Clarke WOODWORKER CBS205 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS DL1020 ISS 1
195MM BENCH TOP BANDSAW
MODEL NO: CBS205
PART NO: 6460072

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INTRODUCTION
Thank you for purchasing this CLARKE 8” (203mm) Bench Top Bandsaw.
Before attempting to operate the machine, it is essential that you read this
manual thoroughly and carefully follow all instructions given. In doing so you
will ensure the safety of yourself and that of others around you, and you can
also look forward to the product 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.
ENVIRONMENTAL PROTECTION
Recycle unwanted materials instead of disposing of them as waste. All
unwanted accessories and packaging should be sorted and taken to a
recycling centre for disposal in a manner which is compatible with the
environment.
ENVIRONMENTAL RECYCLING POLICY
Through purchase of this product, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the WEEE.
In effect, this means that this product must not be disposed of with general
household waste but according to the laws governing Waste Electrical and
Electronic Equipment (WEEE) at a recognised disposal facility.

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SAFETY WARNINGS
WORK ENVIRONMENT
1. Keep the work area clean and well lit. Cluttered and dark areas invite
accidents.
2. DO NOT operate power tools in explosive atmospheres, such as in the
presence of flammable liquids, gases or dust. Power tools create sparks
which may ignite the dust or fumes.
3. Keep children and bystanders away while operating a power tool. Anyone
entering the work area must wear personal protective equipment.
Distractions can cause you to lose control and fragments of work or a
broken blade may fly away and cause injury.
4. Store power tools properly when not in use. Abrasive products should be
stored in a dry, secure place out of the reach of children.
5. Please read these instructions carefully and retain for future reference.
ELECTRICAL SAFETY
1. Power tool plugs must match the outlet. NEVER modify the plug in any way.
DO NOT use adapter plugs with earthed (grounded) power tools.
Unmodified plugs and matching outlets will reduce the risk of electric
shock.
2. DO NOT expose power tools to rain or wet conditions. Water entering a
power tool will increase the risk of electric shock.
3. DO NOT abuse the cable. NEVER use the cable for carrying, pulling or
unplugging the power tool. Keep the cable away from heat, oil, sharp
edges or moving parts. Damaged or entangled cables increase the risk of
electric shock.
4. Position the power cable so that it cannot be inadvertently pulled or
pinched and where it does not cause a trip hazard.
5. Never use the machine if the electric cable or plug is in poor condition.
6. This machine is designed for indoor environments and must not be used for
other purposes.
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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7. If the machine requires repair, always contact your CLARKE dealer. Always
insist on original spare parts. Repairs carried out by unauthorized persons
may be dangerous and invalidate the guarantee.
8. Before cleaning or maintenance operations, always unplug the machine
from the power supply.
PERSONAL SAFETY
1. Stay alert, watch what you are doing and use common sense when
operating a power tool. DO NOT use a power tool while you are tired or
under the influence of drugs, alcohol or medication. A moment of
inattention while operating power tools may result in personal injury.
2. Use personal protective equipment. Always wear eye protection. Safety
equipment such as dust mask, non-skid safety shoes, hearing protection
and a workshop apron capable of stopping small abrasive or workpiece
fragments.
3. Avoid accidental starting. Ensure the switch is in the off position before
plugging in. Plugging in power tools that have the switch on invites
accidents.
4. Remove any adjusting key or wrench before turning the power tool on. A
wrench or a key left attached to a rotating part of the power tool may
result in personal injury.
5. DO NOT overreach. Keep proper footing and balance at all times. This
enables better control of the power tool in unexpected situations. Dress
properly. Do not wear loose clothing or jewellery.
6. Keep your hair, clothing and gloves away from moving parts. Loose
clothes, jewellery or long hair can be caught in moving parts. Keep the
work area clean and tidy.
7. Avoid operator fatigue. Stop the power tool at regular intervals for a short
break to rest hands and arms.
8. Maintain your tools. Keep all working surfaces dry and clean.
POWER TOOL USE AND CARE
1. DO NOT force the machine. Use the correct power tool for your
application. It will do a better and safer job at the rate for which it was
designed.
2. DO NOT use the power tool if the switch does not turn it on and off. Any
power tool that cannot be controlled with the switch is dangerous and
must be repaired.
3. Disconnect the power tool from the power supply before making any
adjustments, changing accessories, or storing the tool. These measures will
reduce the risk of the power tool starting accidently.

