Clarke Woodworker CBS250C Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
DL1020 - ISS 1
ORIGINAL INSTRUCTIONS
250MM BANDSAW WITH STAND
MODEL NO: CBS250C
PART NO: 6460141

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INTRODUCTION
Thank you for purchasing this CLARKE 250mm Bandsaw with stand.
Before attempting to operate the machine, it is essential that you read this
manual thoroughly and carefully follow all instructions given.
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.
ENVIRONMENTAL PROTECTION
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 PRECAUTIONS
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
•AV O I D 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 lead 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.
• 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.
8. Use personnel protective equipment
WARNING: WHEN USING ELECTRIC TOOLS BASIC SAFETY PRECAUTIONS
SHOULD ALWAYS BE FOLLOWED TO REDUCE THE RISK OF FIRE, ELECTRIC
SHOCK AND PERSONAL INJURY INCLUDING THE FOLLOWING. READ ALL
THESE INSTRUCTIONS BEFORE ATTEMPTING TO OPERATE THIS PRODUCT
AND SAVE THESE INSTRUCTIONS

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• Use safety glasses.
• Use ear protection
•Usegloves
• Use face or dust mask if working operations create dust
9. Connect dust extraction equipment
• The tool is provided with a connection for dust extraction and collecting
equipment, ensure these are connected and properly used.
10. DO NOT abuse the power cable
•NEVER yank the power cable to disconnect it from the socket. Keep the
power cable away from heat, oil and sharp edges.
11. Secure work
• Where possible use clamps or a vice to hold the work. It is safer than
using your hand.
12. DO NOT overreach
• Keep proper footing and balance at all times.
13. Maintain tools with care
• Keep cutting tools sharp and clean for better and safer performance.
• Follow instruction for lubricating and changing accessories.
• Inspect the tool power cable periodically and if damaged have it
repaired by a CLARKE service facility.
• Inspect extension cabling periodically and replace if damaged.
• Keep handles dry, clean and free from oil and grease.
14. Disconnect tools
• When not in use, before servicing and when changing accessories such
as blades, bits and cutters, disconnect tools from the power supply.
15. 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.
16. AV O I D unintentional starting
• Ensure switch is in the “off” position when plugging in.
17. Stay alert
• Watch what you are doing, use common sense and DO NOT operate
the tool when you are tired or under the influence of drugs or alcohol.
18. Check damaged parts

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• Before further use of the 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 a CLARKE service centre.
• Have defective switches replaced by a CLARKE service centre.
•DO NOT use the tool if the switch does not turn it on and off.
19. WARNING
• The use of any accessory or attachment other than one recommended
in this instruction manual may present a risk of personal injury.
20. Have your tool repaired by a CLARKE service centre.
• 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.
ADDITIONAL
1. Position the fence on the lower side of the table when bevel-cutting with
the table inclined;
2. Use a suitable holding device when cutting round or irregular shaped
timber to prevent twisting of the work piece;
3. DO NOT use saw blades which are damaged or deformed;
4. DO NOT override the lockout and operate the tool, when the guards
protecting the saw blade is open;
5. DO NOT clean the saw blade whilst it is moving;
6. ALWAYS wear gloves for handling the saw blade and rough material.
7. The push-stick should be used if the distance between the blade and rip
fence is less than approx 150 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 which is marked Nor
coloured Black.
•TheBrown wire must be connected to the terminal which is marked Lor
coloured Red.
•TheYellow and Green wire must be connected to the terminal which is
marked E or coloured Green.
.
WARNING! Read these electrical safety instructions thoroughly
before connecting the product to the mains supply.
WARNING! 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 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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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.
SAFETY SYMBOLS
Read the manual
and safety
instructions before
use
Eye protection
should be worn
Ear protection
should be worn
Dust mask should be
worn
WARNING, Motor
gets hot
Do not touch moving
blade
WARNING, Risk of
injury, use push stick
were possible
Keep children and
bystanders at a safe
distance
Disconnect from
power source
before
maintenance or
repair

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CONTENTS - BANDSAW
Make sure that all parts are un-damaged and are present. If any parts are
missing or damaged please contact your CLARKE dealer immediately.
The following loose components are supplied with the bandsaw assembly.
ITEM DESCRIPTION ITEM DESCRIPTION
1 Bandsaw Assembly 5 Spanner
2 Table 6 Allen Keys (3mm & 4mm)
3 Push Stick 7 Table Insert
4 Parallel Rip Fence Assembly 8 3 x M6 x 16 Bolt, Washer & Nut
1 x M6 x 35 Bolt & Nut

