Clarke CS48 Belt Disc Sander Instruction Manual

BELT & DISC SANDER
MODEL NO: CS48
PART NO: 6500430
OPERATION & MAINTENANCE
INSTRUCTIONS
DL1022 – ISS 5
ORIGINAL INSTRUCTIONS

INTRODUCTION

Thank you for purchasing this CLARKE product.
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 affect your statutory rights.

IN THE BOX

The following should be supplied inside the box.
If any parts are missing, please contact your local CLARKE dealer.

• 1 x Belt disc sander
• 1 x 200mm P80 sanding disc (Fitted)
• 1 x 100mm x 914mm 4″x 36″ Sanding belt (Fitted)
• 1 x Disc table 265×150
• 1 x Belt table 170 x 125
• 1 x Dust bag
• 1 x Wrench
• 1 x Angle Gauge
• 1 x Instruction manual

GENERAL SAFETY RULES

1. ALWAYS learn the machine’s applications, limitations, and specific potential hazards. Read and become familiar with the entire operating manual.
2. ALWAYS use a face or dust mask if the operation is particularly dusty.
3. AlWAYS check for damage before using the machine, check for alignment of moving parts, breakage of parts, and any other condition that may affect the operation of the machine. 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 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, and are not safety glasses.
6. ALWAYS keep the work area clean. Cluttered areas and benches invite accidents.
7. ALWAYS ensure that adequate lighting is available. 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 at a safe distance from the work area, especially when the machine is being used.
9. ALWAYS maintain the machine in top condition. Keep tools/machines clean for the best and safest performance. Follow maintenance instructions.
10. ALWAYS handle with extreme care and do not carry the tool/machine by its electric cable, or pull on the cable to disconnect it from the power supply.
11. ALWAYS ensure the switch is off before plugging it into the mains. Avoid accidental starting.
12. ALWAYS concentrate on the job at 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 the floor clear of oil, scrap wood, etc.
14. ALWAYS dress properly. Loose clothing or jewelry may get caught in moving parts. Wear protective hair covering to contain long hair.
15. ALWAYS guard against electric shock. Avoid contact with earthed surfaces – pipes, radiators, etc.
16. NEVER operate a machine while under the influence of drugs, alcohol, or any medication.
17. NEVER leave the machine running unattended. Turn the power off. Do not leave the machine until it comes to a complete stop.
18. NEVER force the machine, it will do a better and safer job at the rate for which it was designed.
19. NEVER use power tools in damp or wet locations or expose them to rain. Do not use in an explosive atmosphere (around paint, flammable liquids, etc.). Avoid dangerous environments.
20. If the tool begins to make an abnormal noise, or produce excessive vibrations, smoke, or burning odor, turn the tool off immediately and do not operate, until repaired.

EXTRA PRECAUTIONS FOR BELT/DISC SANDERS

1. ALWAYS wear ear protectors/defenders when using this machine.
2. ALWAYS wear a dust mask when using this machine. Be aware that harmful or toxic dust could be produced when sanding some timbers.
3. ALWAYS use the table to support the workpiece.
4. ALWAYS make sure the table and attachments are secure before starting.
5. ALWAYS maintain a clearance of 1.6 mm between the table and the sanding disc.
6. ALWAYS hold the workpiece firmly so that it cannot be torn from your hands.
7. ALWAYS feed the workpiece against the direction of rotation of the disc. i.e the right side of the disc.
8. ALWAYS keep the mains cable well away from the machine and ensure an adequate electrical supply is c
9. ALWAYS close at hand so that the operation is not restricted by the length of the cable.
10. ALWAYS use a dust extraction bag connected to the dust extraction port.
11. ALWAYS ensure that nails or foreign objects have been removed from a workpiece beforehand. Nails etc. will destroy the belt or disc.
12. NEVER sand pieces that cannot be held firmly by hand.

WARNING: WARNING: USE ONLY FOR SANDING WOOD. DO NOT USE FOR MATERIALS CONTAINING ASBESTOS, PAINTED SURFACES, OR MATERIALS THAT EMIT TOXIC PARTICLES.

ELECTRICAL CONNECTIONS

WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAIN SUPPLY.
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.
If the plug has to be changed because it is not suitable for your socket, or because of damage, it must be removed and a replacement fitted, following the wiring instructions are shown below. The old plug must be discarded safely, as
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
If the colors of the wires in the power cable do not agree with the markings on the plug.

