Clarke CCS305 Installation and operation manual

1
12in (305mm)
CONTRACTOR’S SAW
OPERATING & MAINTENANCE
INSTRUCTIONS 0698
Model No. CCS305
Part No. 6460305

2
Thank you for purchasing this CLARKE 12” (305mm) Contractors Saw, which is
designed for light industrial use.
Before operating the machine, please read this booklet thoroughly and carefully
follow the instructions. In doing so you will ensure the safety of yourself and that of
others around you, and you can look forward to the Contractor’s Saw giving you
long and satisfactory service.
GUARANTEE
This CLARKE product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt as proof of purchase.
This guarantee is invalid if the product is found to have been abused or tampered
with in any way, or not used for the purpose for which it was intended.
Faulty goods should be returned to their place of purchase, no product can be
returned to us without prior permission. This guarantee does not affect your statutory
rights.
CONTENTS Page
Safety Precautions .................................................................. 3
Additional Precautions for Workshop Saws ......................... 5
Features ................................................................................... 6
Unpacking ............................................................................... 7
Assembly .................................................................................. 8
Electrical Connections.......................................................... 15
Adjustments ........................................................................... 16
Operation - Rip Sawing ....................................................... 17
Cross Cutting.................................................... 18
Maintenance ......................................................................... 19
Blade Renewal ....................................................................... 20
Specifications ......................................................................... 20
Parts List ................................................................................... 21
Parts & Servicing .................................................................... 21
Parts Diagram ........................................................................ 22

3
SAFETY PRECAUTIONS
GENERAL SAFETY RULES FOR OPERATING MACHINERY
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.
•READ and BECOME FAMILIAR with the entire operating manual. Learn the
machine’s applications and limitations as well as the specific potential hazards
peculiar to it.
•EARTH ALL MACHINES. If the machine is equipped with a three-pin plug, it should
be plugged into a three-pin electrical socket. Never remove the earth pin.
•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.
•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 machine’s
operation. Any damage should be properly repaired or the part replaced. If in
doubt, DO NOT USE the machine. Consult your local dealer.
•DISCONNECT the MACHINE from the power supply before servicing and when
changing accessories such as blades, etc.
•KEEP GUARDS in place and in working order.
•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.
•KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents.
•ALWAYS WEAR EAR PROTECTORS/DEFENDERS.
•DON’T FORCE the machine, it will do a better and safer job at the rate for
which it was designed.
•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.

4
•DRUGS, ALCOHOL, MEDICATION. Do not operate machine while under the
influence of drugs, alcohol or any medication.
•USE RECOMMENDED ACCESSORIES. The use of improper accessories could be
hazardous.
•NEVER LEAVE MACHINE RUNNING UNATTENDED. Turn power OFF. Do not leave
machine until it comes to a complete stop.
•ALWAYS REMOVE PLUG from electrical outlet when adjusting, changing parts,
or working on machine.
•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.).
•KEEP CHILDREN AWAY. All visitors should be kept a safe distance from the work
area, especially whilst operating the unit.
•MAINTAIN MACHINE IN TOP CONDITION. Keep tools sharp and clean for the
best and safest performance. Follow maintenance instructions.
•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.
•WEAR PROPER APPAREL. Loose clothing or jewellery may get caught in moving
parts. Wear protective hair covering to contain long hair.
•MAKE WORKSHOP CHILDPROOF. Cover the saw adequately when not in use, to
prevent children from damaging themselves by tampering with it.
•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.
•HANDLE WITH EXTREME CARE. Whenever transporting or installing machinery,
and always use a lifting device.
•BE AWARE that many accidents are caused by carelessness due to familiarity.
ALWAYS concentrate on the job in hand, no matter how trivial it may seem.

