Clarke CBTSR2 Bench Top Shaper Router Instruction Manual

1. Connect the dust extract if processing wood or similar
  materials.
2. Secure the workpiece before operation.
3. Avoid abnormal posture during operation.

FAQ

Q: Can this machine be used on metal or stone?

A: No, the machine must not be used on metal or stone, it is
ideal for shaping wood and plastic.

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BENCHTOP SHAPER/ROUTER
MODEL NO: CBTSR2
PART NO: 6462091

OPERATION & MAINTENANCE INSTRUCTIONS

ORIGINAL INSTRUCTIONS

GC04/24 Rev 2

INTRODUCTION
Thank you for selecting this Clarke product.
The machine is ideal for shaping wood and plastic and also for cutting out knots, cutting grooves, removing recesses, copying curves and logos, etc. The machine must not be used on metal, stone, etc.
Please note that setting up and adjustment of this product ideally requires some experience of working with this type of equipment.
Save these instructions including all safety warnings and instructions for future reference.

SPECIFICATIONS

Feature Operating Voltage and Frequency Rated Input Wattage: Table Size (with extension) L x W (mm) Speeds Ingress protection rating Spindle height adjustment Shank size Max Dimension of workpiece (L x W x H) Table Insert Sizes Dust Extract Adaptor Diameter
Sound Pressure Sound Power Guaranteed LWa Product Weight (Unpacked):

Specification 230V ~ @ 50 Hz 1500W 1030 x 360 mm 11500 rpm to 24000 rpm IP20 0 – 40 mm 6/8/12mm and ¼” / ½” 650 x 160 x 65 mm 32/47/55/75 mm Outer Dia: 100 mm Inner Dia: 93 mm 89 dB (A) 102 dB 20.9 kg