• The BLUE wire must be connected to the terminal which is marked N or colored black.
• The BROWN wire must be connected to the terminal which is marked L or colored red.
• The YELLOW AND The GREEN wire must be connected to the terminal which is marked E or colored green.

We strongly recommend that this machine is connected to the mains supply through a Residual Current Device (RCD)
If you are not sure, consult a qualified electrician. DO NOT try to do any repairs.

OVERVIEW

ASSEMBLY

CAUTION: THE SANDER MUST ASSEMBLE BEFORE USE. DO NOT PLUG THE UNIT INTO THE POWER SOURCE UNTIL THE MACHINE HAS BEEN COMPLETELY ASSEMBLED.
Installing The Belt Sander Table

1. Attach the belt sander table to the frame with the handwheel and washer supplied.
   • Do not overtighten the handwheel.
   

MOUNTING THE DISC SANDER TABLE

1. Put the disc sander table into position as shown.
2. Put a washer onto the thread of the locking handle and insert the thread through the radius slot.
3. Turn the locking handle clockwise to tighten.
4. Repeat on the other side.
   

MOUNTING THE SANDER ON TO A WORKBENCH
Attach the machine to a workbench or stand before use.

1. Position the machine on the workbench.
2. Mark the workbench through the mounting holes in the sander base.
3. Drill holes in the workbench at the marks.

Use long bolts, spring washers, and nuts (not supplied), to secure the machine to the workbench.
MOUNTING THE DUSTBAG TO THE SANDER
The sender is provided with a dust extraction facility. Please note, however, that this does not preclude the user from wearing a face mask to prevent the inhalation of dust particles

1. Use the dustbag clip to secure the dustbag to the dustbag bracket as shown,
2. Fit the dustbag bracket over the dust extraction port as indicated.
   

OPERATION

WARNING: NEVER TOUCH THE SANDING DISC OR BELT WHILE IT IS MOVING, DO NOT TOUCH THE WORKPIECE AFTER SANDING, IT COULD BE VERY HOT.
WARNING: ALWAYS WEAR SAFETY GLASSES WHEN OPERATING THE SANDER
CAUTION: ALWAYS MAKE SURE THE DISC SANDER TABLE AND BELT SANDER TABLE ARE PROPERLY ADJUSTED AND SECURE BEFORE USE.
ON/OFF BUTTONS
The On/Off buttons are located on the front of the machine.

1. Push the GREEN button (I) to turn the machine on.
2. Push the RED button (0) to turn the machine off.
   • If a failure occurs in the power supply the machine will stop automatically. It will be necessary to push the GREEN button again to continue work.
   

BELT SANDING
HORIZONTAL AND VERTICAL SANDING
You can use the sanding belt in the vertical or horizontal position.
To change from one position to the other:

1. Manually move the sanding belt to the necessary position.
   

SURFACE SANDING ON THE BELT
When sanding flat wide surfaces hold the work tightly to the surface of the belt and against the belt sander table. Keep your fingers away from the sanding belt and use a push or
hold-down stick if possible.

• Exercise extra care when working with very thin pieces.
• Only apply sufficient pressure to allow the sanding belt to remove material.

SANDING INSIDE CURVES
You can sand inside curves using the idler drum end of the belt.

• Hold the work tightly.
• Keep your fingers away from the sanding belt.
• Keep the curve held against the idler drum, moving the work gradually back and forth across the drum.
  

SANDING OUTSIDE CURVES

• Keep the curve pressed against the sanding belt, moving the work from the left to the right of the belt.
• Make sure that you hold the work tightly against the surface of the table.

SANDING DISC

• To stop the work from lifting, only use the right-hand side of the sanding disc.
• Keep the work pressed against the sanding disc, moving from the center of the disc to the right-hand edge.
• Make sure that you hold the work tightly against the surface of the table.
  

MITRE GAUGE
The miter gauge can be used on both tables,

1. Loosen the locking knob.

2. Set the miter fence to the necessary angle.
   • You can adjust the miter gauge to 60 o (right or left).

3. Tighten the locking knob.
   

SANDING SMALL SURFACES USING THE MITRE GAUGE
Use the miter gauge for sanding small end surfaces on the sanding disc.
NOTE: Always move the workpiece across the right side of the sanding disc and hold the work down tightly onto the table surface.

CHANGING THE SANDING DISCS

WARNING: TURN THE POWER OFF AND REMOVE THE PLUG FROM THE OUTLET BEFORE CHANGING THE SANDING DISC.

