttered areas a d
be ches i vite accide ts.
7. ALWAYS e sure that adequate lighti g is available. A
mi imum i te sity of 300 lux should be provided. E sure
that lighti g is placed so that you will ot be worki g i
your ow shadow.
8. ALWAYS keep childre away. All visitors should be kept a safe dista ce from the
work area, especially whilst operati g the machi e.
9. ALWAYS mai tai machi e i top co ditio . Keep tools/machi es
clea for the best a d safest performa ce. Follow mai te a ce
i structio s.
10. ALWAYS ha dle with extreme care do ot carry the tool/machi e
by its’ electric cable, or ya k the cable to disco ect it from the
power supply.
11. ALWAYS e sure the switch is off before pluggi g i to mai s. Avoid
accide tal starti g.
12. ALWAYS co ce trate o the job i ha d, o matter how
trivial it may seem. Be aware that accide ts are caused
by careless ess due to familiarity.
13. ALWAYS keep your proper footi g a d bala ce at all
times - do ’t overreach. For best footi g, wear rubber
soled footwear. Keep floor clear of oil, scrap wood, etc.
4

14. ALWAYS wear proper apparel. Loose clothi g or jewellery may
get caught i movi g parts. Wear protective hair coveri g to
co tai lo g hair.
15. ALWAYS guard agai st electric shock. Avoid co tact with
earthed surfaces..pipes, radiators etc.
16. NEVER operate machi e while u der the i flue ce of drugs, alcohol
or a y medicatio .
17. NEVER leave machi e ru i g u atte ded. Tur power off. Do
ot leave the machi e u til it comes to a complete stop.
18. NEVER force the machi e, it will do a better a d safer job at
the rate for which it was desig ed.
19. NEVER use power tools i damp or wet locatio s or expose
them to rai . Keep your work area well illumi ated. Do ot use
i a explosive atmosphere (arou d pai t, flammable liquids
etc.). Avoid da gerous e viro me ts.
WARNING! Use ONLY for sanding WOOD. DO NOT
DO NOT USE for sanding asbes os,
or ma erials con aining asbes os, pain ed surfaces, or ma erials which produce oxic
ADDITIONAL PRECAUTIONS FOR BELT AND DISK SANDERS
1. ALWAYS wear ear protectors/defe ders whe usi g this machi e.
2. ALWAYS wear a dust mask whe usi g this machi e. Be aware that harmful or
toxic dusts could be produced whe sa di g some woods, lead pai t etc.
3. ALWAYS use the sa dbelt support or table to support the workpiece.
4. ALWAYS check to e sure the table, sa d belt support a d attachme ts are
secure before starti g.
5. ALWAYS mai tai a cleara ce of 2-3mm betwee table a d sa di g belt or disc.
6. ALWAYS hold the workpiece firmly so that it ca ot be ripped from your ha ds
7. ALWAYS feed the workpiece agai st the directio of rotatio of the disc. i.e the LEFT
side of the disk
8. ALWAYS keep the mai s cable well away from the machi e a d e sure a
adequate electrical supply is close at ha d so that the operatio is ot
restricted by the le gth of the cable.
9. ALWAYS use a dust extractio device, properly co ected to the dust
extractio port
10. ALWAYS e sure that ails or a y foreig objects have bee removed from a
workpiece beforeha d. Nails etc., will destroy the belt or disk.
11. NEVER allow the ve tilatio slots i the motor to become blocked.
12. NEVER sa d pieces which ca ot be held firmly by ha d.
5