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4. Store power tools out of the reach of children and do not allow persons
unfamiliar with these instructions to operate the power tool. Power tools are
potentially dangerous in the hands of untrained users.
5. Maintain power tools in top condition. Keep tools/ machines clean for the
best and safest performance. Check for misalignment or binding of
moving parts, broken parts, or any condition that may affect the power
tool’s operation. If damaged, have the power tool repaired before use.
Many accidents are caused by poorly maintained power tools.
6. Use recommended accessories. The use of improper accessories could be
hazardous.
7. Machine cleanliness. DO NOT allow the ventilation slots in the machine to
become blocked with dust. Regularly clean the power tool’s air vents. The
motor fan will draw dust inside the housing and accumulation of material
could cause electrical hazards.
8. Check the power tool for damage before using the machine. Any
damaged part should be inspected 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 CLARKE
dealer.
SERVICING
1. When necessary, have your power tools serviced or repaired by a qualified
person using identical replacement parts. This will ensure that the safety of
the power tool is maintained.
ADDITIONAL PRECAUTIONS FOR BANDSAWS
1. ALWAYS check safety guards are in place and functioning correctly before
switching the machine on.
2. ALWAYS use a push stick & fence for small workpieces wherever practical.
3. ALWAYS use the appropriate saw blade for the material being cut.
4. NEVER touch the blade immediately after use, when changing the blade
always allow time for it to cool.
5. NEVER use damaged blades. (Replacement blades are available from
your CLARKE dealer).
6. NEVER attempt any maintenance or adjustments of the saw band when it
is in motion.
7. DO NOT remove jammed cut off pieces until the blade has stopped.
8. Replace the table insert if the slot has become enlarged.

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9. When cutting wood, ensure any nails or fastenings have been removed
beforehand. Nails will damage the saw blade.
10. When cutting round timber stock, use a suitable jig or fixture to keep the
work from turning.
11. Always ensure the blade is fully tightened and correctly adjusted before
use.
12. Keep the mains cable well away from the working parts of 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.
13. Switch the machine off as soon as the task is completed.
SAFETY SYMBOLS
The following safety symbols may be found on the machine.
Read the manual
and safety
instructions before
use
Eye protection
should be worn
Ear protection
should be worn
Dust mask should be
worn
HAZARD, Motor
gets hot
Disconnect from
power source before
maintenance or
repair
HAZARD, Sharp
Blade

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SPECIFICATIONS
CBS205
Weight 16.9 kg
Dimensions (W x D x H) 391 x 455 x 681 mm
Table Size (W x D) 302 x 304 mm
Throat Width 195 mm
Table Tilt Angle 90 - 45o
Maximum Cutting Depth @ 90o80 mm
Maximum Cutting Depth @ 45o45 mm
Height of Fence 52 mm
Power supply 230V - 50Hz
Rated Input Wattage @230V 250 W
Motor speed 1487 rpm
Blade Speeds 15.83 m/sec
Duty Cycle S2
Sound Pressure Level (Lp) 82.6 dB(A)
Sound Power Level Measured (Lw) 93.6 dB(A)
Blade dimensions
Blade Length (welded loop) 1400 mm
Blade Width 6.35 mm
Blade Tooth Pitch 6 tpi
Blade thickness 0.8 mm

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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.
•TheBlue wire must be connected to the terminal marked Nor coloured
Black.
•TheBrown wire must be connected to the terminal marked Lor coloured
Red.
•TheYellow and Green wire must be connected to the terminal marked Eor
coloured Green.
.
It is 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.
Plug must be BS1363/A Class 1 approved.
Always fit a 5 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 & CONTENTS
Make sure that all parts are un-damaged and are present. If any parts are
missing or damaged please contact your CLARKE dealer immediately.
NODESCRIPTION NODESCRIPTION
1 Bandsaw Assembly 8 Table Nuts (M6), Bolts & Washers
2 Table 9 Push Stick Hook/Nut & Bolt (M6)
3 Parallel Rip Fence Assembly 10 Table Stop Bolt & Lock Nut (M6)
4 Spanner 11 Blade tension Setting Knob
5 Push Stick 12 Upper Cover Release Knob
6 Allen Keys (3mm & 5mm) 13 Lower Cover Release Knob
7 U Shaped Blocker c/w Nuts
(M6) & Bolts
14 Start/Stop Buttons

