Clarke CSS16VB Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
LS0216
VARIABLE SPEED SCROLL SAW
MODEL NO: CSS16VB
PART NO: 6462147

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INTRODUCTION
Thank you for purchasing this CLARKE Variable Speed Scroll Saw.
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.
ENVIRONMENTAL PROTECTION
Recycle unwanted materials instead of disposing of them as
waste. All tools, accessories and packaging should be sorted,
taken to a recycling centre and disposed of in a manner which is
compatible with the environment.
1 x Scroll Saw 2 x 'Pin-less' Blade Clamp Adaptors
1 x 2.5 mm Hexagon Key 1 x Blade 133mm x 2.5mm x 15 t.p.i
1 x Blade Guard Assembly 1 x Blade 133mm x 2.5mm x 18 t.p.i.
1 x T-handled 3.0 mm Hex
Key

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GENERAL SAFETY INSTRUCTIONS
1. Keep work area clear - Cluttered areas and benches invite injuries.
2. Consider work area environment
• Do not expose tools to rain.
• Do not use tools in damp or wet locations.
• Keep work area well lit.
• Do not use tools in the presence of flammable liquids or gases.
3. Guard against electric shock - Avoid body contact with earthed or grounded
surfaces (e.g. pipes, radiators, ranges, refrigerators).
4. Keep other persons away - Do not let persons, especially children, not involved in
the work touch the tool or the extension cord and keep them away from the work
area.
5. Store idle tools - When not in use, tools should be stored in a dry locked-up place,
out of reach of children.
6. Do not force the tool - It will do the job better and safer at the rate for which it was
intended.
7. Use the right tool
• Do not force small tools to do the job of a heavy duty tool.
• Do not use tools for purposes not intended; for example do not use circular
saws to cut tree limbs or logs.
8. Dress properly
• Do not wear loose clothing or jewellery, they can be caught in moving parts.
• Non-skid footwear is recommended when working outdoors.
• Wear protective hair covering to contain long hair.
9. Use protective equipment
• Use safety glasses.
• Use face or dust mask if working operations create dust. <II
10. Connect dust extraction equipment - If the tool is provided for the connection of
dust extraction and collecting equipment, ensure these are connected and
properly used.
11. Do not abuse the cord - Never yank the cord to disconnect it from the socket. Keep
the cord away from heat, oil and sharp edges.
12. Secure work - Where possible use clamps or a vice to hold the work. It is safer than
using your hand.
13. Do not overreach - Keep proper footing and balance at all times.

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14. Maintain tools with care
• Keep cutting tools sharp and clean for better and safer performance.
• Follow instruction for lubricating and changing accessories.
• Inspect tool cords periodically and if damaged have them repaired by an
authorized service facility.
• Inspect extension cords periodically and replace if damaged.
• Keep handles dry, clean and free from oil and grease.
15. Disconnect tools - When not in use, before servicing and when changing
accessories such as blades, bits and cutters, disconnect tools from the power supply.
16. Remove adjusting keys and wrenches - Form the habit of checking to see that keys
and adjusting wrenches are removed from the tool before turning it on.
17. Avoid unintentional starting - Ensure switch is in "off' position when plugging in.
18. Use outdoor extension leads - When the tool is used outdoors, use only extension
cords intended for outdoor use and so marked.
19. Stay alert - Watch what you are doing, use common sense and do not operate the
tool when you are tired.
20. Check damaged parts
• Before further use of tool, it should be carefully checked to determine that it
will operate properly and perform its intended function.
• Check for alignment of moving parts, binding of moving parts, breakage of
parts, mounting and any other conditions that may affect its operation.
• A guard or other part that is damaged should be properly repaired or
replaced by an authorized service centre unless otherwise indicated in this
instruction manual.
• Have defective switches replaced by an authorized service centre.
• Do not use the tool if the switch does not tum it on and off.
21. Warning - The use of any accessory or attachment other than one recommended in
this instruction manual may present a risk of personal injury.
22. Have your tool repaired by a qualified person - This electric tool complies with the
relevant safety rules. Repairs should only be carried out by qualified persons using
original spare parts, otherwise this may result in considerable danger to the user.

