Clarke Woodworker CSS400B Manual

400mm (16") SCROLL SAW
Operating and Maintenance
Instructions
Model No. CSS400B
Part No. 6462150
0107

SPECIFICATIONS
Motor Voltage: ................................................................ 230V, 50Hz, 1 phase.
Rating: .................................................................. 85 Watts
Maximum thickness of cut at 90O: .............................................. 50mm (2")
Maximum thickness of cut at 45O: .............................................. 15mm (5/8")
Throat: ............................................................................................ 400mm (16")
Blade Size: ..................................................................................... 133x2.6x0.25mm
Strokes per minute:....................................................................... 1458
Machine dimensions: ................................................................... 546x255x317mm
Table tilt: ........................................................................................ 0O- 45O left
Blade Type: ................................................................................... Pin (plain type optional)
Gross / Net weight: ....................................................................... 17 / 18kg
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
For Spare Parts and Service,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 & SERVICE CONTACTS
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Thank you for purchasing this CLARKE 400mm (16") Scroll Saw, ideal for DIY applications and the
hobbyist...for modelling etc.
Before operating this machine, please read this leaflet 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 Scroll Saw 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
Specifications .............................................................................................. 2
Parts and Service Contacts ........................................................................ 2
Safety Precautions General ....................................................................... 4
Additional precautions for Scroll Saws ...................................................... 5
Electrical Connections ............................................................................... 6
Principle Parts ............................................................................................... 7
Assembly .................................................................................................... 7
Installation .................................................................................................... 7
Mounting ................................................................................... 7
Blade Ho0lder Alignment ......................................................... 8
Bevel Alignment ....................................................................... 8
Blade Installation/Renewal ...................................................... 9
Blade renewal ........................................................................... 9
Saw Blade Notes ......................................................................................... 9
Operating Characteristics .......................................................................... 10
Straight Line Cutting .................................................................................... 10
Cutting Intricate patterns ........................................................................... 10
Maintenance ............................................................................................... 11
Trouble Shooting .......................................................................................... 11
Parts Diagram .............................................................................................. 12
Parts list .................................................................................................... 13
Declaration of Conformity ......................................................................... 15
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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 may result.
✔ALWAYS 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.
✔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.
✔ALWAYS 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.
✔ALWAYS disconnect the machine from the power supply before servicing and when changing
accessories such as blades, etc.
✔ALWAYS keep guards in place and in working order.
✔ALWAYS wear safety goggles, manufactured to the latest european safety standards and
also use face or dust mask if cutting operation is dusty. Everyday eyeglasses do not have
impact resistant lenses, they are not safety glasses.
✔ALWAYS keep work area clean. Cluttered areas and benches invite accidents.
✔ALWAYS wear ear protectors/defenders.
✔ALWAYS 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.
✔ALWAYS use recommended accessories. The use of improper accessories could be hazardous.
✔ALWAYS remove plug from the electrical outlet when adjusting, changing parts, or working on machine.
✔ALWAYS 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.
✔ALWAYS 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).
✔ALWAYS keep children away. All visitors should be kept a safe distance from the work area,
especially whilst operating the unit.
✔ALWAYS maintain machine in top condition. Keep tools sharp and clean for the best and
safest performance. Follow maintenance instructions.
✔ALWAYS wear proper apparel. Loose clothing or jewellery may get caught in moving parts.
Wear protective hair covering to contain long hair.
✔ALWAYS make workshop childproof. cover the saw adequately when not in use, to prevent
children from damaging themselves by tampering with it.
✔ALWAYS handle with extreme care whenever transporting or installing machinery, and always
use a lifting tool.
✔ALWAYS avoid accidental starting. ensure the switch is off before plugging in to mains.
✔ALWAYS 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.
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SAFETY PRECAUTIONS

