BISCUIT JOINTER Model No: BJ300 Part No:

BISCUIT JOINTER Model No: BJ300 Part No: 6462070 USER INSTRUCTIONS 0406

Thank you for purchasing this CLARKE Biscuit Jointer, which is designed for DIY use only. Please read this instruction leaflet thoroughly and follow the instructions carefully, in doing so you will ensure the safety of yourself and that of others around you, this will also ensure that the Biscuit Jointer will give you long and satisfactory service. Please keep these instructions in a safe place for future reference. CLARKE 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 is 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 Guarantee... 1 General Safety Precautions... 2 Additional Safety Precautions for Power Tools... 3 Additional Safety Precautions for Biscuit Jointers... 4 Electrical Connections... 4 Technical Specification... 5 Parts Description... 6 Setup... 6 Operation... 8 Blade Replacement... 11 Parts List... 12 Maintenance... 14 Trouble Shooting... 14 Hand Arm Vibration Explanation... 15 Declaration of Conformity... 16 Waste electrical products should not be disposed of with household waste. Please dispose of at your local recycling facility. Please Note that details and specifications herein, are correct of time of going to print. However CLARKE International reserve the right to change specifications at any time without prior notice. Copyright CLARKE International All rights Reserved 2006. - 1 -

GENERAL SAFETY PRECAUTIONS WARNING: PLEASE READ ALL INSTRUCTIONS CAREFULLY BEFORE OPERATING 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. ALWAYS Learn the machines applications, limitations and specific potential hazards peculiar to it. Read and become familiar with the entire operating manual. ALWAYS use a face or dust mask. ALWAYS check for damage before use, any damaged part should be checked to ensure that it will operate properly and perform it s intended function. Check for alignment of moving parts, breakage of parts, mountings, and any other condition which may effect the machines operation. Any damage should be properly repaired or the part replaced. If in any doubt DO NOT use the machine. Consult your local dealer. ALWAYS disconnect the tool/machine from the power supply before servicing and when changing accessories. ALWAYS wear safety goggles, manufactured to the latest European safety standards. Everyday glasses do not have impact resistant lenses, they are NOT safety glasses. ALWAYS keep work area clean. Cluttered areas and benches invite accidents. ALWAYS ensure that adequate lighting is available. A minimum intensity of 300 lux should be provided. Ensure the lighting is placed so you will not be working in your own shadow. ALWAYS keep children away. All visitors should be kept at a safe distance from the work area, especially whilst operating the machine. ALWAYS maintain machine in top condition. Keep tools/machines clean for best performance. Follow maintenance instructions. ALWAYS ensure the ON switch if OFF before plugging into the mains. Avoid accidental starting. ALWAYS handle with extreme care, do not carry the tool/machine by it s electrical cable, or yank the cable to disconnect it from the power supply. 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. ALWAYS wear proper apparel. Loose clothing or jewellery may get caught in moving parts. Wear protective hair covering to contain long hair. ALWAYS remove plug from the electrical outlet when adjusting, changing parts, or when working on the machine. - 2 -

GENERAL SAFETY PRECAUTIONS CONTINUED ALWAYS keep your proper footing and balance at all times DO NOT over reach. For best footing wear rubber soled footwear. Keep floor clear of oil, scrap wood etc. ALWAYS use recommended accessories, the use of improper accessories could be hazardous. NEVER operate the machine when under the influence of drugs, alcohol or any medication. NEVER leave the machine running unattended. Turn power OFF. Do not leave the machine until it comes to a complete stop. NEVER force the machine, it will do a better and safer job at the rate for which it was designed. 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 environments. ALWAYS guard against electric shock. Prevent body contact with earthed or grounded surfaces (pipes, radiators etc.) Safety can be further be improved by using a residual current device (RCD). ALWAYS store the tool out of the reach of children, DO NOT allow children to use the tool. ADDITIONAL PRECAUTIONS FOR POWERTOOLS ALWAYS wear ear protectors/defenders as the noise level of this machine can exceed 91dB (A). ALWAYS secure all work sufficiently using a vice or clamps. Do not use hands to secure work as this would be extremely dangerous. ALWAYS switch the machine OFF immediately the task is completed. ALWAYS check that all adjusters, chuck keys and wrenches have been removed BEFORE turning the tool ON. ALWAYS ensure safety devices are in place and are working correctly, if not DO NOT use the machine until rectified. DO NOT use the machine if the electrical cable, plug or motor is in poor condition. DO NOT allow the ventilation slots in the machine to become blocked. DO NOT touch the blade immediately after use, allow time to cool. ALWAYS keep the mains cable well away from the blade and ensure an adequate electrical supply is close at hand so that the operation is not restricted by the length of the cable. ALWAYS connect devices which are provided for dust extraction. NOTE: Connecting such devices does not preclude the user from wearing a mask to prevent the inhalation of dust particles. - 3 -