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SCROLL SAW SAFETY INSTRUCTIONS
1. Wear safety goggles as protection against flying wood chips and saw dust. In many
cases, a full face shield offers even better protection.
2. A dust mask is recommended to keep saw dust out of your lungs.
3. The scroll saw must be bolted securely to a stand or workbench. If the saw has a
tendency to move during certain operations, bolt the stand or workbench to the
floor.
4. A solid wood workbench is stronger and more stable than a workbench with a
plywood table.
5. This scroll saw is for indoor use only.
6. Do not cut pieces of material which are too small to be held by hand.
7. Clear the work table of all objects except the workpiece (tools, scraps, rulers etc.)
before turning the saw on.
8. Make sure the blades’ teeth are pointing down, toward the table, and that the
blade tension is correct.
9. When cutting a large piece of material, support it at the height of the table.
10. Do not feed the workpiece through the blade too fast. Feed only as fast as the
blade will cut.
11. Keep your fingers away from the blade. Use a push stick as you near the end of the
cut.
12. Take care when cutting a workpiece which is irregular in cross section. Mouldings for
example must lie flat, and not ‘rock’ on the table while being cut. A suitable support
must be used.
13. Switch off the saw, and make sure the blade has come to a complete stop before
clearing sawdust or off-cuts from the table.
14. Make sure there are no nails or foreign objects in the part of the workpiece to be
sawn.
15. Be extra cautious with very large or small, or irregularly shaped workpieces.
16. Set up the machine and make all adjustments with the power OFF, and
disconnected from the supply.
17. DO NOT operate the machine with the covers off. They must all be in place and
securely fastened when performing any operation
18. Be sure to use the correct blade size and type.
19. Use ONLY approved replacement saw blades. Contact your local CLARKE dealer for
advice. The use of inferior blades may increase the risk of injury.

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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.
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)

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OVERVIEW
NO DESCRIPTION NO DESCRIPTION
1 Blade guard 9 Dust extraction outlet
2 Top blade holder 10 Table tilt lock knob
3 Workpiece pressure plate 11 Angle adjustment scale
4 Sawdust blower nozzle 12 Saw table
5 Blade 13 Blade tension knob
6 Table insert 14 Hose (sawdust blower)
7 Blade speed regulator 15 Pinless Blade Adaptor
8On/Offswitch

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MOUNTING THE SCROLL SAW
BOLTING THE SCROLL SAW ONTO A WORKBENCH
1. It is recommended that this saw is securely mounted onto a robust
workbench. We recommend that you use the following fixings (not
supplied).
• 4 x Hex bolts M8
• 4 x Hex nuts M8
• 4 x Flat washer Ø 8 mm
2. We recommend that a rubber fine rib matt 420 x 250 x 3 mm (minimum)
13 mm (maximum) is fixed between the workbench and scroll saw to help
minimise vibrations and noise. This mat is not supplied.
• Suitable rubber matting of various thicknesses is available from your
Clarke dealer.
NOTE: Do not over-tighten the screws. Leave enough give for the rubber
mat to absorb any vibration.
WARNING: DO NOT PLUG SAW INTO MAINS UNTIL THE SAW HAS BEEN
FIRMLY MOUNTED TO WORK SURFACE.

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BEFORE CONNECTING TO THE ELECTRICAL SUPPLY
CHOOSING THE RIGHT BLADE
NOTE: As a rule, select narrow blades for intricate curve cutting and
wide blades for straight and large curve cutting.
Scroll saw blades wear out and must be replaced frequently for optimum
cutting results.
Scroll saw blades generally become dull after 1/2 hour to 2 hours of cutting,
depending on the type of material and speed of operation.
Best results are achieved with pieces less than one inch (25 mm) thick.
When cutting workpieces thicker than one inch (25 mm), you must guide the
blade into the workpiece very slowly and take extra care not to bend or twist
the blade while cutting.
PINLESS BLADE ADAPTOR
The pinless blade adaptor allows you to use blades that don't have locating
pins at each end of the blade.
1. Adjust one set screw on each
adaptor until it covers
approximately half the hole when
viewed from above
2. Loosen the other set screw just
enough to slide an adaptor onto
each end of the blade.

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3. Place the blade and adaptors
into the gauge on top of the
machine to set the blade to the
proper length.
CUTTING AT RIGHT ANGLES TO THE UPPER ARM WHEN USING PINLESS BLADES
• Cutting from the side of the saw will be necessary when your workpiece
exceeds 405mm in length. With the blade positioned for side cutting the
table must always remain in the 0° bevel position.
1. Remove both set screws from each blade adaptor, thread them into the
opposite holes in the blade adaptor perpendicular to the adjustment pin.
BLADE TENSION
• Turning the blade tension knob
counterclockwise decreases
(slackens) blade tension.
• Turning the blade tension knob
clockwise increases (or
tightens) blade tension.
1. Pluck the back straight edge of
the blade while turning the
tension adjusting knob.
• The sound becomes higher pitched as tension increases.
NOTE: Do not over-tension the blade. This will help to prolong the life of
the saw blade.
NOTE: Too little tension may cause the blade to bend or break.