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GENERAL POWER TOOL SAFETY WARNINGS
WARNING: READ ALL SAFETY WARNINGS AND ALL INSTRUCTIONS. FAILURE TO FOLLOW THE WARNINGS AND INSTRUCTIONS MAY RESULT IN ELECTRIC SHOCK, FIRE AND/OR SERIOUS INJURY.
1. Keep the work area tidy. · Clutter in the work area can lead to accidents.
2. Take environmental influences into account. · DO NOT expose power tools to rain. · DO NOT use power tools in a damp or wet environment. · Make sure that the work area is well lit. · DO NOT use power tools where there is a risk of fire or explosion.
3. Protect yourself from electric shock. 4. Keep other persons away.
· DO NOT let persons, especially children, not involved in the work touch the machine and keep them away from the work area.
5. Securely store unused power tools. · Unused power tools should be stored in a dry, elevated or enclosed location out of the reach of children.
6. DO NOT overload your power tool. · They work better and more safely in the specified output range.
7. Use the correct power tool for the task. · DO NOT use low-output power tools for heavy work. · DO NOT use the power tool for purposes for which it is not intended.
8. Wear suitable clothing. · DO NOT wear loose clothing or jewelry, which can become entangled in moving parts. · When working outdoors, anti-slip footwear is recommended. · Tie back and restrain long hair.
9. Use protective equipment. · Wear protective eye wear. · Wear a dusk mask when carrying out dust-creating work. 3
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10. Connect the dust extract if you will be processing wood, materials similar to wood or plastics.
· If connections for dust extraction and a collecting device are present, make sure that they are connected and used properly.
· When processing wood materials and plastics, operation in enclosed spaces is only permitted with the use of a suitable extraction system.
11. DO NOT use the power cable for purposes for which it is not intended.
· DO NOT use the power cable to pull the plug out of the socket. Protect the cable from heat, oil and sharp edges.
12. Secure the workpiece.
· Use clamping devices to hold the workpiece in place as it is held more securely than with your hand.
· An additional support is necessary for long workpieces (table, trestle, etc.) in order to prevent the machine from tipping over (if not bolted down).
· Always press the workpiece firmly against the working plate and fence in order to prevent bouncing and twisting of the workpiece.
13. Avoid abnormal posture.
· Make sure that you have secure footing and always maintain your balance.
· Avoid awkward hand positions in which a sudden slip could cause one or both hands to come into contact with the cutter bit.
14. Take care of your tools.
· Keep cutting tools sharp and clean in order to be able to work better and more safely.
· Check the power cable of the power tool regularly and have it replaced by a recognised specialist if damaged.
· Check extension cables regularly and replace them if damaged.
· NEVER remove loose splinters, chips or jammed wood pieces from the cutter bit until it has stopped.
· If the cutter bit is blocked due to abnormal feed force during cutting, turn the machine off and remove the work piece. Ensure that the cutter bit runs freely. Turn the machine back on and start a new cutting operation with less feed force.
15. Before switching on, make sure that any adjusting tools are removed.
16. Avoid inadvertent starting.
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· Make sure that the machine is switched off when inserting the plug into a power outlet.
17. Stay alert.
· Pay attention to what you are doing. DO NOT use the power tool when you are distracted, tired, or under the influence of drugs or alcohol.
18. Check the power tool for potential damage.
· Protective devices and other parts must be carefully inspected to ensure that they are fault free and function as intended prior to continued use of the power tool.
· Check whether the moving parts function faultlessly and do not jam or if parts are damaged. All parts must be correctly mounted and all conditions must be fulfilled to ensure fault free operation of themachine.
· Damaged protective devices and parts must be properly repaired or replaced.
· DO NOT use faulty or damaged connecting cables.
· DO NOT use apower tool if the switch cannot be switched on and off.
19. The use of other accessories than recommended items can have a risk of injury.
20. Have your power tool repaired by a qualified electrician.
· This power tool conforms to the applicable safety regulations. Repairs may only be performed by an electrician using original spare parts or accidents could occur.
21. The operator must always stand in front of the machine while working.
ADDITIONAL SAFETY INSTRUCTIONS FOR ROUTERS
1. Check that cutting bits are in perfect condition before use.
2. Use table insert rings appropriate for the size of the cutting bits.
3. ALWAYS wear suitable personal protective equipment including:
· Hearing protection to avoid the risk of becoming hearing impaired.
· Respiratory protection to avoid the risk of inhaling harmful dust.
· Safety goggles to avoid eye injuries due to flying particles.
4. Beware of injury when handling bits and materials with sharp edges.
5. When working with wood, beware of conditions that cause the release of dust, e.g. the type of material to be processed and the correct setting of the hood/guide plates/guides.
6. Support long workpieces sufficiently to hold their position.
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7. Take care of possible rebound due to any guide for a small workpiece being unsuitable.
8. Use additional equipment when processing narrow workpieces.
9. Tools that have not been maintained can trigger uncontrollable situations. Only use sharp, well maintained cutting bits.
10. Before changing cutting bits or making adjustments, switch off the machine.
11. Select a rotational speed that is suitable for the cutting bit and work material used.

RESIDUAL RISKS
The machine is built according to current and recognized safety regulations. Nevertheless residual risks can occur during work.
· Danger of injury to fingers and hands by the tool due to inappropriate guidance of the work piece.
· Injuries caused by a work piece flying off due to lack of restraint or guidance.
· Health hazards due to wood dust or wood chips. Wear personal protection equipment such as eye protection. Use a ventilation system.
· Injuries by defective tools. Examine the tool regularly for soundness.
· Danger of injury to fingers and hands during tool changes. Wear suitable working gloves.
· Danger of injury when switching on the machine.
· Hazards due to current by use of incorrect electrical connecting cables.
· Residual risks can be minimized if the safety instructions and operating instructions are followed in full.

SAFETY SYMBOLS ON THE MACHINE OR PACKAGING

Read instruction manual before use

Wear ear defenders

Wear safety glasses

Wear a breathing mask.

Wear protective gloves

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ELECTRICAL CONNECTIONS
WARNING! READ THESE ELECTRICAL SAFETY INSTRUCTIONS FULLY BEFORE CONNECTING THE MACHINE TO THE MAINS SUPPLY.

This machine 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, make sure that a plug of identical specification is used.

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 colours of the wires in the power cable do not agree with the markings on the plug:

· Connect the blue wire to the terminal which is marked N.
· Connect the brown wire to the terminal which is marked L.
· Connect the yellow and green wire to the terminal which is marked E or

Plug must be BS1363/A approved.