ADDITIONAL PRECAUTIONS FOR BISCUIT JOINTERS ALWAYS ensure that all nails have been removed from the piece of wood beforehand. Nails will damage the cutting blade. DO NOT lock the cover with the blade in the open position, always ensure it is operating properly, freely returning to fully cover the cutting blade. DO NOT stop the blade by applying lateral pressure on the side of the blade. DO NOT use blades that do not comply with the specifications in this manual. DO NOT use high speed steel (HSS) blades or blades that are deformed or cracked etc. Replacement blades are available from your CLARKE dealer. ELECTRICAL CONNECTIONS This product is provided with a standard 13 amp, 230 volt (50Hz) BS1363 plug, for connection to a standard, domestic electrical supply. Should the plug need replacing at any time, ensure that a plug of identical specification is used. WARNING: This appliance is double insulated. Should it ever be necessary to change the plug, the wires in the mains lead should be wired according to the following colour code: BLUE - NEUTRAL BROWN - LIVE Connect the BLUE coloured wire to the plug terminal marked with a letter N or coloured BLACK. Connect the BROWN coloured wire to the plug terminal marked with a letter L or coloured RED. IMPORTANT!: If this appliance is fitted with a plug which is moulded on to the electrical cable (i.e. non-rewireable) please note: 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. NEVER use the plug without the fuse cover fitted. Should you wish to replace a detached fuse carrier, ensure that the correct replacement is used (as indicated by marker or colour code). The fuse in the plug MUST be replaced with one of the same rating (5 amps) and this must be approved to BS1362. IMPORTANT!: If in any doubt, do not attempt any electrical repair yourself. Consult a qualified technician. IMPORTANT!: 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 the machine, or larger. When using a cable reel, ALWAYS unwind the cable completely. - 4 -

TECHNICAL SPECIFICATION Description: Model No:... BJ300 Part No:... 6462070 Product use:... DIY/Light Industrial Product Specification: Typical Application:... Wood Joining No Load Speed:...11,000 RPM IP Rating:... 20 Fence Adjustment:... 0-135 Cutting Depth Preset Modes: 0:... 8mm 10:... 10mm 20:... 12.3mm Compatible Biscuit Sizes: #0... 15mm Wide x 45mm Long #10... 19mm Wide x 54mm Long #20... 23mm Wide x 60mm Long Drive Shaft Details: Spindle Thread Size:... M10 Spindle Diameter:... 22mm Cutter Details: Outer Diameter:... 100mm Bore Diameter:... 22mm Blade Thickness:... 3.5mm Blade Type:... Tungsten Carbide Tipped Noise Emissions: Sound Pressure:...91.7 db (A) Sound Power Measured:...79 db LWa Sound Power Guaranteed:...102.7 db LWa Vibration Emissions: Measured Emission: (Statement on Page 15)... 2.9 (m/s²) Motor: Operating Voltage & Frequency:... 230V ~ 50Hz Output:... 410W Input Wattage @ 230V Typical Load:... 860W Input Ampere @ 230V Typical Load:... 3.85A Fuse Rating (BS1362):... 5 Amp Dimensions & Weights: Product: (Length x Height x Width)... 360mm x 190mm x 174mm (max) Case Size:... 405mm x 220mm x 160mm Packed Weight:... 4.5Kg Unpacked Weight:...3.22Kg Package Contents: Biscuit Jointer:... x1 Dust Extraction Adaptor:... x1 Dust Bag:... x1 Moulded Plastic Carry Case:... x1-5 -

PARTS DESCRIPTION Handle Fence Sight Window Kerf Guide Bevel Adjustment Lever Depth Adjustment Knob Spindle Lock Lock ON Switch Base Dust Extraction Port Fig.1 ADJUSTING THE CUTTING DEPTH SETUP ALWAYS Switch the tool OFF and unplug from the power supply BEFORE making any adjustments. The cutting depth can be set by turning the depth adjustment knob, (refer to Fig.1). The table below shows the relationship between the settings on the adjustment knob to the cutting depth, material thickness and the associated biscuit. K nob Marking: C utting Depth: M aterial Thickness: Biscuit: 0 8.0mm 8-12mm No: 0 10 10.0mm 12-15mm No:10 20 12.3mm > 15mm No:20-6 -