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CONTENTS - STAND
Make sure that all parts are un-damaged and are present. If any parts are
missing or damaged please contact your CLARKE dealer immediately.
The following loose components are supplied with the stand assembly.
ITEM DESCRIPTION ITEM DESCRIPTION
1 2 x Long Beam - 400mm 6 2 x Assisted Support Leg -
190mm x 260mm
2 4 x Stand Legs - 560mm 7 24 x M8 x 16 Bolt, Washer & Nut
4 x M6 x 16 Bolt, Washer & Nut
4 x M8 x 45 Bolt, Washer & Nut
3 2 x Short Beam - 230mm 8 Allen Key (5mm)
4 4 x Rubber Feet 9 2 x Short Support Plate - 400mm
5 2 x Long Support Plate - 570mm

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ASSEMBLY
ASSEMBLE THE STAND
NOTE: All numbers in brackets correspond to the Contents - Stand list on
page 9.
1. Place the rubber feet (4) onto the
ends of the stand legs (2).
2. Attach the 4 stand legs (2) to the
outside of the 2 long beams (1) &
2 short beams (3), securing each
leg with 4 x M8 x 16 bolts, flat
washers and nuts. Hand tighten
nuts only at this stage.
3. Attach the 2 long support plates
(5) and 2 short support plates (9)
to the legs, secure each with 2 x
M8 x 16 bolts, flat washers and
nuts. Hand tighten nuts only at this
stage.
4. Attach the 2 assisted support legs
(6) to the 2 stand legs (2) on the
long support plate (5) side of the
stand, secure each with 2 x M6 x
16 bolts, flat washers and
nuts.Hand tighten nuts only at this
stage.

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MOUNT THE BANDSAW ON TO THE STAND
1. Lift the bandsaw on to the stand,
making sure the motor is on the
same side as the assisted support
legs.
2. Use the 4 x M8 x 45 bolts, washers
and nuts supplied to attach the
band saw to the stand.
• Put the bolts through the base
of the saw from above.
• Install the washers and nuts on
the underside of the stand and tighten to secure.
3. Tighten all bolts and nuts on the saw and stand.
INSTALL THE SAW TABLE
1. Remove the two screws, knurled
nuts and U shaped packer from
the work table.
2. Guide the work table past the
blade and place on the table
trunnion. Position the table insert
on the work table correctly.
WARNING: WHEN YOU MOUNT THE BAND SAW ON TO THE STAND WE
RECOMMEND THAT YOU GET HELP BECAUSE OF THE WEIGHT OF THE
BANDSAW.

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3. Attach the work table with 3 x M6
x 16 bolts, washers and nuts.
4. Attach the two screws, knurled
nuts and U shaped packer that
were removed in step one and
fasten
•ALWAYS replace the table insert
when worn.
FIT THE RIP FENCE TO THE TABLE
1. Loosen the locking clamp.
2. Slide the rip fence onto the table.
3. Tighten the locking clamp to
secure the rip fence in place.
CONNECTING TO A DUST COLLECTOR
This bandsaw is fitted with a dust port
to enable connection to a dust
collector.
• Outside Diameter 40 mm
• Inside Diameter 35 mm
The bandsaw is now ready to use.

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FUNCTIONS
SWITCHING ON/OFF
1. Press the green ON/START (I)
button to start the bandsaw.
2. Press the red OFF/STOP (O) button
to stop the bandsaw.
NOTE: The blade may continue to
rotate for a short time before
coming to a complete stop.
UPPER BLADE GUARD ADJUSTMENT
1. Rotate the blade guard
adjustment knob:
• Clockwise to raise the blade
guard
• Anti-clockwise to lower the
blade guard.
NOTE: The blade guard should be
positioned approx. 3mm
above the workpiece the
blade is cutting.

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USING THE FENCE
• The rip fence can be used on
either side of the blade.The
scale indicates the distance
from the saw blade to the
fence.
1. Place the fence over the table
and into the required position and
press down the locking clamp to
hold the fence in position.
USING THE PUSH STICK
1. The push stick serves as an
extension of the operators hand
as protection against accidentally
touching the saw blade.
2. The push stick should be used if
the distance between the blade
and rip fence is less than approx.
150mm.
3. Always replace the push stick if
lost or damaged.
4. To reduce the chance of loss
always store the push stick on the
hanging bolt on the side of the
saw (M6 x 35 bolt & locking nut).
Warning: ALWAYS USE A PUSH STICK WHEN STRAIGHT CUTTING SMALL
WORK PIECES USING THE FENCE.

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TILTING THE TABLE
1. Loosen the table tilt clamps.
2. Adjust the table to the required
angle.
• We recommend that you use
an engineers square to ensure
precise accuracy.
3. Retighten the table tilt clamps.
4. When table is level, adjust the limit
stop bolt so table rests on top of
the bolt.
OPERATION
Before commencing work, ensure the work area is clean and tidy and the
bandsaw table is clear of tools etc. Plan your work carefully and set the
bandsaw up accordingly before switching on.
1. Check the blade is correctly tensioned before use (see page 18).
2. Set the upper blade guide as close as practical to the workpiece, no more
than 3mm (see page 13). This provides the best safety for the operator and
gives more accurate results and greater control.
3. 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 the blade from
binding
• 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.

