Clarke WoodWorker CCS1 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS © 0606
Part No. 6462015
185MM CIRCULAR SAW
185MM CIRCULAR SAW
MODEL No. CCS1
Part No. 6460200

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Thank you for purchasing this CLARKE Circular Saw, which is designed for DIY and light
workshop use only.
Before attempting to use the machine, 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 the saw 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.
Specifications
Elec. Supply ..................................................................... 230V 50Hz 1 ph
Power Rating .................................................................. 1200W Motor
Fuse Rating ..................................................................... 13amp
No Load Speed .............................................................. 4,500 RPM
Gross Weight ................................................................... 5.7kg
Cutting Capacity @ 90º ................................................ 64mm
Cutting Capacity @ 45º ................................................ 45mm
Blade/Bore Diameter ..................................................... 185/20mm
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.
Declared vibration emission value in accordance with
EN12096
Measured vibration emission value - a: 2.47m/s2
Uncertainty value - K: 0.99m/s2
Highest measured reading in a single plane 4.56m/s2
Values determined according to EN28622-1
This product Confirms to 98/37/EEC Regulations
When disposing of this product, ensure it is disposed of according to all local ordinances. It must
not be disposed of with general household waste.

Safety Precautions
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. ALWAYS Learn the machines’ applications, limitations and the specific potential hazards
peculiar to it. Read and become familiar with the entire operating
manual.
2. ALWAYS use a face or dust mask if operation is particularly
dusty.
3. ALWAYS check for damage. Before using the machine, any damaged
part, 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.
4. ALWAYS disconnect the tool/machine from the power supply before servicing and when
changing accessories.
5. ALWAYS wear safety goggles, manufactured to the latest European Safety Standards.
Everyday eyeglasses do not have impact resistant lenses, they are not safety glasses.
6. ALWAYS keep work area clean. Cluttered areas and benches
invite accidents.
7. 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.
8. ALWAYS keep children away. All visitors should be kept a safe distance from the work
area, especially whilst operating the machine.
9. ALWAYS maintain machine in top condition. Keep tools/machines
clean for the best and safest performance. Follow maintenance
instructions.
10. ALWAYS handle with extreme care do not carry the tool/machine
by its’ electric cable, or yank the cable to disconnect it from the
power supply .
11. ALWAYS ensure the switch is off before plugging in to mains. Avoid accidental starting.
12. ALWAYS concentrate on the job in hand, no matter how
trivial it may seem. Be aware that accidents are caused
by carelessness due to familiarity.
13. ALWAYS keep your proper footing and balance at all times
don’t overreach. For best footing, wear rubber soled
footwear. keep floor clear of oil, scrap wood, etc.
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14. ALWAYS wear proper apparel. loose clothing or jewellery may
get caught in moving parts. wear protective hair covering to
contain long hair.
15. ALWAYS use recommended accessories. the use of improper
accessories could be hazardous.
16. ALWAYS remove plug from electrical outlet when adjusting,
changing parts, or working on the machine.
17. NEVER operate machine while under the influence of drugs, alcohol or any medication.
18. NEVER leave machine running unattended. turn power off. Do
not leave the machine until it comes to a complete stop.
19. NEVER force the machine. it will do a better and safer job at
the rate for which it was designed.
20. NEVER use power tools 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.).
Avoid dangerous environment.
Additional Precautions For Circular Saws
1. ALWAYS wear ear protectors/defenders as the noise level of this machine can exceed
85dB (A).
2. ALWAYS use the appropriate saw blade for the material being cut.
3. ALWAYS keep the mains cable well away from 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.
4. ALWAYS switch the machine OFF immediately the task is completed.
5. ALWAYS allow sufficient clearance beneath the work to ensure the blade does not
come into contact with the work bench etc.