ADJUSTING THE CUTTING HEIGHT SETUP CONTINUED NOTE: Always unplug the biscuit jointer before making any adjustments. The height can be set by unlocking both of the bevel adjustment levers and sliding the fence to the desired level with the aid of the scale. (refer to fig.1). Normally the height set corresponds to half the material s thickness (biscuit grooves are cut in the centre of the piece). Note: a thicker piece may have more than one biscuit across it s thickness i.e. one at 1/3rd and one at 2/3rds. If the bevel adjustment levers are in the way when working, pull the lever out and turn to a new position. ADJUSTING THE CUTTING ANGLE The cutting angle can be set by unlocking both bevel adjustment levers and moving the fence to the required angle. (refer to fig.1). MOUNTING THE DUST EXTRACTION For dust extraction connect either a vacuum to the dust extraction adaptor or the included dust bag. Regularly empty the dust bag to maintain dust extraction performance. - 7 -

MAKING EDGE TO EDGE JOINTS OPERATION NOTE: Always unplug the biscuit jointer before making any adjustments. 1. Draw a reference mark A at 90 to the centre point of each proposed joint location B, space additional joints along the timbers edge approx. 100mm apart. 2. Clamp the work piece securely so that it will not move during the cut. A 3. Set the plunge depth to the size of biscuits to be used. No.20 biscuits are generally suitable for most applications. If you are using stock which is 15mm or less in thickness then smaller biscuits will be required. 4. Unlock the bevel adjustment levers B and adjust the angle of the fence to 90. Set the height of the fence as required and re-lock the bevel adjustment levers. 5. Hold the tool with one hand on the handle and the other hand on the motor body. 6. Rest the fence on the work piece and align the centre marking on the tool with the line marked on the work piece. 7. Switch the tool on by sliding the ON/OFF switch forward as far as possible. Latch the switch in the ON position by pressing down on the front of the switch, (the motor will run continuously). 8. Maintaining a downward pressure on the fence, plunge the blade into the work piece by pushing the whole tool forwards up to the stop until the cut is complete. 9. Release the forward pressure and allow the tool to return so the blade is clear of the work piece. Switch the tool OFF by pressing on the back of the ON/OFF switch. 10. ALWAYS allow the motor to stop before removing the tool from the work piece. 11. Repeat steps 5-11 until all slots are cut. 12. Once all biscuit slots have been cut, place a biscuit in each joint and dry assemble the work pieces. Check that each joint lines up and fits. 13. Disassemble the work pieces and place a bead of glue in each slot, also spread glue over the entire surface of the joint. 14. Reassemble the work pieces and clamp together until the glue has set. - 8 -

MAKING MITRE JOINTS OPERATION CONTINUED NOTE: Always unplug the biscuit jointer before making any adjustments. 1. Using a combination square draw a reference mark A through the centre point of each joint perpendicular to the mitred edge B. A 2. Follow the cutting instructions (2-14) for edge to edge jointing on page 8. B MAKING BUTT JOINTS 1. Position the mating pieces together and draw a reference mark A at 90 to the centre point of each proposed joint location B,. A 2. Follow the cutting instructions (2-14) for edge to edge jointing on page 8. B MAKING CORNER JOINTS 1. Position the pieces together and draw a reference line on the outside face of one piece and the end of the second piece. 2. Follow the cutting instructions (2-11) on page 8 and cut a slot into the end of piece A. 3. Clamp piece B that it protrudes above your work bench. 4. Without changing any of the settings on the jointer. Follow the cutting instructions (5-14) on page 8 and cut a slot into the face of piece B. A B - 9 -