ELECTRICAL CONNECTIONS
Co ect the mai s lead to a sta dard, 230 volt (50Hz) electrical supply through a
fused good quality 13 amp BS 1363 plug, or a suitable fused isolator switch.
WARNING: THIS APPLIANCE MUST BE EARTHED
IMPORTANT: The wires i the mai s lead are coloured i accorda ce with the
followi g code:
Gree & Yellow - Earth
Blue - Neutral
Brow - Live
As the colours of the flexible cord of this applia ce may ot correspo d with the
coloured marki gs ide tifyi g termi als i your plug, proceed as follows:
• Co ect GREEN & YELLOW cord to termi al marked with a letter “E” or Earth
symbol “ ” or coloured GREEN or GREEN & YELLOW.
• Co ect BROWN cord to termi al marked letter “L” or coloured RED.
• Co ect BLUE cord to termi al marked letter “N” or coloured BLACK.
We s rongly recommend ha his uni is fi ed wi h a Residual Curren Device (RCD).
FUSE RATING
The fuse i the plug for this applia ce must be rated at 5 amps a d a y
replaceme t must be ASTA approved to BS 1362.
IMPORTANT NOTICE
If this applia ce is fitted with a plug which is moulded o to the electric cable (i.e.
o rewireable) please ote:
1. This plug must be throw away if it is cut from the electric cable. There is a
da ger of electric shock if it is subseque tly i serted i a socket outlet.
2. Never use the plug without the fuse cover fitted.
3. Should you wish to replace a detachable fuse carrier, e sure that the correct
replaceme t is used (as i dicated by marki g or colour code).
4. Replaceme t fuse covers ca be obtai ed from your local dealer, or a
electrical stockist.
6

PRE-ASSEMBLY CHECK
7
Separate all parts from packi g materials a d check each item with the “Table of
Loose Parts.” Make certai all items are accou ted for, before discardi g a y packi g
material.
WARNING: If a y parts are missi g, do ot attempt to assemble the Belt a d Disc
Sa der, plug i the mai s lead, or switch u til the missi g parts are obtai ed a d
I stalled correctly.
WARNING: For your ow safety, ever co ect plug to power source u til all assembly
steps are complete a d u til you have read a d u derstood the e tire ow ers ma ual.
WARNING: The use of any accessory/a achmen , o her han hose
recommended in his ins ruc ion manual, may presen a risk of
personal injury.
LOOSE PARTS
Should a y of the compo e ts be missi g or damaged the please co tact your
CLARKE dealer immediately for a replaceme t.
ItemDescriptio Qty.
A Belt a d Disc Sa der Assembly 1
B Ow er’s Ma ual 1
C Table 1
D Sa di g Disc I
E Table Support 1
F Disc Guard 1
G Work Stop 1
HMitre Gauge 1
ItemDescriptio Qty.
TABLE OF LOOSE PARTS
I Bag co te ts
K ob 1
Washer, 6.5 x 17.8 x 1.6 5
Screw, Pa Hd. M4. 2
Switch Key 1
Lockwasher, Ext. M6 4
Scale Label 1
Screw, Hex Hd. M6 4
Hex “L” Wre ch 6mm 1

ASSEMBLY
8
Tools Required
Moun ing To Workbench
If Belt a d Disc Sa der is to be used i a perma e t locatio , it should be faste ed securely
to a firm supporti g surface such as a workbe ch.
If mou ti g to a workbe ch, holes should be drilled through supporti g surface of the
workbe ch usi g dime sio s illustrated.
1. The u it should be bolted securely usi g 5/16" screws, flat washers a d hex uts ( ot
i cluded). Screw le gth should be 1½" plus the thick ess of the be ch top.
2. Locate a d mark the holes where belt a d disc sa der is to be mou ted.
3. Drill (2) 3/8" diameter holes through workbe ch.
4. Place the machi e o the workbe ch alig i g holes o base with holes drilled i
workbe ch.
5. I sert two 5/16" screws, thread o the washers a d uts, the tighte the uts.
Moun ing To A Board
A alter ate method of mou ti g is to faste belt a d disc sa der to a mou ti g board.
The board should be of sufficie t size to avoid tippi g of sa der while i use. A y good
grade of plywood or chipboard with a 3/4" mi imum thick ess is recomme ded. (Thi er
chipboard ca break.)
CAUTION: To avoid I jury from tool
moveme t, use 5/16" or larger screws and
nu s.
1. Follow i structio s for mou ti g to
workbe ch, substituti g a board 18" x
24" mi imum size a d usi g 5/16 i ch flat
head screws, Iockwashers, a d hex uts
( ot i cluded). Screw le gth should be
1-1/2" plus the thick ess of the mou ti g
board.
NOTE: For proper stability, holes must be
cou ter su k so screw heads are flush with
the bottom surface of supporti g board.