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ASSEMBLY
PREPARATION
For maximum stability the bandsaw should be bolted firmly to either a
workbench, a suitable stand, or a piece of plywood, 5/8”(15.9mm) thick, and
the plywood should be clamped firmly to a workbench whenever the
bandsaw is being used.
The saw must be located in an area large enough to allow you to work freely,
taking into account the likely size of your workpiece, ensuring adequate
lighting.
Make sure also that an adequate electrical supply is close by. Take extra care
if extension leads are used. Make sure that there is no possibility of tripping
over the lead when moving around the work area.
FITTING THE TABLE
1. Place the bandsaw on a flat level
surface
2. Remove the U Shaped Blocker
from the table (if fitted).
3. Fit the table to the bandsaw using
3mm allen key x 3 nuts and bolts
and 18mm flat washers (A,B & C).
Ensure the saw blade is central in
the table slot.
4. Screw the table stop bolt into the
underneath of the table (See page 11).
5. Re-fit the U Shaped Blocker to the table.
6. Hang the push stick and spanner on the hook/nut on the side of the
machine for safe keeping.
7. Fit the rip fence to the table if
required.

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ADJUSTING THE COMPONENTS
TILTING THE TABLE
1. Loosen the table tilt knobs and
adjust the table to the desired
angle.
2. Use the angle indicator scale on
the table tilting bracket, to find
the desired angle.
3. Re-tighten the table tilt knobs to
secure the table. For assured
accuracy, we recommend
checking the tilt angle using a set
square.
4. With the table exactly level, it
should rest on the stop bolt shown.
Adjust the height of the bolt by
screwing it in or out of the table
and securing with the locknut.
Check with a set square that the
table is exactly level when resting
on the stop bolt.
TRACKING THE SAW BLADE
1. Open the upper and lower covers
by releasing the cover knobs on
the front of the machine.
• The panels will not open unless the
twist knobs are first released.
2. Manually rotate the upper wheel,
taking care of the sharp blade.
If the saw blade does not run on the
centre of the rubber tyre, the
tracking needs to be corrected
before use by adjusting the tilt angle of the upper bandsaw wheel.
3. Turn the blade tracking knob clockwise or anticlockwise until the saw
blade tracks centrally on the rubber tyre of both wheels.

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4. After adjusting, close both covers.
ADJUSTING THE BLADE TENSION
1. ALWAYS make sure the machine is
unplugged from the power supply
2. Raise the upper blade guide fully
by twisting the blade guide
setting knob.
3. Check the tension by pressing
with a finger against the side of
the blade, halfway between the
table and upper guide.
• The blade should not flex
sideways by more than 2 mm at its longest span.
4. Turn the blade tension knob to adjust the tension.
• Turning the blade tension knob clockwise will increase the blade tension.
BLADE GUIDES / BEARING SETTING
The upper and lower blade guides
need to be re-adjusted after any
blade change or tracking
adjustment.
1. Loosen the set-screws (A) and
position the guide pins 0.5 mm
from the blade. Tighten the set
screws.
2. Loosen the socket-headed bolt
(B) and adjust guide pin carrier
position, so that guide pins are positioned 1- 2mm from teeth of blade.
Retighten the socket-headed bolt (B).
3. Repeat the process with the lower blade guide located in the lower
section of the bandsaw.
• Note that the lower guide assembly is identical but installed upside-down.
and that access to the socket-headed bolt (B) is through the holes
provided.
CAUTION: TOO MUCH TENSION CAN CAUSE THE SAW BLADE TO BREAK.
TOO LITTLE TENSION CAN CAUSE THE BLADE TO MAKE IRREGULAR
(WANEY) CUTS.

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.
UPPER BLADE GUIDE ADJUSTMENT
The height of the upper blade guide
needs to be adjusted prior to every
cutting operation to accommodate
the height of the workpiece.
The upper blade guide should be set
approx 3 mm above the workpiece.
Set the upper blade guide by turning
the adjusting knob to the desired
height and securing in position with
the locking knob.
PREPARING FOR WORK
1. Press the green button to start the
bandsaw.
2. Press the red button to stop the
machine at any time.

