USER INSTRUCTIONS0507

Model No: BJ300Part No: 6462070

BISCUIT JOINTERBISCUIT JOINTER

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- 1 -- 16 -

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, thiswill also ensure that the Biscuit Jointer will give you long and satisfactory service.

Please keep these instructions in a safe place for future reference.

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.

Waste electrical products should not be disposed of with household waste. Please dispose of at your localrecycling facility.

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

CONTENTS

CLARKE GUARANTEEThis CLARKE product is guaranteed against faulty manufacture for a periodof 12 months from the date of purchase. Please keep your receipt as proofof purchase.

This guarantee is invalid if the product is found to have been abused ortampered with in any way, or not used for the purpose for which is wasintended.

Faulty goods should be returned to their place of purchase, no productcan be returned to us without prior permission.

This guarantee does not effect your statutory rights.

GENERAL SAFETY PRECAUTIONS

• ALWAYS Learn the machines applications, limitations and specific potentialhazards 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 checkedto ensure that it will operate properly and perform it’s intended function. Checkfor alignment of moving parts, breakage of parts, mountings, and any othercondition which may effect the machines operation. Any damage shouldbe properly repaired or the part replaced . If in any doubt DO NOT use themachine. Consult your local dealer.

• ALWAYS disconnect the tool/machine from the power supply before servicingand when changing accessories.

• ALWAYS wear safety goggles, manufactured to the latest European safetystandards. Everyday glasses do not have impact resistant lenses, they are NOTsafety glasses.

• ALWAYS keep work area clean. Cluttered areas and benches invite accidents.

• ALWAYS ensure that adequate lighting is available. A minimum intensity of 300lux should be provided. Ensure the lighting is placed so you will not be workingin your own shadow.

• ALWAYS keep children away. All visitors should be kept at a safe distancefrom the work area, especially whilst operating the machine.

• ALWAYS maintain machine in top condition. Keep tools/machines clean forbest performance. Follow maintenance instructions.

• ALWAYS ensure the ON switch if OFF before plugging into the mains. Avoidaccidental starting.

• ALWAYS handle with extreme care, do not carry the tool/machine by it’selectrical 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. Beaware that accidents are caused by carelessness due to familiarity.

• ALWAYS wear proper apparel. Loose clothing or jewellery may get caught inmoving 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.

WARNING:PLEASE READ ALL INSTRUCTIONS CAREFULLY BEFORE OPERATING

As with all machinery, there are certain hazards involved with theiroperation and use. Exercising respect and caution will considerably lessenthe risk of personal injury. However, if normal safety precautions areoverlooked or ignored, personal injury to the operator or damage toproperty, may result.

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 operatorvia the handle, or hand used to steady the tool. Vibration from about 2 to 1500 herz is potentiallydamaging 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 painfulconditions 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……ineffect, a daily vibration dose.

Tools are tested using specialised equipment, to approximate the vibration level generated undernormal, acceptable operating conditions for the tool in question. For example, a grinder used at45° 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 theaverage 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 couldvibrate under normal conditions. These values appear in the declaration on page 7.

HAND-ARM VIBRATION

You will note that a third value is given in the specification - the highest measured reading in asingle 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/s2 are considered hazardous when used for prolonged periods. Atool with a vibration value of 2.8 m/s2 may be used for up to 8 hours (cumulative) per day,whereas a tool with a value of 11.2 m/s2 may be used for ½ hour per day only.

The graph below shows the vibration value against the maximum time the respective tool may beused, per day.

The uncertainty factor should also betaken into account when assessing arisk. The two figures ‘a’ and ‘K’maybe added together and the resulantvalue used to assess the risk.

It should be noted that if a tool is usedunder abnormal, or unusualconditions, then the vibration levelcould possibly increase significantly.Users must always take this intoaccount and make their own riskassessment, using the graph as areference.

Some tools with a high vibration value, such as impact wrenches, are generally used for a fewseconds at a time, therefore the cumulative time may only be in the order of a few minutes perday. Nevertheless, the cumulative effect, particularly when added to that of other hand heldpower tools that may be used, must always be taken into account when the total daily dose rate isdetermined.

