Clarke CMS 200 Installation and operation manual

0401

PLEASE READ THIS MANUAL THOROUGHLY
BEFORE USE.
If you have any problems using, or setting up
this machine,
ring this number...020 8988 7400
• Press 1 for Parts
• Press 2 for Technical Assistance
2
WARNING!
Due to the gearing arrangement, this machine generates
considerable noise. Do not be alarmed as this is quite normal for
this type of machine.
We strongly recommend that you wear ear defenders during use.
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: [email protected]
PARTS & SERVICING

Thank you for purchasing this CLARKE 8 inch Compound Mitre Saw which
is designed for DIY/Hobby use only.
Before operating the Mitre Saw please read this leaflet thoroughly and
carefully follow all instructions. This will ensure the safety of yourself and
that of others around you, and you can also 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 ............................................................... 4
Additional Precautions for Mitre Saws ............................... 6
Electrical Connections ......................................................... 7
Principle Parts ........................................................................ 8
Features ................................................................................. 9
Assembly.............................................................................. 10
Operation ...... Cross Cutting ............................................. 10
Mitre Cutting ............................................. 11
Bevel Cutting ............................................ 12
Compound Mitre Cutting ........................ 12
Maintenance ...................................................................... 13
Blade renewal........................................... 13
Adjustments ......................................................................... 15
Specifications ...................................................................... 15
Maximum Cutting Sizes ...................................................... 15
Parts Lists and Diagrams ............................................. 16 - 17
3

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.
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. DISCONNECT the MACHINE from the power supply before servicing
and when 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 a face or dust mask if the 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.
4

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.
19. MAINTAIN MACHINE IN TOP CONDITION. Keep tools sharp and clean
for the best and safest performance. Follow maintenance instructions.
21. 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.
22. WEAR PROPER APPAREL. Loose clothing or jewelry may get caught
in moving parts. Wear protective hair covering to contain long hair.
23. MAKE WORKSHOP CHILDPROOF. Cover the saw adequately when not
in use, to prevent children from damaging themselves by tampering
with it.
24. 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.
25. HANDLE WITH EXTREME CARE Whenever transporting or installing
machinery, and always use a lifting tool.
26. AVOID ACCIDENTAL STARTING. Ensure the switch is OFF before plugging
in to mains.
27. 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.
5

ADDITIONAL SAFETY INSTRUCTIONS
for MITRE SAWS
1. 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.
2. Use a solid wood workbench which will not move under load.
3. This saw is for indoor, domestic use only.
4. Clear the work table of all objects except the workpiece (tools, scraps,
rulers etc.) before switching on the saw.
5. Keep your fingers well away from the blade.
6. Switch off the saw, and make sure the blade has come to a complete
stop before clearing sawdust or off-cuts from the table.
7. Make sure there are no nails or foreign objects in the part of the
workpiece to be sawn.
8. Set up the machine and make all adjustments with the power OFF,
and disconnected from the supply.
9. DO NOT operate the machine with the guards removed. They must all
be in place and securely fastened when performing any operation
10. Use ONLY approved replacement saw blades. Contact your local
CLARKE dealer for advice. The use of inferior blades may increase the
risk of injury.
11. DO NOT saw any material that does not have a flat surface on which
to bear.
12. This machine is designed for cutting wood. DO NOT use for cutting
metal, plastics or masonry.
13. Do Not force the blade, lower it gently into the work.
14. Ensure you have complete control of the Cutting Head at all times.
When a cut is completed, return it to its uppermost position gently. DO
NOT allow it to snap back heavily under spring pressure.
15. Always clamp the work to the table...DO NOT perform freehand
operations.
16. Ensure that the portion of the workpiece being cut bears firmly against
the back fence.
17. Provide adequate support for long workpieces.
18. Never use solvents for cleaning plastic parts as this could cause
damage to the material. A soft damp cloth only is required.
6

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 IS DOUBLE INSULATED
IMPORTANT: The wires in the mains lead are coloured in accordance with
the following code:
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 BROWN cord to terminal marked with “L” or coloured RED.
Connect BLUE cord to the terminal marked with “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 covers can be obtained from your local dealer or
most electrical stockists.
Fuse Rating
The fuse in the plug must be replaced with one of the same rating -13amps
and this replacement must be ASTA approved to BS1362.
Cable Extension
If a cable extension is needed, it is essential to ensure that the size of the
conductors is at least the same size as those of the power cable supplied.
7