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INSTALLING BLADES
1. Unplug the saw from the power source.
2. Remove the table insert.
3. Turn the blade tension knob
anticlockwise to remove the
tension from the saw blade (if
fitted).
• The following replacement
blades are available from your
Clarke Dealer, : 15TPI (Part No:
AWNCSS400C035A) 18TPI (Part
No AWNCSS400C035B)
4. Press down the upper arm and
hook the blade to the blade
holder. The blade holder has two
slots.
•Useslot1 to cut in line with the
upper arm.
•Useslot2 to cut at right angles
to the upper arm.
• If you are using pinless blades
hook the blade adaptor to the
front of the blade holder.
5. Turn the blade tension knob
clockwise to re-tension the blade.
6. Replace the table insert.

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REMOVING BLADES
1. Turn off the saw and unplug it from the power source.
2. Remove the table insert.
3. Turn the blade tension knob
anticlockwise to remove the
tension from the saw blade.
4. Press down on the top blade
holder and remove the blade.
5. Remove the blade from the lower
blade holder.
6. Lift the blade up and out.
TILTING THE SAW TABLE
1. Undo the table lock knob.
2. Tilt the table to the required angle
then tighten the table lock knob
to secure.
IMPORTANT: For precision work you
should first carry out a trial cut and
then re-adjust the tilt angle as
required.
For precise work always double
check the angle of the saw table
with a protractor or similar angle measure.

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SQUARING THE SAW TABLE TO THE BLADE
1. Loosen the pressure plate
adjustment knob.
2. Raise the pressure plate and lock
it in the raised position.
3. Loosen the table lock knob and
tilt the table until it is
approximately at right angles to
the blade.
4. Place a small square on the saw
table next to blade and lock the
table at 90° to square.
5. Retighten the table lock knob
SETTING THE SCALE INDICATOR
6. Loosen the securing screw holding
the scale indicator. Move the
indicator to the 0° mark and
securely tighten the screw.
• Remember, the scale is a guide
only and should not be relied
upon for precision.
• Make practice cuts on scrap
material to ensure your angle
settings are correct.
7. Lower the pressure plate so it just rests on top of the workpiece and secure
in place.
WARNING: TO AVOID ACCIDENTAL STARTING WHICH COULD RESULT IN
SERIOUS INJURY, TURN THE SAW OFF, AND UNPLUG THE SAW FROM THE
POWER SOURCE.

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ON / OFF SWITCH
To start the saw, press the ON button
(I). To stop, press the OFF button (O).
NOTE: The machine is equipped
with a magnetic switch to
prevent it being switched on
again accidentally after a
power failure.
SPEED SETTING
The speed regulator allows you to set
the blade speed appropriate to the
material to be cut.
The speed may be adjusted from 550
to 1600 SPM (Strokes Per Minute).
• To increase the strokes per
minute, turn the speed selector
clockwise.
• To decrease the strokes per
minute, turn the speed selector
counterclockwise.
SAWDUST BLOWER
The sawdust blower is designed and
preset to direct air to the most
effective point on the cutting line.
Make sure the pressure plate is
adjusted to secure the workpiece
and direct air at the cutting surface.

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OPERATION
Before starting a cut, turn the saw on and listen to the sound it makes. If you
notice excessive vibration or an unusual noise, stop the saw immediately and
unplug it. Do not restart the saw until you have corrected the problem.
• It is expected that some blades may break until you learn how to use
and adjust the saw correctly. Plan the way you will hold the workpiece
from start to finish.
• Hold the workpiece firmly against the saw table.
• Use gentle pressure and both hands when feeding the workpiece into
the blade. Do not force the cut.
• Guide the blade into the workpiece slowly because the teeth are very
small and can only remove material on the down stroke.
• Avoid awkward operations and hand positions where a sudden slip
could cause serious injury from contact with the blade. Never place
your hands in the blade path.
• When cutting irregularly shaped workpieces, plan your cut so the
workpiece will not pinch the blade.
CARRYING OUT INTERNAL CUTS
One feature of a scroll saw is that it can be used to make scroll cuts within a
workpiece without breaking or cutting through the edge or perimeter of the
workpiece.
1. To carry out internal cuts in a workpiece, firstly remove the blade.
2. Drill a 6.3 mm (1/4”) hole inside the boundary of the aperture to be cut
from the workpiece.
3. Place the workpiece on the saw table with the drilled hole above the
blade access hole.
4. Install the blade through the hole in the workpiece and adjust the blade
tension.
5. When you have completed the internal cuts, remove the blade from the
blade holders and take the workpiece off the table.
WARNING: BEFORE REMOVING OFFCUTS FROM THE TABLE, TURN THE SAW
OFF AND WAIT FOR THE BLADE TO COME TO A FULL STOP TO AVOID
SERIOUS PERSONAL INJURY.