MAKING T JOINTS OPERATION CONTINUED NOTE: Always unplug the biscuit jointer before making any adjustments. A T joint is used when the end of one piece is joined to the face of another, a typical application would be connecting the shelves of a bookcase to the vertical supports. 1. Position the vertical pieces on a level surface with the inside faces, uppermost. (refer to A on fig.2). 2. Determine the location for each biscuit joint and mark the horizontal and vertical centre lines on each piece. NOTE: measure carefully to ensure the centre lines on both pieces line up. B Fig.2 A 3. Securely clamp a piece of timber 9.5mm below the centre line squarely across the width of the board ( B on fig.2). This will be used as a guide for the base of the jointer. NOTE: The centre of the cutting 9.5mm blade is offset 9.5mm above the jointer s base. 4. Unlock the bevel adjustment levers and set the fence angle to 0. 5. Set the plunge depth to the size of biscuits to be used. 6. Hold the tool with one hand on the handle and the other hand on the motor body. 7. Rest the base of the jointer up against the edge of the guide piece of timber B, with the cutter pointing down towards board A. Align the centre line of the tool with the vertical centre line marked on the board. 8. Switch the tool on by sliding the ON/OFF switch forward as far as possible. Latch the switch in the ON position by pressing down on the front of the switch, (the motor will run continuously). 9. Maintaining a downward pressure, plunge the blade into the work piece by pushing the whole tool forwards up to the stop until the cut is complete. 10. Release the forward pressure and allow the tool to return so the blade is clear of the work piece. Switch the tool OFF by pressing on the back of the ON/OFF switch. 11. ALWAYS allow the motor to stop before removing the tool from the work piece. 12. Reposition and clamp the guide board and repeat steps 6-11 until all slots are cut. 13. Once all biscuit slots have been cut into the faces of the boards follow the cutting instructions (2-14) on page 8 for cutting slots into the end of the boards which will form the shelves. - 10 -

BLADE REPLACEMENT ALWAYS switch off and isolate from the mains supply by removing the plug from the mains socket BEFORE changing the blade. 1. Remove the kerf guide by unscrewing the two screws with a cross head screwdriver. (circled in fig.3). 2. Place the biscuit jointer upside down on a workbench. Remove the plastic insert disc on the base plate by inserting a small slotted screwdriver into the recess slot and levering it out. (circled in fig.4). Fig.3 Fig.4 3. Depress the spindle lock, and using a peg spanner in the holes circled in fig.5 undo the flange nut by turning the spanner anticlockwise. 4. Push the body of the jointer forward to expose the blade allowing it to be removed. 5. When inserting a new blade push the body of the jointer forward to allow the blade to be passed over the spindle. Fig.5 6. To ensure the blade is in the correct position over the spindle, manually turn the blade (blade should rotate freely) the arrow on the case indicates the direction of rotation. 7. Replace the flange nut by pushing down on the spindle lock button and tightening the flange with a peg spanner. 8. Replace the plastic insert disc making sure that it is firmly in position and is flush with the outer base housing. 9. Replace the kerf guide and tighten the two cross head screws making sure that the slot in the kerf guide lines up with the blade and the guide does not protrude beyond the base plate. - 11 -

PARTS LIST - 12 -

PARTS LIST ITEM: DESCRIPTION: PART NO: 1. Rubber bearing shoe... HT30001 2. Bearing... HT30002 3. Armature... HT30003 4. Check ring... HT30004 5. Bearing cap... HT30005 6. Bearing... HT30006 7. Stop pin... HT30007 8. Spring... HT30008 9. Check ring... HT30009 10. Screw... HT30010 11. Gear case... HT30011 12. Bearing... HT30012 13. Check ring... HT30013 14. Spring ring... HT30014 15. Gear... HT30015 16. Bearing cap... HT30016 17. Bearing... HT30017 18. Front cap... HT30018 19. Spring washer... HT30019 20. Screw... HT30020 21. Wood ruff key... HT30021 22. Output shaft... HT30022 23. Screw... HT30023 24. Spring... HT30024 25. Cable jacket... HT30025 26. Screw... HT30026 27. Cable plug... HT30027 28. Back cap... HT30028 29. Screw... HT30029 30. Brush holder... HT30030 31. Carbon brush... HT30031 32. Switch... HT30032 33. Stator... HT30033 34. Screw... HT30034 35. Fan baffle... HT30035 36. Pin... HT30036 37. Screw... HT30037 38. Handle... HT30038 39. Bevelled gear... HT30039 ITEM: DESCRIPTION: PART NO: 40. Spring washer... HT30040 41. Nut... HT30041 42. Screw... HT30042 43. Slide switch knob... HT30043 44. Switch draw bar... HT30044 45. Spring... HT30045 46. Condenser... HT30046 47. Switch... HT30047 48. Screw... HT30048 49. Cord clamp... HT30049 50. Screw... HT30050 51. Handle... HT30051 52. Right board... HT30052 53. Adjust knob... HT30053 54. Seat... HT30054 55. Pin... HT30055 56. Spring... HT30056 57. Screw... HT30057 58. Collecting bag... HT30058 59. Bend pipe... HT30059 60. Positioning pin... HT30060 61. Collecting pipe... HT30061 62. Screw... HT30062 63. Flange... HT30063 64. Blade... HT30064 65. Flange nut... HT30065 66. Bottom cap... HT30066 67. Nut... HT30067 68. Spring... HT30068 69. Lock knob... HT30069 70. Angle board... HT30070 71. Screw... HT30071 72. Screw... HT30072 73. Slot board... HT30073 74. Lock screw... HT30074 75. Fence... HT30075 76. Transparent cover... HT30076 77. Spring lock... HT30077-13 -