PRINCIPAL PARTS OF THE SAW
8
Fig.1
Fig.2

FEATURES (Ref. Fig. 3)
As its’ name implies, the machine is a Bevel/Mitre Saw, capable of straight
cross cutting, and cutting bevels and mitres, or a combination of the two.
The main arm, or Cutting Head, carries the motor and the tungsten carbide
saw blade. It is allowed to swivel to produce mitre cuts and tilt to the left
to produce bevel cuts.
The maximum sizes of wood that may be cut in any of these processes is
given under Specifications on page 15.
A dust extraction outlet (E) is provided at the rear of the machine. If required
it can be connected to a vacuum cleaner which will provide fast and
efficient removal of sawdust. The vacuum cleaner may be used
continuously or intermittently depending upon your requirements.
Saw blades with a bore of 18mm or 20mm may be used.
This saw is not designed for cutting metal, plastics or masonry.
9
Fig.3

ASSEMBLY and INSTALLATION. Ref: Fig. 3
The saw is fully assembled and adjusted at the factory. On receipt inspect
the machine to ensure that all parts are accounted for and that no
damage was incurred during transit.
Loose items are: 1x Peg spanner, and 1x Box spanner
Any deficiency or damage should be reported to your CLARKE dealer
immediately.
Mount the machine on a firm solid base that will not move under load.
Ensure there is an appropriate electrical supply, and adequate lighting,
so that you will not be working in your own shadow.
Four holes are provided, one at each corner of the base, so that the
machine may be bolted permanently to a workbench for added stability,
using 8mm bolts (not provided). Alternatively it may be bolted to a piece
of plywood with a thickness of 16mm (5/8”).
The Cutting Head is locked in its lower position for transit purposes. To release
it, pull out the Head Locking Knob (B), (It may be necessary to apply slight
downward pressure to the head in order to do so), and allow the head to
rise to its upper position gently, under control.
The head will lock in its upper position, and is prevented from being lowered
until the Head Release Button (A) is pressed
OPERATION. (Ref Fig.4)
A. Cross Cutting. (at 90°)
First, set the work in place with one end firmly clamped against the table
and back fence.
It is important to ensure that one end of the workpiece is completely free
to move i.e. NOT clamped or held in any way. This will normally be the off-
cut or shorter end.
NOTE: If the workpiece is not entirely straight, ensure that the portion at
either side of the intended cut rests firmly against the table and back
fence.
When satisfied, make a final check to ensure that all safety precautions
are being complied with, then pull and hold the starter switch (G, Fig.1),
and allow the blade to reach full speed. If any unusual sounds or vibrations
occur, release the starter switch immediately and investigate the cause.
10

When satisfied, press the
Head Release Button (A), and
gently lower the head so that
the blade makes contact
with the workpiece. Do not
force the blade, a light
pressure is all that is required.
You will notice that to provide
maximum safety, the blade is
not exposed at any time, and
the guard rises automatically
as the blade is lowered.
Nevertheless, NEVER treat the
machine with indifference,
and NEVER be casual with
your approach.
To switch off, release the
starter switch whilst still maintaining full control of the head. NEVER allow
the head to spring upwards - always maintain control. Wait for the blade
to stop completely before removing the workpiece, off-cuts etc.
B. Mitre Cutting
This is a cross cutting operation, except that the saw blade is set at an
angle to the work, but remains perpendicular to the table. This is achieved
by mounting the complete
Head assembly on a table
which is free to rotate by up
to 45° .
To set the required mitre angle
unscrew the table securing
screws (H, fig.5), and rotate
the table, with the head and
saw blade, to the desired
position, lining up the angle
on the scale with the mark on
the edge of the table (J, fig.5).
Lock the table in position with
the locking screws (H).
The procedure for cutting is
the same as that for cross
cutting.
11
Fig.5
Fig.4