Earth (Green and Yellow)
Neutral (Blue)

Always fit a 13 Amp fuse.
Live (Brown)

Ensure that the outer sheath of the cable is firmly held by the clamp

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.
CABLE EXTENSIONS
Always use an approved cable extension suitable for the power rating of this machine. The conductor size should also be at least the same size as that on the machine, or larger.

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INVENTORY
The following items are supplied for fitting/assembly. 1. Fence (52) 2. Sliding Bracket (64) 3. Fence Plate (66) 4. Downwards Pressure Bar (63) 5. Mounting Bracket for the above (56) 6. 2 x Pressure Pads (68) 7. Square Mounting Plates (61) 8. Square Supports (60) 9. Elevating Handle (31) 10. Table Extensions (41 & 71) 11. Kickback Safety Fence (103) 12. Mounting Bracket for the above (104) 13. Dust Extractor Adaptor (53) – (not shown) 14. Transparent Tool Guard (50) – (not shown) 15. 6mm Collet (78) 16. 8mm Collet (77) 17. 12 mm Collet 18. Table Insert Rings (49) 19. Spanners (73) 20. 3mm Hex Key (74) 21. 4mm Hex Key (75) 22. Mitre Fence (99) 23. Push Blocks (72) 24. Fixings Packs 25. Table extension alignment bracket Numbers in brackets refer to pages 26-29.
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COMPONENT INVENTORY
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ASSEMBLY

MOUNTING THE MACHINE
It is recommended to fix the machine to a workbench using the four holes provided.
· Holes must be drilled in the workbench which align with those on the machine base.
· Each corner must be secured to the workbench using nuts and bolts long enough to go through the workbench (not supplied).
· The workbench must be large enough to prevent tilting of the machine when working.
ASSEMBLING THE FENCE
Before starting work the fence must be assembled and fitted to the work table.
FITTING THE SLIDING BRACKET TO THE FENCE

Parts needed for this step

1 x

Fence

1 x

Sliding bracket

1 x

Carriage bolt

1 x

Plastic cap nut

1 x

Washer

M6 x 25 M6 6mm

1. Insert the carriage bolt into the fence from below as shown.

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2. Drop the sliding bracket over the bolt so that it sits in the grooves on the fence.
3. Secure in place using the washer and plastic cap nut.

FITTING THE FENCE PLATES

Parts needed for this step

4 x

Carriage bolt

4 x

Plastic cap nut

4 x

Washers

2 x

Fence plates

1. Insert the 4 carriage bolts into the attachment holes and screw them on finger tight with a washer and a plastic cap nut.

M6 x 20 M6 6mm

2. Slide the fence plates over the carriage bolt heads. · Make sure that the fence plates are at the same height.
3. Tighten the plastic cap nut to lock the fence plates in position.
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FITTING THE DOWNWARD PRESSURE BAR

Parts needed for this step

1 x

Mounting Bracket

2 x

Bolt

2 x

Nut

4 x

Washers

1 x

Pressure Bar

2 x

Carriage Bolts

2 x

Wingnuts

1. Fit the mounting bracket to the central part of the main fence as shown.

M6 x 40 M6 6mm
M6 x 35 M6

2. Secure in place using 2 x M6 x 40 bolts (from below), 2 washers and 2 x M6 nuts supplied.

3. Position the pressure bar and lock in position using the 2 carriage bolts, 2 washers and 2 wing nuts provided.
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FITTING THE PRESSURE PADS

Parts needed for this step

2 x

Pressure pads

2 x

Square mounting plate

2 x

Square supports

2 x

Clamp

2 x

Allen screws

2 x

Plastic cap screws

4 x

Carriage bolts

4 x

Plastic cap nuts

4 x

Washers

1. Insert the 2 square supports in the 2 square sockets on the main part of the fence.
2. Secure them with the 2 Allen screws from below.

NOTE: You will need to slide the sliding bracket forward to gain access to one of the holes.