✗NEVER force the machine. it will do a better and safer job at the rate for which it was designed.
✗NEVER operate machine while under the influence of drugs, alcohol or any medication.
✗NEVER leave machine running unattended. Turn power off. Do not leave machine until it
comes to a complete stop.
✗NEVER 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.
✗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.
ADDITIONAL SAFETY INSTRUCTIONS FOR SCROLL 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. 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.
3. A solid wood workbench is stronger and more stable than a workbench with a
plywood table.
4. This scroll saw is for indoor use only.
5. Do not cut pieces of material which are to small to be held by hand.
6. Clear the work table of all objects except the workpiece (tools, scraps ,rulers etc.)
before turning the saw on .
7. Make sure the blades’ teeth are pointing down, toward the table, and that the
blade tension is correct.
8. When cutting a large piece of material, support it at the height of the table.
9. Do not feed the workpiece through the blade too fast. Feed only as fast as the
blade will cut.
10. Keep your fingers away from the blade. Use a push stick as you near the end of the cut.
11. Take care when cutting a workpiece which is irregular in cross section. Moulding for example
must lie flat, and not ‘rock’ on the table as it is being cut. A suitable support must be used.
12. Take care when ‘backing off’ a workpiece from the blade, as the blade may bind
in the ‘kerf’. In this event, switch OFF the machine and disconnect from the supply.
Wedge open the kerf, and withdraw the workpiece.
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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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 MUST BE EARTHED
IMPORTANT: The wires in the mains lead are coloured in accordance with the following code:
Green & Yellow - Earth
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 GREEN & YELLOW coloured cord to plug terminal marked with a letter “E” or Earth
symbol “ ” or coloured GREEN or GREEN & YELLOW.
•Connect BROWN coloured cord to plug terminal marked with a letter “L” or coloured RED.
•Connect BLUE coloured cord to plug terminal marked with a letter “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 (5 amps) and this replacement
must be ASTA approved to BS1362.
ELECTRICAL CONNECTIONS
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PRINCIPAL PARTS OF THE SCROLL SAW
ASSEMBLY
Your Scroll Saw is fully assembled, except for the Blade Guard, and the Air tube. To attach these
components, proceed as follows:
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Fig. 1
Position the Blade guard and Air Tube in the manner
shown in Fig1a, i.e. with the Air Tube Bracket on the
inside of the Blade Guard, at the LEFT side of the guard
- looking at the front. (See also Fig.1 above)
Slide the pivot bolt through the slotted holes in the
Guard and Bracket, then through the mounting on
top of the Upper Arm. Thread on the Flat Washer and
M6 Nyloc nut and nip up sufficient so as not to crush
the Guard, but to allow it to pivot easily.
NOTE that the bolt head should sit snugly, and bottom
out in the slotted hole in the blade guard (arrowed in
Fig. 1a). This prevents the bolt from turning when
threading on the Nyloc nut.
INSTALLATION
Plan your installation. Ensure adequate space is available, with good lighting and ventilation,
and an adequate electrical supply is close at hand.
1. MOUNTING
Your Scroll Saw is provided with 3 mounting holes, and it is strongly recommended that you mount
the machine on a solid surface. A pad between the saw and the workbench is further
recommended. The best dimensions being - 21" x 12" x ½”. Ensure you use flat washers between
the bolt head and the mounting hole, and do not over tighten the bolts.
Fig. 1a

2.BLADE HOLDER ALIGNMENT
It is important that the blade holders are checked for alignment before use. Misaligned holders
will cause the blade to wander, and reduce the blades life expectancy.
To check the alignment,
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2.1 Visually check to ensure the upper Blade holder
is perfectly in line with the upper arm.
If it is not (as indicated in Fig. 2), firstly slacken
the tension on the blade by turning the blade
tension knob (19), two full turns anticlockwise,
then slacken off the blade holders hex. socket
head securing screw, sufficiently to move the
holder. Tighten securely when the holder is
directly in line with the arm.
2.2 Remove the side cover (5), by unscrewing the
three retaining screws, to give access to the
lower holder.
2.3 Visually check to ensure the blade holder is
perfectly in line with the Lower Arm.
If it is not, slacken off the holders single hex.
socket head securing screw, sufficiently to
move the holder. Tighten securely when the
holder is directly in line with the arm.
On completion, replace the side cover and
table insert then retension the blade by turning
the tensioner until the blade is felt to be firm.
NOTE: If the blade tends to wander during use, the blade
may be too loose or re-check this adjustment as it may
take one or two attempts to get it right. Also see page 11
- Straight Line Cutting, for other causes of blade wander.
Fig..4
When the table is perpendicular to the blade,
tighten the bevel lock knob.
Loosen the screw holding the pointer (66), adjust
the pointer to 0O, then retighten the screw.
The bevel scale is a convenient indicator, but it is
not guaranteed to be 100% accurate. Where
absolute accuracy is required, always double
check with a protractor before starting a cut.
3. BEVEL ALIGNMENT (see fig. 4)
To align the bevel indicator, loosen the table bevel lock knob (63), and level the table until it is at
right angles to the blade. Use a small square to be sure that the angle between blade and table
is 90o.
Fig. 3
Fig. 2