6. ALWAYS ensure the blade is fully tightened before use.
7. ALWAYS let saw stop completely before putting down.
8. ALWAYS check blade guard has returned before putting saw down.
9. NEVER use the saw with the riving knife removed, (see Fig. 1).
10. NEVER operate the saw when the blade guard is not working properly. Guard should
be checked for correct operation before each use.
11. NEVER start the saw when the blade is in contact with the work.
12. NEVER allow the ventilation slots in the machine to become blocked.
13. DO NOT use the machine if the electric cable, plug or motor is in poor condition.
14. When cutting e.g. doors etc ensure all nails have been removed beforehand. Nails will
damage the saw blade.
14. Replacement blades are available from your CLARKE dealer.
Note :
The guard is operating correctly when it moves freely and readily returns to closed position
Additionally, please keep these instructions in a safe place for future reference.

Electrical Connections
This product is provided with a standard 13 amp, 230 volt (50Hz), BS 1363 plug, for
connection to a standard, domestic electrical supply. Should the plug need changing at
any time, ensure that a plug of identical specification is used.
WARNING
This appliance is Double Insulated, and the two wires in the mains lead should
be wired up in accordance with the following colour code:
BLUE - NEUTRAL
BROWN - LIVE
• Connect the BLUE coloured cord to the plug terminal marked a letter “N”
• Connect the BROWN coloured cord to the plug terminal marked a letter “L”
If this appliance is fitted with a plug which is moulded on
to the electric cable (i.e. non-rewireable) 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 Clarke dealer or most electrical stockists.
FUSE RATING
The fuse in the plug must be replaced with one of the same rating (13 amps) and this
replacement must be ASTA approved to BS1362.
If in doubt, consult a qualified electrician. Do not attempt any electrical repairs yourself.
CABLE EXTENSION.
Always use an approved cable extension suitable for the power rating of this tool (see
specifications), the conductor size should also be at least the same size as that on the
machine, or larger. When using a cable reel, always unwind the cable completely.
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Changing Saw Blade
Note : Item numbers refer to parts list.
Ensure saw is switched off and isolated from the mains supply, by removing the plug from
the socket.
Loosen depth adjusting knob, (see Fig.1) and set to minimum cut depth.
Fig. 1
Fig. 2
WARNING
It is extremely important that you note the order of all the
washers etc when removing saw blade, in order to refit them
in the right order with new blade.
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Using the special wrench, (supplied), hold the blade securely, (see Fig. 2), unscrew
(anticlockwise) and remove, allen screw and washer, (item Nos 53 & 52) with allen key
(supplied), also remove special washer, (item No 51).
Open blade guard fully and remove blade by tilting up and sliding out.
Fit new blade in reverse order, ensure allen screw is tight.
IMPORTANT Ensure correct rotation direction
Fig. 1

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Adjustments
Ensure the machine is disconnected from the mains supply before attempting to make
any adjustment.
Depth Of Cut
Always keep correct depth setting. The correct depth setting for all cuts should not exceed
6mm below the material being cut. More blade depth will increase the chances of kick-
back and result in a rough cut.
1. Loosen depth adjustment knob, (see Fig. 1).
2. Hold base flat against workpiece and raise or lower saw until the required depth is
obtained.
3. Tighten depth adjustment knob securely, (hand tight only).
Rip Fence
The rip fence is used when making parallel cuts up to 100mm wide, it helps prevent the
blade from twisting in the cut and causing kickback.
1. Install the side fence into the slots on the front sole plate.
2. Adjust the fence to the required position by measuring from the edge of the blade
tooth, to the edge of the fence where it rests against the workpiece.
3. Tighten clamp screw, (see Fig. 1), securely, (hand tight only).
Bevel Setting (angle)
1. Loosen angle adjusting levers 1 & 2, (see Fig. 1).
2. Adjust to required angle setting on the bevel scale, (ref angle lever 1).
3. Tighten levers 1 & 2 securely, (hand tight only).
WAR N I NG
BE AWARE that incorrect or improper use of this machine could cause KICKBACK.