C. Straight Bevel Cutting
As with Mitre Cutting, this is a cross cutting operation, except that the
blade is not perpendicular to the table, (see fig. 6).
Ensure the table is set so that the
mark (J), on the edge of the
table, lines up with the zero on
the scale on the bed.
The 45° adjuster is factory set so
that when the Head is tilted to
its fullest extent the blade will cut
a perfect 45° bevel.
If however you require any other
angle, you should proceed as
follows:
Cut a mitre of the required
angle, on a spare piece of
wood, and use this as a
template for your bevel cut.
Slacken off the Bevel Locking Nut (C,
fig.7), using the box spanner
provided, and swing the Head to the
side. Lower the arm, and bring your
template up to the saw blade. When
satisfied that the edge of template
and blade are parallel, lock the
head in position with lock nut (C).
Your angle is now set.
The procedure for cutting is the same
as that for cross cutting....press start
switch G, wait for full speed to develop, then lower the blade to the
workpiece.
D. Compound Mitre and Bevel Cutting.
Having determined the angles you require, firstly set the bevel angle, using
the procedure described above, and then the mitre angle.
NOTE: Compound mitre and bevel cuts, at a full 45°, can only be made
when the head is turned to the left.
The procedure for cutting is the same as that for cross cutting.
12
Fig.7
Fig.6

MAINTENANCE
1. General
The machine is maintenance free, except for changing the saw blade
when necessary, maintaining adjustments, and ensuring that after use,
you clean away any sawdust or wood chips, with a low pressure air line or
brush, paying particular attention to the motor air vents which should be
kept clear at all times.
Should the motor not function normally, it is possible that it has become
clogged with saw dust, in which case, it will be necessary to disassemble
the motor in order to clean the various components. Contact your CLARKE
dealer for advice.
2. Changing the Saw Blade
IMPORTANT: Exercise extreme care when handling the saw blade. The
tips are extremely sharp, and careless handling could result in severe
personal injury.
1. With the machine disconnected from the mains supply, and the
cutting head in the raised position, slacken off the blade securing
bolt.
This is achieved by holding the outer flange steady with the peg
spanner provided, whilst turning the securing bolt (see fig. 8),
CLOCKWISE. The bolt has a LEFT HAND THREAD.
Do not remove the bolt completely.
13
Fig.9Fig.8

2. Remove the four bolts shown at F, Fig.9, and remove the Upper Blade
Guard Cover.
3. With the cover removed, unscrew the blade securing bolt, with its
washer, completely. Pull off the outer flange, and then the blade.
(Take great care when handling the blade).
You should take this opportunity to clean the inside of the blade guard
of any dust build-up and check generally for security of parts.
NOTE: This machine is capable of accepting blades with bores of 18 and
20mm.
4. Check the bore of your
replacement blade. If it is the
same as the blade you are
replacing, simply mount it on
to the boss of the inner flange
shown in fig. 10, with the
blade tips facing down at the
front. Ensure the parts are
perfectly clean, and the
blade sits snugly on the boss.
5. Replace the outer flange
followed by the securing bolt
with washer - remembering
the bolt has a left hand thread. Leave the bolt finger tight.
6. Replace the upper blade guard cover and securing bolts (F). Tighten
the bolts, but do not overtighten them as this could strip the threads
NOTE:
If you are replacing a 18mm bore blade with an 20mm bore blade, or
vice versa, it will be necessary to pull off the inner flange from the motor
shaft, turn it through 180° and then replace it. The correct boss will now
face outwards allowing you to properly mount the new blade.
7. With the upper blade guard cover secure, tighten the blade securing
bolt using the peg and socket spanners and provided. Do not
overtighten and DO NOT use extensions to the socket spanner lever.
NOTE: The use of HSS blades is NOT recommended.
14
Fig.10

If you find that the cross cut is not entirely square, it will be necessary to
adjust the head using the 90° adjuster screw shown in Fig. 2 on page 8.
To do this, place a small square on the table. Lower the arm, and bring
the square up to the blade to test for accuracy.
Should any adjustment be required, slacken off the Bevel Locking Nut
and the 90° adjuster screw securing nut, then screw the adjuster
accordingly whilst holding the head firmly against the stop. Tighten the
securing nut when the head is exactly perpendicular.
Similarly should the 45° stop require adjusting, use a 45° template up against
the saw blade to set the adjuster to the correct position.
ADJUSTMENTS
SPECIFICATIONS
Motor: .................................................. 230V 50Hz 1 phase.
Running Current ....................... 5Amps
Power Rating: ........................... 800 Watts
Speed: ...................................... 4500RPM
Fuse Rating ........................................... 13Amps
Dimensions: (Head Lowered) ............. 365x345x270mm
Dimensions: (Head Raised) ................ 365x345x410mm
Blade size: (Fitted) ............................... 205mm 40T 18mm Bore
Noise level ........................................... 109.7dB at 1M
Vibration Level ..................................... 22.2m/s² (Normal Load)
Gross weight ....................................... 7.2kg
Part Number ......................................... 6500755
15
Please note that the details and specifications contained herein, are correct at the time of going to
print. However, CLARKE International reserve the right to change specifications at any time without
prior notice. Always consult the machine’s data plate
Type of Cut Depth Thickness
Cross (90°) 50mm 100mm
Mitre (at 45°) 50mm 70mm
Bevel (at 45°) 35mm 100mm
Compound (at 2x 45°) 35mm 70mm
Maximum Cutting Sizes