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4. BLADE INSTALLATION / RENEWAL
4.1 Before installing or removing blades, ensure the saw is
switched OFF and disconnected from the power supply.
Remove the blade as follows:
a. Slacken off blade tension by turning the tensioner
anticlockwise at least two turns.
b. Very carefully prise oput the Table insert.
c. Remove the side cover - 3 screws.
d. Apply a slight downward pressure on the upper arm
whilst holding the blade firmly, allowing the pins at the
top of the blade to be disengaged from the recesses
in the upper blade holder. It is now a simple matter to
Fig. 5
NOTES ON SAW BLADES
disengage the blade pins from the lower blade holder and lift the blade out through the
access hole in the table.
NOTE:
Whilst the blade is out of the housings, look at the blade housings closely. You will observe that the blade slots
and pin recesses are made so you can position the blade for cutting from the front, or from the side (see fig.
5). Cutting from the side is necessary when your workpiece is over 16" long.
IMPORTANT: Side cutting can only be performed when the bevel is set at 0O.
4.2 With the blade teeth pointing DOWNWARDS, slot the new blade into the lower housing so
that the pins on the end of the blade, engage in the recess in the holder. Holding the
blade firmly, apply downward pressure to the upper arm, whilst slotting the pins in the upper
end of the blade into the slot in the upper holder, again, making sure the blade pins correctly
engage in the recess in the holder.
4.3 Replace the table insert and side cover, then re-tension to the blade, by turning the tension
knob (19) clockwise until you feel the blade is firm. Check to ensure that the blade pins are
properly seated, top and bottom.
BLADES BREAK FOR FIVE PRINCIPAL REASONS:
1. Too much tension or too little tension on the blade.
2. Overworking the blade by feeding the workpiece too fast.
3. Twisting or bending the blade by feeding the workpiece off-centre.
4. Over use - the blade has reached the end of its useful life.
5. Feeding too much material into the saw, - more than the maximum 2" depth for which it
was designed.
HOW TO DETERMINE THE RIGHT BLADE FOR THE JOB
This scroll saw accepts a wide variety of blade widths and thicknesses. The width of the blade ,
the thickness of the blade, and the number of teeth per inch (TPI) are determined by the type of
material and size of the radius being cut. Here are several examples:
TPI WIDTH THICKNESS MATERIAL NOTE
10 2.8mm 0.5mm Medium curves on 1/4" to 1-3/4"
0.11" 0.020" wood, wallboard, hardboard.
15 2.8mm 0.5mm Same as above, plus wood
0.11" 0.020" 1/8" to 1-1/2" thick
18 2.4mm 0.25mm Extra thin cuts on soft woods to 1/4"
0.095" 0.011 and parquetry
As a general rule, select the
narrowest blades
recommended for intricate
curve cutting and widest
blades for straight and large
curve operations.

SCROLL SAW OPERATING CHARACTERISTICS
The scroll saw’s unique ability is cutting intricate curves which other saws cannot do. A scroll saw
can also be used for straight line cutting such as cross cuts, ripping and bevels,
The following is a list of points to remember when using a Scroll Saw.
1. The saw does not cut wood by itself. You feed the workpiece into the blade, letting the
blade cut the wood as you move the piece forward.
2. You must guide the wood into the blade SLOWLY, because the teeth are very small, and cut
ONLY on the down stroke. If you push the wood into the blade too rapidly, you can easily
break the blade.
3. Although the capacity of the saw accepts wood up to 2" thick, better results are obtained
with wood no more than 1" thick. For wood thicker than 1", you must guide the wood into
the blade very slowly, taking care not to bend or twist the blade.
4. The teeth on the blade will wear out sooner or later. The blade must therefore be replaced
often to obtain the best cutting results. A blade will stay sharp for ½ hour to 2 hours of
continuous running, depending on the material being cut.
5. Be aware that the blade has a tendency to follow the grain of the wood - the line of least
resistance. You can compensate for this by watching the grain carefully and guiding the
wood past the saw blade.
6. If you are not familiar with scroll saws, there will naturally be a learning period - a period to
learn the saw itself, and a period to learn how the wood and saw work together. Expect
some blade breakages, Scroll Saw blades are fairly fragile - not the same types of blade
you find on a handsaw or circular saw.
STRAIGHT LINE CUTTING
A little practice will be necessary in order to create a straight line cut. This is due to the very design
and nature of the machine itself. The saw blade is quite fragile and due to several different
influences, will tend to wander off line. These influences include the following:
1. Blade tension. A slack blade will naturally wander off line.
2. Condition of the blade. A dull blade requires a greater effort to guide it through the work.
thereby tending to force it off line.
3. Blade holders misaligned. The holders are secured with a single hex. socket head screw.
Slacken the screw and adjust the holder so as to align correctly. The blade should be in line
with the table, and not twisted.
CUTTING INTRICATE PATTERNS
One capability a scroll saw has that other saws do not, is cutting intricate patterns inside a
workpiece. To do this, you should adopt the following procedure.
1. Drill a 1/4" hole in the middle of the workpiece, in a area which will not be a part of the
finished object.
2. Switch off and unplug the machine from the supply.
3. Remove the blade from the machine.
4. Place the workpiece on the table, with the 1/4" hole over the access hole in the table.
5. Replace the blade, through the hole in the workpiece, (teeth downwards), and Re-tension
the blade.
6. Plug the saw back in. Check to ensure that the workpiece is not touching the blade before
switching ON.
When you are finished, switch off the saw and disconnect it from the supply, remove the blade,
remove the workpiece, and reinstall the blade
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TROUBLESHOOTING
MAINTENANCE
A. Apply a thin coat of paste wax on the work table from time to time. This will help the wood
glide across the table more smoothly.
B. The motor is permanently lubricated. Do not try to oil the motor bearings or service any
internal parts of the motor. If the power cable is worn, frayed, cut or damaged, replace it.
Do not try to patch it up with electrical tape as this could lead to more trouble.
Breaking Blades. 1. Incorrect tension. 1. Adjust blade tension.
2. Overworked (worn out) blade. 2. Reduce feed rate or replace
blade.
3. Wrong blade being used. 3. Use narrow blades for thin
wood, wider blades for
thicker wood.
4. Twisting blade in wood. 4. Avoid side pressure on blade.
Motor Will Not Run. 1. Defective cord, plug or outlet. 1. Unplug saw, replace
defective parts.
2. Defective motor. 2. Repairs MUST be made by a
qualified technician. Call
Clarke Service dept. for
advice.
Excessive Vibration 1. Improper mounting of saw. 1. See proper mounting
instructions (p7)
(Some vibration is 2. Unsuitable mounting surface. 2. Replace plywood
inevitable when the workbench surface with solid
saw and motor are lumber surface.
running) 3. Loose table or table rubbing 3. Tighten table adjuster knob.
against motor.
4. Motor mount is loose. 4. Tighten motor mount screws.
Blade Runout 1. Blade holders not aligned. 1. Loosen screws holding
blade holder to rocker arms.
Adjust position of blade
holders.
Retightenholder screws
2. Insufficient Blade tension 2. Increase Blade tension
3. Dull Blade causing excesive 3. Renew Blade and correctly
force to be used at workpiece tension.
PROBLEM PROBABLE CAUSES SUGGESTED REMEDY