M6 x 16 M6 x 20 M6 x 35 M6 6mm

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3. Slide the square mounting plate into the clamp as shown.
4. Slide the clamp over the square support as shown.
5. Secure in place by tightening the knob on the clamp. Repeat for the other assembly.
6. Fit the pressure pads to the square mounting plates using 4 carriage bolts, 4 washers and 4 plastic cap nuts.
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FITTING THE FENCE ONTO THE WORKING TABLE

Parts needed for this step

1 x

Carriage bolt

1 x

Carriage bolt

2 x

Plastic cap nuts

2 x

Washers

M6 x 20 M6 x 40 M6 6mm

1. Fix the 2 plastic cap screws into the grooves in the fence using the washers and carriage bolts as shown.
· The longer carriage bolt goes on the right, when viewing the fence from the rear.
2. Put the tops of the carriage bolts through the opening in the table.
3. Position the fence as required and tighten the plastic cap nuts.
FITTING THE HANDLE

Parts needed for this step

1 x

Handle

1 x

Nut (already fitted)

1. Slide the handle over the shaft making sure it engages with the pin.
2. Secure in place using the nut.

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FITTING THE TABLE EXTENSION

Parts needed for this step

2 x

Table extensions

1 x

Table alignment tool

8 x

Allen screws

6 x

Allen screws

14 x Washers

8 x

Hexagonal nyloc nuts

6 x

Spring washers

1. Remove the fence and use the table alignment tool to accurately position the table extension for assembly. Tighten the wingnuts to secure in position.
2. Flip the unit upside down onto a smooth flat surface.

3. Attach the extension table to both sides with 4 allen screws M5 x 20, 4 washers and 4 hexagonal nyloc nuts M5.

M5 x 20 M5 x 12 5mm M5 5mm

4. Also secure using 3 allen screws (M5 x 12), 3 washers and 3 spring washers each.
5. Align the table and tighten all screws.
6. Repeat for the other table extension.
7. Flip the unit the right way up again (with assistance if required). Remove the alignment bracket and replace the fence.
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FITTING THE KICKBACK SAFETY FENCE