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USING THE FENCE
The fence can be used on both sides of the blade.
1. Engage the fence with the table
and move to the required
position. The scale indicates the
distance from the saw blade to
the fence.
2. Ensure the fence is parallel to the
blade groove.
3. Press down the locking lever to
clamp the fence in position.
CONNECTING TO A DUST COLLECTOR
This bandsaw is fitted with a dust port
for connection to a dust collector if
available.
• The connector size is 36 mm i/d
(40 mm o/d)
USING THE PUSH STICK
The push-stick serves as an extension of
the operators hand as protection
against accidentally touching the saw
blade.
The push-stick should be used if the rip
fence is close to the blade.
When not in use, the push-stick can be
stored on the hook provided on the
bandsaw frame.

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PRACTICAL OPERATION
Before commencing work, ensure the work area is clean and tidy and the
machine table is clear of tools etc. Plan your work carefully and set the
machine up accordingly before switching on.
• Check the blade is correctly tensioned before use (see page 12).
• Set the upper blade guide as close as practical to the workpiece. This
provides the best safety for the operator and giving more accurate results
and greater control.
• Adjust the height of the upper blade guide to achieve the best control. The
guide should always be set to just clear the top of the workpiece by
approximately 3mm.
• Switch on and allow the saw blade to reach full speed before proceeding.
• Use both hands to feed the workpiece. The work must be held flat on the
table at all times to prevent binding with the blade. Use a steady, even
pressure, just sufficient to keep the blade cutting.
• Always use the rip fence where possible to eliminate any sideways
movement of the work. This is most important when the table is tilted at an
angle.
• Remember that the blade removes material during the cut creating a gap
called the ‘kerf’, which must be allowed for when cutting to exact sizes.
Plan your cut so that the kerf is the scrap side of the line you wish to cut.
Where necessary, allow a little more material for finishing.
• Always use a suitable holding device when cutting round or irregular
shaped timber to prevent twisting of the work piece.
TYPES OF CUT
Several types of cut are possible with this saw i.e. rip cutting, cross cutting,
freehand cutting.
RIP CUTTING
This term refers to cutting timber in the same direction as the grain, rather than
across it. You can rip wood freehand to a drawn pencil line, but best results
are obtained by using the rip fence.
If the table is set level, set the rip-fence to the left hand side of the blade,
allowing you to use your right hand to hold the work firmly against the fence.
The scale on the table indicates the distance of the fence from the saw blade
and can be used as shown on page 14.

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When cutting a bevel rip, with the table tilted at any angle up to 45o, set the
rip fence to the right hand side of the blade if the width of the workpiece
allows it. With the fence on the ‘downhill’ side of the table, it will help support
the workpiece.
The width of cut indicator (scale) on the guide rail may be used to set the rip
fence to the required cutting position.
Long workpieces may require additional support in the form of blocks or rollers
and may be pulled as well as pushed to pass them through the bandsaw.
CROSS CUTTING
This term refers to cutting timber at right angles to the grain. This type of cut
can also be made freehand.
Make sure the work is held firmly against the table. Be careful to keep your
fingers away from the blade, particularly at the end of the cut.
FREEHAND CUTTING
The ease with which many different and varied shapes can be cut is one of
the most important features of the bandsaw.
When freehand cutting, always feed the work slowly so that the blade can
follow the line you wish to cut. Make sure not to drag the work off line, forcing
the blade sideways or twisting it.
In many cases, it is helpful to rough cut about 6mm away from the line. For
difficult curves which may be too tight for the blade, make relief cuts at 90° to
the face of the curve so that these scraps will fall away as the final radius is
sawn.
Each blade has a minimum radius which it will be able to cut, dependant
upon its width. The blade supplied is 6.35mm wide and able to cut as little as
62mm radius, beyond which the stress may cause it to break. If using a
different blade, a bandsaw blade radius chart should be consulted.