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STACK CUTTING
Stack cutting may be used when several identical shapes need to be cut.
Several workpieces may be stacked one on top of the other and secured to
each other before cutting.
Pieces of wood may be joined together by placing double sided tape
between each piece or by wrapping tape around the corners or ends of the
stacked wood.
The stacked pieces must be attached to each other in such a way that they
can be handled on the table as a single workpiece.
WHAT TO DO IF THE SAW BLADE JAMS IN THE WORKPIECE
When withdrawing the workpiece, the blade may bind in the kerf (cut). This is
usually caused by sawdust clogging the kerf or by the blade coming out of
the blade holders. If this happens:
1. Place the switch in the OFF position.
2. Wait until the saw has stopped and unplug it from the power source.
3. Remove the blade and the workpiece.
Wedge the kerf open with a small flat screwdriver or wooden wedge then
remove the blade from the workpiece.
WARNING: TO AVOID SERIOUS PERSONAL INJURY, DO NOT CUT SEVERAL
WORKPIECES AT A TIME UNLESS THEY ARE PROPERLY ATTACHED TO EACH
OTHER.

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MAINTENANCE
GENERAL MAINTENANCE
• Keep your scroll saw clean.
• Do not allow pitch to accumulate on the saw table. Clean it with
gum and pitch remover.
POWER CABLE
CLEANING
• Never use water or chemical cleaners to clean your scroll saw. Wipe
clean with a dry cloth.
• Always store your scroll saw in a dry place. Keep all working controls
free of dust.
LUBRICATION
Lubricate the arm bearings with oil after 10 hours of use. Re-oil after every 50
hours of use or whenever there is a squeak coming from the bearings as
follows:
1. Turn saw on its side.
2. Prise off the rubber caps covering the pivot shafts.
3. Squirt a small amount of SAE 20 oil around the shaft end and bronze
bearing.
4. Let the oil soak in overnight in this condition. Next day repeat the above
procedure for the opposite side of the saw.
WARNING: TURN OFF AND UNPLUG THE SAW BEFORE CARRYING OUT ANY
MAINTENANCE WORK ON YOUR SCROLL SAW.
WARNING: IF THE POWER CABLE IS WORN, CUT, OR DAMAGED IN ANY
WAY, HAVE IT REPLACED IMMEDIATELY BY A QUALIFIED SERVICE
TECHNICIAN. FAILURE TO DO SO COULD RESULT IN SERIOUS PERSONAL
INJURY.

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REPLACE CARBON BRUSHES
Your saw has externally accessible carbon brushes that should be checked
periodically for wear.
1. Using a flat blade screwdriver,
remove the top brush assembly
cap from the top of the motor.
2. Gently pry the brush assembly out
using a small screwdriver.
3. The second carbon brush can be
accessed through the access port
on the bottom of the motor.
Remove this in the same way.
• If either of the brushes are
shorter than 1/4 in. (6 mm), replace both brushes as a pair.
4. Make sure the brush cap is positioned correctly (straight). Tighten the
carbon brush cap using a hand screwdriver only. Do not overtighten.
SPECIFICATIONS
WARNING: TURN OFF AND UNPLUG THE SAW BEFORE CARRYING OUT ANY
MAINTENANCE WORK ON YOUR SCROLL SAW.
Model Number CSS16VB
Rated Voltage (V) 230 V
Input Power 90 W
Throat Depth 406 mm
Max. Cut 50 mm
Stroke 15 mm
Speed 550 - 1600 strokes per minute
Table Size 415 x 255 mm
Table Tilt 0-45o
Sound Power (Lwa dB) 87.4 dB
Dimensions (L x W x H) 610 x 320 x 360 mm
Weight 10 kg

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DECLARATION OF CONFORMITY