Kickback occurs when the blade stalls rapidly and the saw is driven back towards you.
Blade stalling is caused by any action which pinches the blade into the wood being cut.
Release the ON/OFF switch immediately if blade binds or stalls.
Kickback could cause you to lose control of the saw and could result in personal injury
Common Causes Of Kickback
1. Incorrect blade depth setting, (Blade protruding more than 6mm below workpiece).
2. Sawing into knots or nails etc.
3. Twisting blade while making cut.
4. Sawing with a dull, gummed up, or improperly set blade.
5. Not supporting workpiece securely.
6. Cutting warped or wet timber.
7. Forcing saw through the cut.
Operation

Starting A Cut
The ON/OFF trigger/switch is located on the handle.
To start the saw push IN and hold the trigger safety button on the side of handle, (see Fig 1)
at the same time depress the trigger switch, and keep it depressed.
When the motor has reached maximum speed, place the end of the sole plate on the
workpiece, line up 0º mark on cutting line and move it slowly forward, (Always cut in forward
direction),
If cutting at an angle of 45º, line up with the 45º mark on sole plate.
Alternatively, the rip fence can be fitted to cut parallel to the edge of the workpiece.
Always operate the saw by holding it firmly with both hands.
Never place your hands on or near the workpiece.
Always Maintain Control
Always support work as near as possible to the cut.
Always Support work so that the cut is on your right hand side.
Always Clamp workpiece so that it will not move during the cut.
Always Place workpiece, good side down, i.e. the side on which the finished appearance
is important.
Note :
Before beginning a cut, draw a guide line along the desired line of cut, then place the front
edge of the sole plate on that part of the work that is solidly supported. Never place your
saw on the part of the work that will fall off when the cut is made.
Cross Or Rip Cut
When making a cross or rip cut, align your line of cut with the outer blade notch on the sole
plate (0º). Since the blade thickness may vary, always test on a scrap piece first to deter-
mine how much , if any, the guideline must be offset to produce an accurate cut.
Parallel Cut
Making a parallel cut using the rip fence.
Position the face of the rip fence firmly against the edge of the workpiece, this makes a
true cut without pinching the blade.
The guiding edge of the workpiece must be straight for your cut to be straight. Use caution
to prevent your blade from binding in the cut.
Bevel Cut
The angle of cut of your saw can be adjusted from 0º and 45º, there is a cutting indication
notch in the sole plate to assist in lining up the line of cut.
Align your line of cut with the inner guide on the sole plate, (45º), when making full 45º bevel
cuts, make a test cut on a scrap piece first, again to determine how much offset, if any, is
needed.
IMPORTANT
DO NOT plug in to the mains, unless you have ensured the tool is switched OFF.
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8. Tool misuse or incorrect operating procedures.
9. Failure to adhere to the correct refitment of the saw blade.
10. Using the wrong saw blade.

DUST EXTRACTION
The Saw is provided with a dust extraction facility, where a dust bag or vacuum extractor
may be connected to the right hand side of the machine. Please note however, that this
does not preclude the user from wearing a face mask to prevent the inhalation of dust
particles.
It is an EEC requirement that a dust extraction facility be provided on power tools, however,
due to the nature of the tool, some of the dust produced will be forced into the surrounding
atmosphere, and will not be collected.
Trouble Shooting
Saw is overheating
This indicates the machine is dirty. Clean the ventilation holes, and blow out with compressed
air or clean with a dry cloth.
Overloading the machine will also cause overheating. Do not use for heavy duty work, and
do not apply excessive pressure.
Excessive sparking occurs
This indicates worn brushes. This problem is quickly remedied but you should consult your
CLARKE dealer for parts and advice.
Saw does not operate when switched ON
Check to ensure the fuse is sound and replace if necessary. If the fuse is sound or blows
repeatedly, consult your CLARKE dealer.