9
Clamping To Workbench
The belt a d disc sa der ca be
clamped directly to the board usi g two
or more “G” clamps o base of u it (o e
clamp o each e d).
Ins alling Sanding Disc And Guard
1. Locate sa di g disc a d peel
backi g from disc. Alig perimeter of
disc with plate a d press disc firmly
i to positio all the way arou d.
2. Locate disc guard a d two M4 pa
head screws, from loose parts bag.
3. Positio disc guard agai st lower 1/3
of disc alig i g holes as show .
4. Usi g a cross head type screwdriver,
faste the pa head screws securely
applyi g slight pressure to thread the
holes.
Ins alling Work Suppor S op
1. Locate the work support a d M6 hex
screw, washer a d lockwasher.
2. Hold work support i to positio a d
faste as show . Do ot overtighte .

10
Ins alling Table Assembly
1. Locate table support a d (3) M6 hex
head screws, flat washers a d
lockwashers amo g loose parts.
2. Positio table support agai st table,
alig i g holes as show .
3. Faste table support to table as show .
4. Locate washer 6.5 x 17.8 x 1.6 a d k ob
amo g loose parts.
5. Positio table support i correspo di g
holes o side of base as show . Make
sure the 9.5mm diameter i dex pi
alig s with upper hole.
6. Place washer o threaded shaft of
k ob a d i sert through slot i to
threaded holes of base
7. Loose the (3) hex head screws
a d adjust table so ,that a gap of
1/16” ONLY exists betwee the
table a d the disc..
WARNING: To avoid rapping he
work or fingers be ween he
able and sanding surface, he
able edge should be a
maximum of 1/16 inch from
sanding surface.

11
Auxiliary Moun ing For Ver ical Sanding
1. Remove backstop lock bolt a d remove
work support.
2. Remove table assembly by removi g table
lock k ob a d washer.
NOTE: Belt bed may be raised to vertical
positio by loose i g hex socket screw a d
raisi g bed. See “Positio i g Belt Bed” o page
16.
3. Attach table assembly to auxiliary holes i
belt bed. Make sure i dex pi is i the
upper hole whe sa di g table is i the
vertical positio .
Squaring Table Assembly
WARNING: To avoid injury from acciden al s ar ,
make sure ool is unplugged before aligning.
1. Usi g a combi atio square, check the
a gle of the worktable with the disc.
NOTE: The combi atio square must be “true”
- See “Assembly - Tools Needed” sectio o
page 8 for checki g method .
2. If the table is ot 90º with the disc, loose
table lock k ob screw a d tilt table.
3. Adjust worktable square to the disc a d
retighte table lock k ob.
4. Attach scale label to 0º mark o dust guard.
Ins alling he Sanding Bel -Tensioning And Tracking
WARNING: To avoid injury from acciden al s ar ,
swi ch “OFF”, remove key and disconnec from power
ou le before removing or ins alling sanding bel .
O the smooth side of the sa di g belt, is a “directio al
arrow.” The sa di g belt must ru i the directio of this
arrow so that the splice does ot come apart.
1. Slide te sio lever to the right to release the belt
te sio .
2. Place the sa di g belt over the pulleys with the
directio al arrow poi ti g as show .
Make sure the belt is ce tred o both pulleys.

3. Slide te sio lever to the left to apply belt
te sio .
4. Tighte hex socket screw whe bed is i
desired positio .
5. Plug i the power cord. Tur switch “ON” a d
immediately “OFF,” oti g if the belt
te ds to slide off the idler pulley or drive pulley.
If it did ot te d to slide off, it is TRACKING
properly.
6. If the sa di g belt moves toward
the disc, tur the tracki g k ob
clockwise 1/4 tur .
7. If the sa di g belt moves away
from the disc, tur the tracki g
k ob a ticlockwise 1/4 tur .
8. Tur switch “ON” a d immediately
“OFF” agai , oti g belt
moveme t. Readjust tracki g
k ob if ecessary.
12