Parts needed for this step

1 x

Kickback safety fence

1 x

Mounting bracket

2 x

Cross head screws with washers

2 x

Carriage bolts

2 x

Washers

2 x

Wing nuts

1. Align the mounting bracket with the two holes on the front of the table.

M5 x 10 M6 x 25 6mm M6

2. Insert the two cross head screws with washers into the holes and tighten.
3. Install the kickback safety fence · You can adjust the fence to the thickness of the work piece.
4. After setting, fix it in place with the help of the two carriage bolts, 2 washers and 2 wing nuts.
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CONNECTING TO A DUST EXTRACTOR
Slide the suction hose of the dust extractor unit onto the dust extraction port at the rear of the moulding fence.
· For hoses with a dia of 100 mm, using the adapter supplied.
FITTING THE TRANSPARENT TOOL GUARD
1. Remove downward pressure bar and bracket shown on page 12. 2. Place transparent tool guard in
position as shown.
3. Insert pin to secure. · Check to see the guard functions correctly before use.
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BEFORE USE
INSTALLING AND CHANGING THE COLLETS AND CUTTING BITS
WARNING: BEFORE CARRYING OUT ANY ADJUSTMENT OR MAINTENANCE, MAKE SURE THAT THE MACHINE IS DISCONNECTED FROM THE MAINS SUPPLY. 1. Remove the insert rings from the table.
2. Loosen the securing screw and use the handle to raise the spindle to its highest position.
3. Press and hold the Spindle Lock button.
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4. Loosen the collet nut using the spanners provided and remove the cutting bit and collet nut if required.
5. Insert the required collet/collet nut and tighten it slightly.
6. Insert the bit into the collet. · At least 3/4 of the cutting bit shank must be gripped in the collet before tightening.
7. Press and hold the spindle lock button and tighten the collet nut securely. · Before every use of the machine make sure that the cutting bit is secure.
8. Place the insert rings back in to their original position. · The insert rings must be used in order to keep the spacing between table and cutter to a minimum. Only fit enough insert rings so as to allow the bit to come through the surface of the table without touching the rings. · Before switching on check the insert rings are seated correctly.
9. Reconnect the machine to the power supply.
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ADJUSTMENTS
SPEED CONTROL
The speed control has 6 speeds. Determine the optimal setting by testing on a scrap piece of wood.
NOTE: The use of the correct setting will increase the life-span of the cutter. It, also affects the quality of the cut.
RAISING/LOWERING THE CUTTER
To raise or lower the spindle height. 1. Loosen the securing screw. 2. Use the handle to raise or lower
the spindle to the required height. 3. Tighten the securing screw.
ADJUSTING THE FENCE
1. Loosen the plastic cap screws shown on the back of the fence.
2. Move the fence to the desired position.
3. Re-tighten the plastic cap screws to keep the fence in this position.
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OUTFEED FENCE OFFSET
Once the workpiece passes the cutting bit it may be thinner then when it started. If so you should adjust the left fence to compensate for the missing material.
1. Loosen the plastic cap screws. 2. Move the left fence towards you
slightly and tighten the plastic cap screws.
ADJUST THE CROSS-CUTTING JIG
1. Loosen the locking knob. 2. Set the jig to the desired angle. 3. Tighten the locking knob.
· Always make a sample cut in a piece of waste material in order to guarantee the angles are correct.
SWITCHING ON AND OFF
· Press the green ON (I) button to start the machine.
· Press the red OFF (O) button to stop the machine.
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USING THE MACHINE
1. Insert an appropriate cutting bit. 2. Adjust the machine speed and adjust the fence so that the material is
supported along its entire length. 3. Switch the machine on by pressing the green ON (I) button. 4. Make sure the workpiece is firmly pressed against the fence. 5. Push the work piece softly from right to left against the turning direction of
the cutting bit. · Keep your speed constant. DO NOT push too fast as it would slow down
the motor. · Feeding the work piece too fast will result in poor cutting quality. There is
also the risk of damaging the cutting bit or the machine motor. · Feeding the work piece too slowly will result in burnt spots on the work
piece. · The correct intake speed depends on the cutting bit size, the material
type of the workpiece and the cutting depth. It is recommended to practice first with a piece of scrap wood in order to determine the correct speed. 6. With very hard wood and important cuts it may be better to work progressively, taking several shallow cuts until the desired depth is achieved. 7. Switch the machine off by pressing the red OFF (O) button.
OVERLOAD SWITCH
The machine is fitted with an overload switch to protect the motor. In the event of an overload situation, the machine will cut out automatically. After a short time press the overload reset button to reset the machine.
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MAINTENANCE AND SERVICING
WARNING: BEFORE CARRYING OUT MAINTENANCE, MAKE SURE THAT THE MACHINE IS DISCONNECTED FROM THE MAINS SUPPLY.
CLEANING
· Keep all safety devices, air vents and the motor housing free of dirt and dust. Wipe the equipment with a clean cloth or blow it with compressed air at low pressure (always wear PPE when using compressed air).
· We recommend that you clean the machine as soon as you have finished using it.
· DO NOT use cleaning agents or solvents as these could attack the plastic parts of the machine.
· Make sure that no water can enter the machine. The ingress of water into a power tool increases the risk of an electric shock.
CUTTING BITS · Any resin must be cleaned off the cutting bits at regular intervals with an appropriate resin remover.
STORAGE
· Store the machine and accessories out of children’s reach in a dark, dry place at above freezing temperature. The ideal storage temperature is between 5 and 30°C.
· Ideally, store the machine in its original packaging. · Cover the machine in order to protect it from dust and moisture. · Store the operating manual with the machine.
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COMPONENT PARTS
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COMPONENT PARTS