PARTS DIAGRAM
16

PARTS LIST
No. Description Part No.
1 Foot HTCMS20001
2 Clamp HTCMS20002
3 Base HTCMS20003
4 Turntable HTCMS20004
5 Washer HTCMS20005
6 Backfence HTCMS20006
7 Screw, M6X28 HTCMS20007
8 Eccentric spacer HTCMS20008
9 Screw, M6X16 HTCMS20009
10 Screw HTCMS20010
11 Support base HTCMS20011
12 Screw, fixed HTCMS20012
13 Nut, M8 HTCMS20013
14 Screw, M5X18 HTCMS20014
15 Nut, M5 HTCMS20015
16 Screw, M6X16 HTCMS20016
17 Roker arm HTCMS20017
18 Guard HTCMS20018
19 Screw, M5X12 HTCMS20019
20 Main Pivot HTCMS20020
21 Bolt HTCMS20021
22 Bracket HTCMS20022
23 Pressure sleeve HTCMS20023
24 Long nut HTCMS20024
25 Spring HTCMS20025
26 Nut, MS HTCMS20026
27 Guard cover HTCMS20027
28 Spring HTCMS20028
29 Positioning screw HTCMS20029
30 Washer HTCMS20030
31 Frame HTCMS20031
32 Washer HTCMS20032
33 Fixed washer HTCMS20033
34 Nut, HTCMS20034
35 Pin HTCMS20035
36 Washer HTCMS20036
37 Push rod HTCMS20037
38 Positioning bolt HTCMS20038
39 Spring HTCMS20039
40 Washer HTCMS20040
41 Cable support HTCMS20041
42 Screw, M5X12 HTCMS20042
43 Cord clamp HTCMS20043
44 Screw, M4X12 HTCMS20044
44 Bolt, M6X45 HTCMS20045
46 Nut, M6 HTCMS20046
47 Nut, MS HTCMS20047
48 Bush, HK0709 HTCMS20048
49 Washer HTCMS20049
50 Key HTCMS20050
51 Gear HTCMS20051
52 Transmission shaft HTCMS20052
53 Ball bearing base HTCMS20053
54 Screw, M4X50 HTCMS20054
55 Ball bearing HTCMS20055
56 Precision washer HTCMS20056
57 Cover HTCMS20057
58 Screw, M4X8 HTCMS20058
59 Inner Flange HTCMS20059
60 Saw Blade HTCMS20060
61 Outer Flange HTCMS20061
62 Spring washer HTCMS20062
63 Bolt, M8X25 HTCMS20063
64 Ball bearing HTCMS20064
65 Armature HTCMS20065
66 Ball bearing HTCMS20066
67 Plate HTCMS20067
68 Screw, M4X58 HTCMS20068
69 Stator assy. HTCMS20069
70 Casing HTCMS20070
71 Brush HTCMS20071
72 Bush spring HTCMS20072
73 Brush holder HTCMS20073
74 Inducer HTCMS20074
75 Rear cover HTCMS20075
76 Screw, HTCMS20076
77 Handle LH HTCMS20077
78 Screw, M4X18 HTCMS20078
79 Capacitor HTCMS20079
80 Switch HTCMS20080
81 Nut, MS HTCMS20081
82 Screw, M5X11 HTCMS20082
83 Cable shroud HTCMS20083
84 Power cable HTCMS20084
85 Handle RH HTCMS20085
86 Cover HTCMS20086
87 Screw, M4X34 HTCMS20087
88 Locking knob HTCMS20088
89 Frame HTCMS20089
90 Square washer HTCMS20090
91 Screw, M6X12 HTCMS20091
No. Description Part No.
17

19