GETTING TO KNOW YOUR BELT/DISC SANDER
WARNING: To avoid injury from acciden al s ar , swi ch “OFF” and disconnec from power
source before making any adjus men s.
1. Work Support. Supports the workpiece o the sa di g belt.
2. Hex Socket Head Screw. Loose i g screw allows belt bed to be raised to the vertical
positio .
3. Tracki g K ob. Tur i g k ob a ticlockwise causes sa di g belt to move towards
the disc; tur i g k ob clockwise causes sa di g belt to move away from the disc.
4. Te sio Lever. Slidi g lever to the right releases the sa di g belt te sio ; slidi g lever
to the left applies belt te sio .
5. Table Lock K ob. Loose i g k ob allows the work table to be tilted for bevel sa di g.
(Scale poi ter o table tru io ; scale attached to base.)
6. Auxiliary Mou ti g Hole. Allows table assembly to be mou ted for e d sa di g whe
the bed is placed i vertical positio .
7. O -Off Switch.
13

2. I sert fi ger u der switch lever a d PULL
e d of switch out.
3. To tur machi e “OFF”... PUSH lever i .
NEVER LEAVE THE MACHINE UNATTENDED
UNTIL IT COMES TO A COMPLETE STOP.
4. To lock switch i OFF positio .., hold switch
IN with o e ha d... REMOVE key with
other ha d.
WARNING: For your own safe y, always lock
he swi ch “OFF” when machine Is no In use
... remove key and keep I In a safe place...
also... In he even of a power failure (all of
your ligh s go ou ) urn swi ch off.., remove
he key and s ore I remo e from he machine.
ON-OFF Swi ch
The ON/OFF switch has a locki g feature. This
feature is i te ded to help preve t
u authorised a d possibly hazardous use by
childre a d others.
1. To tur machi e “ON’ i sert key i to
switch.
NOTE: Key is made of yellow plastic, located
i loose parts bag .
14

OPERATING INSTRUCTIONS
Bevel Sanding
WARNING: To avoid rapping he work or
fingers be ween he able and sanding
surface, he able should be reposi ioned
on he able suppor o re ain a maximum
of 1/16 Inch dis ance be ween sanding
surface and able.
Raising Bel Bed
A bed locki g hex socket head screw locks the belt bed i a vertical or horizo tal positio .
To adjust vertical positio :
The worktable ca be tilted from 00 to 450 for
bevel sa di g. Loose the table lock k ob a d
tilt the work-table to desired a gle as show .
Retighte table lock k ob.
1. Remove the work support.
2. Loose the hex socket head locki g screw usi g a 6mm
hex. wre ch
3. Positio belt bed vertically as show a d tighte the
hex. socket head screw.
15

Surface Sanding On The Sanding Bel
WARNING: To avoid injury from slips, jams or hrown
pieces, adjus he backs op o clear he sanding
surface by no more han 1/16”. When checking
clearance be ween he bel and work suppor ,
press he bel fla agains he bed benea h i .
Hold the workpiece firmly with both ha ds,
keepi g fi gers away from the sa di g belt.
Keep the e d up agai st the backstop
a d move the work eve ly across the
sa di g belt. Use extra cautio whe
sa di g very thi pieces.
For sa di g lo g pieces, remove the work support.
Apply o ly e ough pressure to allow the sa di g belt to remove
material.
It is more co ve ie t to sa d the e ds of lo g work-
pieces with sa di g belt i a vertical positio .
See “Basic Operatio - Positio i g Belt Bed” for
adjusti g the belt bed, a d see “Assembly -
I stalli g Table Assembly” for adjusti g worktable.
Move the work eve ly across the sa di g belt. For
accuracy, use a mitre gauge.
Sanding Curved Edges
End Sanding On The Sanding Bel
Always sa d i side curves o the idler
pulley as show .
WARNING: Never a emp o sand
he ends of a workpiece on he idler
pulley. Applying he end of he
workpiece o he idler pulley could
cause he workpiece o fly up and
resul in an injury.
16