5
ADDITIONAL SAFETY INSTRUCTIONS for WORKSHOP SAWS
•Wear safety goggles as protection against flying wood chips and saw dust. In
many cases, a full face shield is even better protection. A dust mask is also
recommended to keep saw dust out of your lungs.
•This saw is designed for light industrial use only.
•Clear the work table of all objects except the workpiece (tools, scraps, rulers
etc.) before turning on the saw.
•Keep your fingers well away from the blade, use a push stick as you near the
end of the cut.
•Switch off the saw and make sure the blade has come to a complete stop
before clearing sawdust or off-cuts from the table.
•Make sure there are no nails or foreign objects in the part of the workpiece to
be sawn.
•Set up the machine and make all adjustments with the power OFF and
disconnected from the supply.
•DO NOT operate the machine with the guards removed. They must all be in
place and securely fastened when performing any operation.
•Use ONLY approved replacement saw blades. Contact your local CLARKE
dealer for advice. The use of inferior blades will increase the risk of injury.
•DO NOT saw any material that does not have a flat surface on which to bear.
•This machine is designed for cutting wood. DO NOT use for cutting metal or
plastic.
•DO NOT attempt to cut round or tubular work (logs etc.).
•Do not cut pieces of material which are too small to be guided by hand.
•Do not feed the workpiece through the blade too quickly, hold material firmly
and feed into blade at a moderate speed.
•When cutting a large piece of material, support it at the height of the table
with supports or use an assistant.
•Never let go of a workpiece, ALWAYS maintain control.
•Never touch, or hold on to, a piece that has been cut off whilst the power is on
or the blade is rotating.
•Ensure the surface on which the saw stands is firm, solid and non-slip.
•DO NOT use the saw for non-through-cut operations. The Upper Blade Guard
MUST be in place at all times.

6
FEATURES
The Contractor’s Saw may be used for rip cutting or cross cutting timber up to
70mm (2¾”) in depth.
A double height Rip Fence is provided and may be secured at any desired position
for quick and accurate rip sawing. The max. width obtainable, using the rip fence is
280mm (11”).
For speed and accuracy, a guide is also provided for cross cutting. It is adjustable
so that mitres of up to 45° may be created.
The Upper Blade Guard is hinged to allow it to ride over the timber as the timber
moves over the blade.
IMPORTANT: The Blade Guard must always be in place.
The Lower Blade Guard comprises a box, on to which is mounted the motor and
saw blade. A hinged cover gives access to the blade and other components.
IMPORTANT: This cover must always be in place and secure.
The box is secured by two pivot bolts and two large (Saw Blade) Tilt Adjuster knobs.
Slackening these knobs allows the complete box, with motor and blade, to move
about the pivot bolts so that the blade may tilt by up to 45° - in one direction. It is
then secured in position by tightening the same adjuster knobs.
Extending from the bottom of the box is a handle, used for raising and lowering the
blade and is explained under ‘Operation’.
At one end of the box, (the rear end), a 48mm (17/8”) dia hole is provided for use as
a dust extraction outlet. If required it can be connected to a dust extraction device
which will provide fast and efficient removal of sawdust. The dust extractor may be
used continuously or intermittently depending upon your requirements.
Construction of the base unit is in heavy, corrosion resistant, galvanised steel and is
maintenance free. The machine is nevertheless designed for indoor use. Should it
be used outdoors, every attempt should be made to ensure it is protected from the
elements. Do not use in wet conditions.

7
1. Saw Blade
2. Riving Knife
3. Upper Blade Guard
4. Rip Fence
5. Rip Fence Support
6. Quadrant
7. Long Guide Bar (for cross cutting)
8. Short Guide Bar (for ripping)
9. Corner Support - 2 pcs
10. Table Insert
11. Table Top
12. Leg - 4 pcs
13. Short Strut - 2 pcs
14. Long Strut - 2 pcs
15. Handle - 2 pcs
16. Motor Assy.( incl. Switch Box assy).
17. Switch Box Bracket
18. Trailing Socket
19. Axle
20. Wheel - 2 pcs
21. Axle Bracket - 2 pcs
22. Lower Blade Guard Box Assy
23. Push Stick
A. 5 Scalloped Knobs ( 3 female - small, 2
male - large), 1 Winged Knob, 4 Feet and
1 Handle assy. (contained in one bag)
In addition to the foregoing list, the packing carton contains a bag with all necessary fixing screws,
nuts, collars, and washers.Please refer to the parts list for details.
UNPACKING
Unpack the shipping carton in a clean flat area, so that you have ample room to
work, and lay out all components neatly so that they may be clearly identified.
Check to ensure that no damage was suffered in transit. Should there be any
damage, please contact your Clarke dealer immediately.
Check the parts, referring to fig.1 and the list which follows: Fig.1
1