No Description

Chuck

X-Pan head screw & washer

Motor rise & fall guide bar

X-Pan head screw

Motor

Motor connecting plate

Slider

Hex socket cap screw

Guide profile

10 Pointer

11 Hex bolt

12 Hex nut

13 Bevel gear support

14 Deep groove ball bearing

15 Hex nut

16 Hex socket cap screw & washers

17 Hex socket cap screw & washers

18 Support assembly

19 Bevel gear

20 Vertical adjustment screw

21 Circlip

22 Flat key

23 Circlip

24 Vertical adjustment shaft gear

25 Vertical adjuster

26 Roll pin

27 Handle spindle

28 Handle cap

29 Handle

30 Dome nut

No Description 31 Adjusting handle wheel 32 Rise and fall shaft 33 Motor mounting bracket 34 Locking knob 35 Locking rod 36 Hex socket cap screw 37 Hex socket cap screw 38 Hex socket cap screw 39 Spring washer 40 Flat washer 41 Work table side extension 42 Washer 43 Work table 44 M5 Locknut 45 Hex socket cap screw 46 End cap 47 Straight pin 48 Hex socket cap screw 49 Insert ring assembly 50 Plastic tool cover 51 Left end cap 52 Main fence 53 Dust extract adaptor 54 M6 Locknut 55 Hex bolt M6x40 56 Mounting bracket 57 Locking knob 58 Square mounting 59 Coachbolt M6x35 60 Square support post

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61 T-bar 62 Hex socket cap screw M6x16 63 Pressure bar 64 Sliding cover bracket 65 Coachbolt M6x20 66 Fence Plate 67 X-Pan head screw M5x15 68 Pressure pad 69 Lock knob 70 Hex socket cap screw M5x12 71 Worktable side extension 72 Push blocks 73 Long wrench 74 Allen wrench S4 75 Allen wrench S5 76 Short wrench 77 Chuck 12mm 78 Chuck 6mm 79 Base assembly 80 Transformer box 81 Circuit board 82 Hex nut M4 83 X-Pan head screw 84 X-Pan head s/t screw 85 Washer 86 Power plug 87 Cable gland 88 Circlip 89 Power cable gland 90 X-Pan head screw/washer 91 Cable clamp 92 Front panel 93 Over-current protection 94 On/off switch

95 Circuit board 96 Rear panel 97 X-Pan head screw/washer 98 Base plate 99 Metre plate assembly 100 X-Pan head screw/washer 101 Butterfly nut 102 Washer A6 103 Safety fence assembly 104 Mounting bracket 105 X-Pan head screw/washer 106 Coachbolt M6x25 107 Chuck ring 108 Chuck nut 109 Collet 110 Chuck ring 111 Chuck nut 112 Collet 113 Chuck ring 114 Chuck nut 115 Collet 116 Long fence assembly 1 117 Long fence assembly 118 Pan head screw M5x12 119 Long fence connector 120 Washer 121 Screw M4x12 122 Fence 123 Grille 124 Dowel 125 S/t screw 126 Mounting plate 127 Countersunk screw 128 S/t screw

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129 Plate connecting bracket 130 Connecting bar 131 Securing knob 132 Mitre base with scale 133 Screw 134 Washer 135 Slide arm 136 Table top cover plate C 137 Table top cover plate D

138 Table top cover plate B 139 Table top cover plate A 140 Self tapping screw 141 Switch box cover 142 Connecting box 143 Switch 144 Sheath 145 X-Pan head screw 146 Handle bush

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ENVIRONMENTAL PROTECTION
Through purchase of this tool, 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 tool must not be discarded with general waste. Refer to the laws governing Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal facility.
GUARANTEE
The machine is guaranteed against faulty manufacture for a period of 12 months from the date of purchase. Your receipt is required as proof of purchase. This guarantee is invalid if the machine is found to have been abused, tampered with, or not used for the purpose for which it was intended. Faulty goods must be returned to their place of purchase, it must not be returned to us without prior permission. This guarantee does not effect your statutory rights.
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DECLARATION OF CONFORMITY – UK
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DECLARATION OF CONFORMITY – CE
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Documents / Resources

Clarke CBTSR2 Bench Top Shaper Router [pdf] Instruction Manual
CBTSR2, 6462091, CBTSR2 Bench Top Shaper Router, CBTSR2, Bench Top Shaper Router, Top Shaper Router, Shaper Router, Router

References

User Manual

CBTSR2 Bench Top Shaper Router

Product Information

Specifications:

Product Usage Instructions

General Power Tool Safety Warnings

Additional Safety Instructions for Routers

Usage Instructions:

FAQ

Q: Can this machine be used on metal or stone?

Documents / Resources

References

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