Always sa d outside curves o the left
side of ce tre o the sa di g disc as
show .
WARNING: Applyi g the workpiece to
the right side of the disc could cause
workpiece to fly up (kick-back) a d
result I a I jury.
Sanding Small End Surfaces On The Sanding Disc
and resul in an Injury.
WARNING: For your own safe y,
urn swi ch “OFF” and remove plug
from power source ou le before
adjus ing your sander.
NOTE: Use a combi atio square
to square the mitre gauge to the
face of the disc (combi atio
square must be “true” - See
“U packi g - Tools Required”
sectio o page 8 for checki g
this method). If it is ot square,
loose the mitre gauge k ob a d
move the mitre gauge slightly
u til it is square. Without movi g
the mitre gauge, tighte the k ob
securely.
NOTE: Use of a Mitre Gauge is
recomme ded for this operatio .
Always move the work across left side of
ce tre o the sa di g disc face as
show .
The table may be tilted for bevelled
work.
Always positio the workpiece to the left
of ce tre o sa di g disc with disc
rotati g a ticlockwise as show .
WARNING: Applying he workpiece
o he righ side of he disc firs could
cause workpiece o fly up (kickback)
17

MAINTENANCE
WARNING: For your own safe y, swi ch “OFF” and remove plug from power source
before adjus ing, main aining, or lubrica ing your bel and disc sander.
WARNING: To avoid elec rocu ion or fire, any repairs o elec rical sys ems should be
done only by qualified service echnicians. The uni mus be reassembled exac ly o
fac ory specifica ions.
If the mai s lead is wor or cut, or damaged i a y way, have it replaced immediately.
Freque tly blow out or vacuum a y dust that may accumulate i side the motor.
A coat of wax applied to the worktable will make it easier to feed the work while fi ishi g.
Do ot apply wax to the abrasive belt table because the belt could pick up the wax a d
deposit it o the pulleys, causi g the belt to slip.
Lubrica ion
The BALL BEARINGS i this machi e are packed with grease at the factory. They require
o further lubricatio . Sleeve beari gs should be lubricated with 30 weight oil or equivale t
after each 10 hours of operatio .
Removing Pulley Cover And Ins alling Drive Bel
1. Usi g a cross head screwdriver,
remove the screw located i the
middle of the cover.
2. Remove the cover.
3. Loose (3) screws to allow pulleys
to move e ough to place the belt
arou d them. Place belt arou d
the motor pulley a d drive pulley as
show .
18

4. Slightly tighte (3) screws. Adjust
te sio of belt by putti g blade
screwdriver i adjusti g hole. Push up
o screwdriver to tighte te sio
betwee pulleys.
5. Tighte screws fully, bei g careful ot
to disturb the belt.
6. Test belt te sio by placi g fi gers o
either side of belt a d squeeze.
There should be about a 1/4" give to
the belt.
NOTE: Excessive tight ess o pulley belt
may cause i creased oise a d over load
motor. Excessive loose ess o pulley belt
may cause belt to fail prematurely.
7. Locate the pulley cover a d positio it i side the relief edges of pulley housi g.
8. Usi g a cross head screwdriver, rei stall a d tighte the flat head screw.
TROUBLESHOOTING
Trouble Probable cause Remedy
Motor will ot ru . 1. Defective O -Off switch 1. Replace defective parts before
Defective switch lead usi g belt/disc sa der agai .
Defective switch box.
2. Bur t out motor or relay. 2. A y attempt to repair this motor
or relay may create a HAZARD
u less repair is carried out by a
qualified electricia .
Machi e slows dow 1. Drive belt too tight. 1. Decrease belt te sio , see
whe sa di g. Mai te a ce sectio ,
“Removi g Pulley Cover a d
I stalli g Drive Belt’.
2. Too much pressure applied 2. Ease up o pressure.
to workpiece.
Sa di g Belt ru s off 1. Not tracki g properly. 1. Adjust tracki g, see Assembly
pulleys. I structio s, “I stalli g the
Sa di g Belt Te sio i g a d
Tracki g’.
Wood bur s while 1. Sa di g disc or belt is 1. Replace disc or belt.
sa di g glazed with sap.
Excessive oise. 1. Drive belt too tight. 1. Decrease belt te sio , see
Mai te a ce Sectio
“Removi g Pulley Cover a d
I stalli g Drive Belt’.
19

PARTS DIAGRAM
20