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PARTS DIAGRAM

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PARTS LIST
No. Description Qty Part No. No. Description Qty Part No.
1 Bolt HT400B01
2 Spring Washer HT400B02
3 Warning Label HT400B03
4 Base HT400B04
5 Left Cover HT400B05
6 Screw HT400B06
7 Frame HT400B07
8 Pin Upper HT400B08
9 Pin Lower HT400B09
10 Screw HT400B10
11 Label (A) HT400B11
12 Label (B) HT400B12
13 Plastic Cap HT400B13
14 Label HT400B14
15 Draw Bolt HT400B15
16 Tension Block (B) HT400B16
17 Tension Block (A) HT400B17
18 Small Insert (B) HT400B18
19 Knob HT400B19
20 Pin HT400B20
21 Small Insert (A) HT400B21
22 Right Cover HT400B22
23 Pressure Plate HT400B23
24 Spring HT400B24
25 Bush HT400B25
26 Top Arm HT400B26
27 Screw HT400B27
28 Upper Blade Holder HT400B28
29 Spacer HT400B29
30 Blade see below
31 Screw HT400B31
32 Bearing Washer (A) HT400B32
33 Plate HT400B33
34 Bearing HT400B34
35 Spring Washer HT400B35
36 Nut HT400B36
37 Clamp Plate HT400B37
38 Screw HT400B38
39 Lower Arm HT400B39
40 Bearing Washer (B) HT400B40
41 Lower Blade Holder HT400B41
42 Plastic Tube HT400B42
43 Screw HT400B43
44 Air bag Base HT400B44
45 Washer HT400B45
46 M6 Nyloc Nut HT400B46
47 Blade Guard HT400B47
48 Top Protecting Cover HT400B48
49 Air Bag HT400B49
50 Bolt HT400B50
51 Housing HT400B51
52 Cam HT400B52
53 Screw HT400B53
54 Spring Pin HT400B54
55 Table Insert HT400B55
56 Motor HT400B56
57 Copper Tube HT400B57
58 Tension Spring HT400B58
59 Screw HT400B59
60 Table HT400B60
61 Screw HT400B61
62 Bevel Scale Housing HT400B62
63 Table Locking Knob HT400B63
64 Nut HT400B64
65 Screw HT400B65
66 Bevel Pointer HT400B66
67 Bracket HT400B67
68 Screw HT400B68
69 Protecting Plate HT400B69
70 Protection Cover HT400B70
Replacement Blades (Packs of 10)
10tpi Part No. 6470067
15tpi Part No. 6460110
20tpi Part No. 6470072

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