1. Remove the miter gauge and work table. See “Mounting The Disc Sander Table” on page 7.

2. Remove the disc guard screws and disc guard.
   

3. Remove the sanding disc from the disc plate.
   • The abrasive discs are attached to the plate with a pressure-sensitive adhesive.

4. Make sure that the disc plate is clean.
   • Replacement sanding discs are available from your Clarke dealer.Grit| Part number
   ---|---
   Fine| 6500440
   Medium| 6500441
   Coarse| 6500442

NOTE: ‘Hook and loop sanding discs cannot be used with this machine.

5. Remove the paper backing from the new abrasive disc.
6. Align the edge of the abrasive disc with the plate and press the disc into position, leaving no loose edges.
7. Replace the disc guard, disc guard screws, and work table.
   NOTE: ‘Hook and loop sanding discs cannot be used with this machine.

CHANGING THE SANDING BELTS

CAUTION: CHECK THE INSIDE OF THE BELT FOR A “DIRECTION ARROW”. IF PRESENT, INSTALL THE BELT WITH THE ARROW POINTING IN THE SAME DIRECTION AS THE DIRECTION INDICATOR ON THE HOUSING.

1. Remove the table See “Installing The Belt Sander Table” on page 7.

2. Pull the bottom of the tension lever out to release the belt tension.

3. Remove the screw from the lower cowling and slide the cowling off.
   

4. Loosen the screws shown and lift off the rear plate.

5. Remove the sanding belt from the rollers.
   • Replacement sanding belts are available from your Clarke dealer.Grit| Part number
   ---|---
   Fine| 6502096
   Medium| 6500808
   Coarse| 6502101

6. Fit the new belt onto the rollers.

7. Replace all the parts removed in reverse order.

8. Engage the tension lever to apply tension to the belt.
   

9. Check the belt tracking (described in “Belt Tracking” on page 14) before use and adjust if necessary.

BELT TRACKING
The belt-tracking adjustment is set at the factory so that the abrasive belt will run true on the drums. If, however, the belt should track to one side or the other, an adjustment can be made by turning the tracking knob.
TO TRACK THE SANDING BELT

1. Use your hand to roll the belt toward the belt sander table.
   • If the sanding belt does not move to either side after several full turns, it is tracking correctly.
   • If not adjust the belt tracking dial slightly and roll the belt again.
   •Repeat as necessary.
   

NOTE: Do not make large adjustments to the belt tracking dial and remember it may take some time for the belt to react to any change you make.

MAINTENANCE

WARNING: ALWAYS DISCONNECT THE TOOL FROM THE POWER SOURCE BEFORE MAKING ANY ADJUSTMENTS, INSTALLING OR PERFORMING MAINTENANCE.
CAUTION: TOOL SERVICING MUST BE PERFORMED ONLY BY QUALIFIED REPAIR PERSONNEL. SERVICE OR MAINTENANCE PERFORMED BY UNQUALIFIED PERSONNEL COULD RESULT IN A RISK OF INJURY. WHEN SERVICING A TOOL, USE ONLY IDENTICAL REPLACEMENT PARTS.
CAUTION: FOLLOW INSTRUCTIONS IN THE MAINTENANCE SECTION OF THIS SERVICE MANUAL. USE OF UNAUTHORISED PARTS OR FAILURE TO FOLLOW MAINTENANCE INSTRUCTIONS MAY CREATE A RISK OF ELECTRIC SHOCK OR INJURY.

1. Clean the machine, belt, and disc after each use.
2. Keep the machine dry, clean, and free of oil and grease.
3. Keep the machine in a safe and dry area, out of reach of children.
4. During use, sanding belts and discs can become dirty with sanding debris.
   Use a stick belt cleaner (available at most hardware stores) to remove unwanted material from the belt/disc.

SPECIFICATIONS

EXPLODED DIAGRAM

DECLARATION OF CONFORMITY

A SELECTION FROM THE VAST RANGE OF

PARTS & SERVICE: 0208 988 7400
Parts Enquiries
Parts@clarkeinternational.com
Servicing & Technical Enquiries
Service@clarkeinternational.com
SALES: UK 01992 565333 or Export 00 44 (0)1992 565335
Clarke INTERNATIONAL Hemnall Street, Epping, Essex CM16 4LG
www.clarkeinternational.com   
Parts & Service: 020 8988 7400 /
E-mail: Parts@clarkeinternational.com or
Service@clarkeinternational.com

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