Maintenance
Always inspect the tool before use, and ensure it is in top condition.
Ensure all air vents are clear, (use compressed air to clean the machine where possible).
Check the power cable to ensure it is sound and free from cracks, bare wires etc. avoid
using solvents when cleaning plastic parts, most plastics are susceptible to damage from
the various types of commercial solvents.
All bearings etc, in this tool are lubricated with a sufficient amount of high grade lubricant
for the tools lifetime under normal operating conditions, therefore no further lubrication is
required.
Accessories
A wide range of accessories is available from your nearest CLARKE dealer, for further
information, contact your nearest dealer, or telephone CLARKE International Sales
department on 01992 565300.
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No. Part No Description Qty No. Part No Description Qty
Parts List
1 GRCSS1001 Cable 1 37 GRCSS1037 Spindle 1
2 GRCSS1002 Cable Protector 1 38 GRCSS1038 Screw 2
3 GRCSS1003 Board 1 39 GRCSS1039 Distance Collar 1
4 GRCSS1004 Screw 2 40 GRCSS1040 Screw 1
5 GRCSS1005 Capacitor 1 41 GRCSS1041 Rubber Stop 1
6 GRCSS1006 Switch 1 42 GRCSS1042 Screw 2
7 GRCSS1007 Handle 1 43 GRCSS1043 Spring 1
8 GRCSS1008 Washer 3 44 GRCSS1044 Pin 1
9 GRCSS1009 Screw 2 45 GRCSS1045 Bearing Holder 1
10 GRCSS1010 Washer 1 46 GRCSS1046 Bearing 1
11 GRCSS1011 Spring washer 4 47 GRCSS1047 Safety Cover 1
12 GRCSS1012 Screw 1 48 GRCSS1048 Bearing Gland 1
13 GRCSS1013 Handle 1 49 GRCSS1049 Blade Flange 1
14 GRCSS1014 Nut 2 50 GRCSS1050 Saw Blade 1
15 GRCSS1015 Screw 1 51 GRCSS1051 Special Washer 1
16 GRCSS1016 Tail Cover 1 52 GRCSS1052 Washer 1
17 GRCSS1017 Screw 1 53 GRCSS1053 Screw 1
18 GRCSS1018 Brush 2 54 GRCSS1054 Cover 1
19 GRCSS1019 Carbon Brush 2 55 GRCSS1055 Washer 1
20 GRCSS1020 Housing 2 56 GRCSS1056 Screw 2
21 GRCSS1021 Stator 1 57 GRCSS1057 Cover 1
22 GRCSS1022 Fan Guide 1 58 GRCSS1058 Nut 2
23 GRCSS1023 Screw 2 59 GRCSS1059 Knob 1
24 GRCSS1024 Flange 1 60 GRCSS1060 Washer 1
25 GRCSS1025 Bearing 80028 1 61 GRCSS1061 Screw 1
26 GRCSS1026 Armature 1 62 GRCSS1062 Screw 1
27 GRCSS1027 Bearing 80101 1 63 GRCSS1063 Knob 1
28 GRCSS1028 Choke 1 64 GRCSS1064 Nut 1
29 GRCSS1029 Gear Box 1 65 GRCSS1065 Knob 1
30 GRCSS1030 Bearing 8x12x8 1 66 GRCSS1066 Bracket 1
31 GRCSS1031 Housing 1 67 GRCSS1067 Bracket 1
32 GRCSS1032 Riving Knife Base 1 68 GRCSS1068 Guide 1
33 GRCSS1033 Riving Knife 1 69 GRCSS1069 Bracket 1
34 GRCSS1034 Plate 1 70 GRCSS1070 Label 1
35 GRCSS1035 Screw 1 71 GRCSS1071 Brush Cap 2
36 GRCSS1036 Gear 1 72 GRCSS1072 Screw 1
PARTS & SERVICE TEL: [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [email protected]
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Parts Diagram
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