8
ASSEMBLY
A. Lower Blade Guard Box
1. Place the table face down on a sheet of cardboard (or similar).
2. Between the two side brackets lies a hinged flap. Lift and rotate it against spring
pressure through 180Oso that it lies flat against the underside of the table. Hold
it in this position temporarily with a suitable weight.
3. Invert the lower blade
guard box, and lower it
into place between the
two side brackets as
shown in fig.2, ensuring the
hinged door of the box
faces the hinged flap.
Locate the box with two
large scalloped knobs
(item A), one each side,
through the slotted holes
inthe side brackets as
shown. Screw the knobs
home but do not tighten
them fully.
These knobs are referred to as the Blade Tilt Adjuster Knobs.
4. Manoeuvre the box so that the pivot bolt holes (see fig 2), line up with the holes
in the side brackets and insert the special shouldered bolts (item B), from inside
the box.
Screw on the self locking nuts, ensuring the shoulders ofhe bolts are sitting snugly
in the holes in both the box AND the side bracket. Tighten the self locking nuts,
but only sufficiently so as to allow the box to pivot smoothly about the shouldered
bolts, and then secure the box firmly by tightening the Blade Tilt Adjuster Knobs
(A).
B. Motor Assembly and Attachments
5. Insert the motor shaft through the hole in
the Blade Guard Box. The plastic cable
housing on the motor should be facing
you. i.e. when the table is on its feet, the
plastic cable box will face downwards.
Secure the motor assembly to the
moveable plate, within the box, using four
M5 x 25mm screws with flat and spring
washers. Tighten the screws to no more
than 12 lbf ft.
NOTE: It is strongly advised that assistance be used to support the weight of the
motor, when tightening the screws, to avoid the possibility of it tilting.
A
B
Self
locking
nut
Fig.2
C
Lower Blade
Guard Box
Pivot Bolt Hole
Side Bracket
Hinged
Flap with
weight
✓
Fig 2A
✗

9
IMPORTANT: Make absolutely sure that the motors’ end plate sits snugly in the hole
in the Blade Guard Box, as shown in Fig2A. The register on the end plate must be
completely through the hole.
6. Attach the Blade Height Adjuster Handle (fig.2 item C), to the adjuster bolt.
Line up the hole in the handle with that in the bolt, insert the roll pin provided
and tap it into place.
C. Rip Fence and Cross Cut Guide Bars, and Legs
7. Lay the Rip Fence and Cross Cut Guide Bars, together with the two Corner
Supports, alongside the table as shown in fig. 3. The rounded ends of the corner
supports should be attached to the guide brackets, not to the table.
With a leg placed in the inside of the corner of the table, insert the screws
through the brackets, table top and leg, using the flat and spring washers
supplied. (i.e. a flat washer next to the screw head, and a flat washer followed
by a spring washer with the nut).
Use the M5 x 20mm screws where the thickness of the guide brackets is to be
taken into account, and M5 x 15mm screws otherwise.
Do not tighten the nuts at this stage - leave them finger tight. The guide brackets
and all four legs should now be loosely bolted in place.
D. Legs and Struts
8. Attach the long and short leg struts to the legs ensuring the screws are entered
in the elongated holes in the struts, with the long strut on top of the short one,
and the open angle of the strut facing you, (i.e. will normally be facing
downwards).
Ensure flat and spring washers are used, as detailed previously.
(Cross Cut) Guide Bar (long)
(RipFence)
GuideBar
(short)
Fig.3
CornerSupport
CornerSupport

10
9. Attach a rubber foot to each leg, placing a flat washer either side of the hole
in the leg. Screw on the nut and tighten securely.
E. Wheels and Axle Assy
10. In order to install the wheels and axle assembly, first attach all components to
the axle as follows:
Refer to fig 4, and on to each end in turn, thread on:
1. a wheel
2. a 10mm flat washer
3. the axle bracket, with the angle portion facing outwards as shown,
in fig. 4, and the sloping edge downwards towards the foot - as shown
in Fig 4A
4. an 8mm flat washer
5. an 8mm spring washer
6. an M8 nut, which may be tightened securely.
Attach the brackets to the legs, (on the opposite end of the table to that
carrying the short guide bar), with the screws, flat and spring washers provided.
11. With assistance, turn the table to an upright position and rock it vigorously,to
ensure it is completely stable and that no part in under stress. When satisfied,
tighten all nuts systematically starting at the top and working down.
It is recommended that you use gloves during this operation as protection
against the sharp edges that you may encounter.
NOTE:
a. Before tightening the screws securing the guide bar brackets, pull the brackets
apart as far as possible on their elongated holes. (indicated by the arrows in fig
3)
b. For future reference, the FRONT of the table is that end carrying the short guide
bar.
Fig.4 Fig.4A
C
A
A
BC D E
F
Axle
Angle portion facing outwards Foot
Sloping edge of bracket facing
down towards the foot