MAINTENANCE Always inspect the tool before use and ensure it is in top condition. Keep the ventilation slots clear at all times, prevent foreign matter from entering. Check the power cable to ensure it is in sound condition and free from cracks, bare wires etc. Avoid using solvents to clean the plastic parts of the jointer, most plastics are susceptible to damage from the various types of commercial solvents. Use a moist soft cloth only. Lubricate all moving parts at regular intervals. After extensive use the grease in the gearbox will require replenishment, consult your CLARKE dealer regarding this. TROUBLE SHOOTING PROBLEM: Biscuit Jointer is Overheating. CAUSE: The tool is dirty. Tool is being overloaded. TROUBLE SHOOTING: Clean the ventilation holes, blow out with compressed air or clean with a dry cloth. Do not use for heavy duty work, do not apply excessive pressure. PROBLEM: Excessive Sparking Occurs. CAUSE: Worn motor brushes. TROUBLE SHOOTING: Consult your CLARKE dealer for parts and advise. PROBLEM: Biscuit Jointer does not operate when switched ON. CAUSE: Blown fuse. TROUBLE SHOOTING: Check the fuse is sound and replace if required. If the fuse continues to blow or the fuse is sound and the jointer fails to operate consult your CLARKE dealer. - 14 -

HAND-ARM VIBRATION Employers are advised to refer to the HSE publication Guide for Employers. All hand held power tools vibrate to some extent, and this vibration is transmitted to the operator via the handle, or hand used to steady the tool. Vibration from about 2 to 1500 herz is potentially damaging and is most hazardous in the range from about 5 to 20 herz. Operators who are regularly exposed to vibration may suffer from Hand Arm Vibration Syndrome (HAVS), which includes dead hand, dead finger, and white finger. These are painful conditions and are widespread in industries where vibrating tools are used. The health risk depends upon the vibration level and the length of time of exposure to it in effect, a daily vibration dose. Tools are tested using specialised equipment, to approximate the vibration level generated under normal, acceptable operating conditions for the tool in question. For example, a grinder used at 45 on mild steel plate, or a sander on softwood in a horizontal plane etc. These tests produce a value a, expressed in metres per second per second, which represents the average vibration level of all tests taken, in three axes where necessary, and a second figure K, which represents the uncertainty factor, i.e. a value in excess of a, to which the tool could vibrate under normal conditions. These values appear in the declaration on page 7. You will note that a third value is given in the specification - the highest measured reading in a single plane. This is the maximum level of vibration measured during testing in one of the axes, and this should also be taken into account when making a risk assessment. a values in excess of 2.5 m/s 2 are considered hazardous when used for prolonged periods. A tool with a vibration value of 2.8 m/s 2 may be used for up to 8 hours (cumulative) per day, whereas a tool with a value of 11.2 m/s 2 may be used for ½ hour per day only. The graph below shows the vibration value against the maximum time the respective tool may be used, per day. The uncertainty factor should also be taken into account when assessing a risk. The two figures a and K may be added together and the resulant value used to assess the risk. It should be noted that if a tool is used under abnormal, or unusual conditions, then the vibration level could possibly increase significantly. Users must always take this into account and make their own risk assessment, using the graph as a reference. Some tools with a high vibration value, such as impact wrenches, are generally used for a few seconds at a time, therefore the cumulative time may only be in the order of a few minutes per day. Nevertheless, the cumulative effect, particularly when added to that of other hand held power tools that may be used, must always be taken into account when the total daily dose rate is determined. - 15 -

- 16 -