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• Always use a suitable holding device when cutting round or irregular
shaped timber to prevent twisting of the work piece.
CHANGING THE SAW BLADE
REMOVING THE BLADE
1. Loosen the 2 knurled screws and
remove the U shaped packer.
2. Open the upper and lower doors.
Turn the door locks clockwise to
unlock.
3. Loosen the setting knob anti-
clockwise until the bandsaw
blade has slackened.
4. Remove the old blade and
replace with a new blade (see
page 17).
WARNING: DISCONNECT THE SAW FROM THE MAINS SUPPLY BEFORE
CHANGING THE BLADE.

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FITTING A BLADE
1. Slide the new blade over the wheels, making sure the teeth point towards
the front of the saw.
NOTE: Turning the wheels as you do so makes this easier.
• Centre the blade on the rubber tyres of the wheels.
2. Tighten the blade tension setting
knob clockwise until the blade no
longer slips off the bandsaw
wheels.
3. Turn the upper wheel clockwise
by hand to make sure that the
blade tracks correctly on the
wheels.
• If not see “Tracking the Saw
Blade” on page 18.
4. Close and secure the doors.
5. Replace the U shaped packer.
6. Tension bandsaw blade; Align the
bandsaw blade and align the
blade guides. Run the saw for at
least one minute, stop the saw,
unplug and recheck the settings
and tension (see page 18).
WARNING: BLADES ARE NORMALLY SUPPLIED COILED, TAKE CARE WHEN
UNCOILING THE SAW BLADE AS THEY HAVE A TENDENCY TO SPRING
OPEN. WE HIGHLY RECOMMEND THAT CUT PROOF GLOVES ARE WORE
WHEN FITTING A BLADE.

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ADJUSTING THE BLADE TENSION
NOTE: Ensure the saw is turned
off and unplugged
before commencing.
1. Adjust the saw blade so it sits
dead centre on the rubber
tyres of the bandsaw wheels.
2. Raise the upper blade guard
fully (see page 13).
3. Turn the blade tension setting
knob to required tension.
• Turning the setting knob clockwise increases the blade tension.
• Turning the setting knob counter clockwise reduces the blade tension.
4. Check the tension by pressing with a finger against the side of the blade,
halfway between the table and upper guard.
• The blade should not flex more than 2 mm.
TRACKING THE SAW BLADE
If the saw blade does not run on the
centre of the rubber tyre, the
tracking needs to be corrected by
adjusting the tilt of the upper
bandsaw wheel.
1. Loosen locking nut
2. Turn blade tracking adjustment
knob:
• Turn clockwise if the saw blade
runs towards the front of the
saw
CAUTION: TOO MUCH TENSION CAN CAUSE THE BLADE TO BREAK. TOO
LITTLE TENSION CAN CAUSE THE BLADE TO MAKE IRREGULAR CUTS.

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• Turn anti-clockwise if the saw blade runs towards the rear of the saw.
3. Tighten locking nut.
ADJUST THE GUIDE/THRUST BEARINGS AND LOWER BLADE GUIDES
The guide/thrust bearings and the lower blade guides help keep the blade
tracking straight and correctly aligned during use.
UPPER BLADE GUIDE ALIGNMENT
NOTE: The bearing and guide pins need to be readjusted after every
bandsaw blade change or tracking.
The upper blade guide consists of:
• A thrust bearing (supports the bandsaw blade from the rear)
• Two guide pins (providing lateral support)
UPPER THRUST BEARING ADJUSTMENT
1. If necessary, adjust the blade
tension and tracking. (see page
18)
2. Using the 3mm allen key, loosen
the locking screw and adjust the
bearing so that it is approximately
0.5mm from the blade.
3. Retighten the locking screw.
UPPER GUIDE PIN ADJUSTMENT
1. Using the 3mm allen key, loosen
the locking screws.
2. Press the guide pins together,
keeping 0.5mm distance
between guide pin and saw
blade.
3. Retighten the locking screws.
LOWER BLADE GUIDE ALIGNMENT
NOTE: The bearing and guide pins need to be readjusted after every
bandsaw blade change or tracking.
The lower blade guide consists of:
• A thrust bearing (supports the bandsaw blade from the rear)
• Two guide pins (providing lateral support)

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LOWER THRUST BEARING ADJUSTMENT
1. Open the lower door.
2. Remove the table, trunnion and
plastic safety cover from the saw.
3. Raise the upper blade guide fully.
4. If necessary, align and tighten the
bandsaw blade (page 18)
5.
6. Using the 3mm allen key, loosen
the locking screw and adjust the
bearing so that it is approximately
0.5mm from the blade.
7. Retighten the locking screw.
LOWER GUIDE PIN ADJUSTMENT
1. Using the 3mm allen key, loosen
the locking screws
2. Press the guide pins together,
keeping 0.5mm distance
between guide pin and saw
blade
3. Retighten the locking screws.