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MAINTENANCE
CLEANING
Accumulated dust and chips should be removed from inside the bandsaw
frequently. Open the upper and lower covers, use a soft brush and/or vacuum
cleaner to remove sawdust. If compressed air is used, ensure it is set to no
more than 10 psi and ALWAYS wear eye protection.
At the end of every work session, clean sawdust away from the motor vents.
CHANGING THE SAW BLADE
1. Remove the U shaped blocker
from the table.
2. Open the upper and lower
covers.
3. Set the upper blade guide to its
lowest position.
4. Loosen the blade tension setting
knob until the saw blade has
slackened.
5. Remove the saw blade from the
machine.
6. Fit a fresh saw blade, passing it
behind the side guard and
aligning it with the upper and
lower blade guides. Centre the
blade on the rubber tyres of the
wheels. Ensure the teeth are
pointing downwards towards the
table.
WARNING: ALWAYS SWITCH OFF THE MACHINE AND DISCONNECT FROM
THE POWER SUPPLY BEFORE CARRYING OUT ANY CLEANING OR
MAINTENANCE TASKS.
WARNING: THE TEETH OF THE BLADE ARE SHARP. TAKE CARE WHEN
HANDLING THE BLADE IN SITUATIONS SUCH AS UNPACKING, MOUNTING
OR REPLACING.

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7. Tighten the blade tension setting knob.
8. Set the blade tracking as described on page 11.
9. Close the upper & lower covers.
10. Adjust the blade tension as described on page 12.
11. Adjust the upper blade guide as described on pages 13.
12. Replace the U shaped blocker.
CHANGING THE WHEEL PULLEY TYRES
Eventually the rubber tyres on the bandsaw pulley wheels may wear due to
the constant contact with the blade. Remove the saw blade as described on
page 17, then lift the edge of the tyre with a small screwdriver and carefully
work off the wheel. Ease on the new tyre, ensuring it sits evenly around the
wheel.
We recommend that both tyres are changed at the same time.
BLADE GUIDES
Blade guides should be inspected regularly for wear or chipping, and
replaced if necessary. See page 13 for blade guide adjustments.
BEARINGS
All bearings used in the construction of your bandsaw and its motor are sealed
and lubricated for life.
STORAGE
Switch off the bandsaw and disconnect the power cable.
Cover the machine with a plastic bag and store it in a dry location and out of
the reach of children.
OPTIONAL ACCESSORIES
REPLACEMENT BLADES
Suitable blades are available from your CLARKE stockist:
• 6tpi Bandsaw blade: Part No 6460058
DUST EXTRACTORS
A suitable dust extractor is available from your CLARKE stockist:
• CWVE1 Vacuum Dust Extractor: Part no 6471168

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TROUBLESHOOTING
FAULT CHECK SOLUTION
The unit fails to
operate
1. Check for power failure if
the unit is plugged in.
2. Check the switch is on and
that the fuse is not blown.
3. Upper or lower door
safety switch not
engaged.
1. Plug the unit into the
socket.
2. Replace fuse or switch
on.
3. Check that upper/lower
doors are fully closed
making sure the safety
switches are seated
correctly
Blade breaks 1. Faulty alignment (tracking)
2. Blade guides incorrectly
adjusted.
3. Feeding the work too fast.
4. Forcing or twisting the blade
around a tight radius.
5. Blade too tight.
6. Blunt teeth.
7. Blade is badly welded or
brazed.
8. Wrong blade fitted.
9. Bandsaw left running when
not in use.
1. Carry out tracking
adjustments (p11).
2. Re-adjust blade guides
(p13)
3. Lower the feed rate
4. For tight curves, make
relief cuts fairly close
together at 90º to the
curve. A narrower blade
will make a tighter
curve.
5. Relieve blade tension
6. Renew blade
7. Renew blade
8. Fit only quality blades
supplied by your CLARKE
dealer.
9. Always switch machine
off when not in use.
Noise or vibration 1. Blade not correctly aligned.
2. Guides not securely set.
1. Carry out tracking
adjustments (p11).
2. Tighten the locking
knob. Check guides are
correctly set.
Blade runs off the
cutting line
1. Blade guides incorrectly
adjusted.
2. Blade tracking mal-adjusted
3. Blade tension too slack.
4. Wrong blade fitted (too
thin).
1. Re-adjust blade guides
(p13).
2. Carry out tracking.
adjustment (p11).
3. Re-tension blade.
4. Fit correct blade.

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PAR TS DIAGR AM