- 2 - - 15 -

• ALWAYS keep your proper footing and balance at all times DO NOT overreach. For best footing wear rubber soled footwear. Keep floor clear of oil,scrap wood etc.

• ALWAYS use recommended accessories, the use of improper accessories couldbe hazardous.

• NEVER operate the machine when under the influence of drugs, alcohol orany medication.

• NEVER leave the machine running unattended. Turn power OFF. Do not leavethe machine until it comes to a complete stop.

• NEVER force the machine, it will do a better and safer job at the rate for whichit was designed.

• NEVER use power tools in damp or wet locations or expose them to rain. Keepyour work area well illuminated. Do NOT use in explosive atmosphere (aroundpaint, flammable liquids etc.). Avoid dangerous environments.

• ALWAYS guard against electric shock . Prevent body contact with earthed orgrounded surfaces (pipes, radiators etc.) Safety can be further be improvedby using a residual current device (RCD).

• ALWAYS store the tool out of the reach of children, DO NOT allow children touse the tool.

• ALWAYS wear ear protectors/defenders as the noise level of this machine canexceed 91dB (A).

• ALWAYS secure all work sufficiently using a vice or clamps. Do not use hands tosecure 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 beenremoved BEFORE turning the tool ON.

• ALWAYS ensure safety devices are in place and are working correctly, if notDO NOT use the machine until rectified.

• DO NOT use the machine if the electrical cable, plug or motor is in poorcondition.

• 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 anadequate electrical supply is close at hand so that the operation is notrestricted 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 amask to prevent the inhalation of dust particles.

ADDITIONAL PRECAUTIONS FOR POWERTOOLS

GENERAL SAFETY PRECAUTIONS CONTINUED

- 3 -- 14 -

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 aresusceptible to damage from the various types of commercial solvents. Use amoist soft cloth only.

• Lubricate all moving parts at regular intervals.

• After extensive use the grease in the gearbox will require replenishment, consultyour CLARKE dealer regarding this.

TROUBLE SHOOTING

PROBLEM: Biscuit Jointer is Overheating.

CAUSE: TROUBLE SHOOTING:

The tool is dirty.

Tool is being overloaded.

Clean the ventilation holes, blow outwith compressed air or clean with adry cloth.

Do not use for heavy duty work, donot apply excessive pressure.

PROBLEM: Excessive Sparking Occurs.

CAUSE: TROUBLE SHOOTING:

Worn motor brushes. Consult your CLARKE dealer for partsand advise.

PROBLEM: Biscuit Jointer does not operate when switched ON.

CAUSE: TROUBLE SHOOTING:

Blown fuse. Check the fuse is sound and replaceif required. If the fuse continues toblow or the fuse is sound and thejointer fails to operate consult yourCLARKE dealer.

PARTS LIST

ITEM: DESCRIPTION: PART NO:

1. Rubber bearing shoe ....... HT300012. Bearing ............................... HT300023. Armature ............................ HT300034. Check ring .......................... HT300045. Bearing cap ....................... HT300056. Bearing ............................... HT300067. Stop pin .............................. HT300078. Spring .................................. HT300089. Check ring .......................... HT3000910. Screw .................................. HT3001011. Gear case .......................... HT3001112. Bearing ............................... HT3001213. Check ring .......................... HT3001314. Spring ring .......................... HT3001415. Gear .................................... HT3001516. Bearing cap ....................... HT3001617. Bearing ............................... HT3001718. Front cap ............................ HT3001819. Spring washer .................... HT3001920. Screw .................................. HT3002021. Woodruff key ..................... HT3002122. Output shaft ....................... HT3002223. Screw .................................. HT3002324. Spring .................................. HT3002425. Cable support ................... HT3002526. Screw .................................. HT3002627. Cable plug ......................... HT3002728. Back cap ............................ HT3002829. Screw .................................. HT3002930. Brush holder ....................... HT3003031. Carbon brush ..................... HT3003132. Switch .................................. HT3003233. Stator ................................... HT3003334. Screw .................................. HT3003435. Fan baffle ........................... HT3003536. Pin ........................................ HT3003637. Screw .................................. HT3003738. Handle ................................ HT3003839. Bevelled gear .................... HT30039

ITEM: DESCRIPTION: PART NO:

40. Spring washer .................... HT3004041. Nut ....................................... HT3004142. Screw .................................. HT3004243. Slide switch knob .............. HT3004344. Switch draw bar ................ HT3004445. Spring .................................. HT3004546. Condenser ......................... HT3004647. Switch .................................. HT3004748. Screw .................................. HT3004849. Cord clamp ....................... HT3004950. Screw .................................. HT3005051. Handle ................................ HT3005152. Right board ........................ HT3005253. Adjust knob ........................ HT3005354. Seat ..................................... HT3005455. Pin ........................................ HT3005556. Spring .................................. HT3005657. Screw .................................. HT3005758. Collecting bag .................. HT3005859. Bend pipe .......................... HT3005960. Positioning pin ................... HT3006061. Collecting pipe ................. HT3006162. Screw .................................. HT3006263. Flange ................................. HT3006364. Blade ................................... HT3006465. Flange nut .......................... HT3006566. Bottom cap ........................ HT3006667. Nut ....................................... HT3006768. Spring .................................. HT3006869. Lock knob........................... HT3006970. Angle board ...................... HT3007071. Screw .................................. HT3007172. Screw .................................. HT3007273. Slot board ........................... HT3007374. Lock screw ......................... HT3007475. Fence .................................. HT3007576. Transparent cover ............. HT3007677. Spring lock .......................... HT30077

- 4 - - 13 -

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 itis 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 orcracked etc. Replacement blades are available from your CLARKE dealer.

ELECTRICAL CONNECTIONSThis product is provided with a standard 13 amp, 230 volt (50Hz) BS1363 plug, forconnection to a standard, domestic electrical supply. Should the plug needreplacing at any time, ensure that a plug of identical specification is used.

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 adanger 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 correctreplacement is used (as indicated by marker or colour code).

• The fuse in the plug MUST be replaced with one of the same rating (13 amps)and this must be approved to BS1362.

IMPORTANT!:If in any doubt, do not attempt any electrical repair yourself. Consult a qualifiedtechnician.

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 themachine, or larger. When using a cable reel, ALWAYS unwind the cable completely.

WARNING:This appliance is double insulated.

Should it ever be necessary to change the plug, the wires in themains lead should be wired according to the following colour code:

BLUE - NEUTRALBROWN - LIVE

• Connect the BLUE coloured wire to the plug terminal marked with aletter ‘N’ or coloured BLACK.

• Connect the BROWN coloured wire to the plug terminal marked witha letter ‘L’ or coloured RED.

PARTS LIST

- 5 -- 12 -

TECHNICAL SPECIFICATIONDescription:Model No: ................................................................................................ BJ300Part No: ................................................................................................. 6462070Product use: ................................................................................................. DIY

Product Specification:No Load Speed: ............................................................................. 11,000 RPMIP Rating: ........................................................................................................ 20Fence Adjustment: ................................................................................ 0°-135°

Cutting Depth Preset Modes: 0: .............................................................. 8mm10: .......................................................... 10mm20: .......................................................... 12mm

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: .................................. M10Spindle Nominal Diameter ................... 18mmInner Blade Flange Diameter: ............. 22mm

Cutter Details: Outer Diameter: .................................. 100mmBore Diameter: ...................................... 22mmBlade Thickness: ................................... 3.5mmBlade Type: ........... Tungsten Carbide Tipped

Noise Emissions:Sound Pressure: ................................................................................91.7 dB (A)Sound Power Measured: ...................................................................79 dB LWaSound Power Guaranteed: ......................................................... 102.7 dB LWa

Vibration Emissions:Measured Emission: (Statement on Page 15) .................................. 2.9 (m/s²)

Motor:Operating Voltage & Frequency: ................................................. 230V ~ 50HzOutput: ...................................................................................................... 410WInput Wattage @ 230V Typical Load: ...................................................... 860WInput Current @ 230V Typical Load: ....................................................... 3.85AFuse Rating (BS1362): ............................................................................ 13 Amp

Dimensions & Weights:Product: (Length x Height x Width) .......... 360mm x 190mm x 174mm (max)Case Size: .............................................................. 405mm x 220mm x 160mmPacked Weight: ........................................................................................ 4.5KgUnpacked Weight: ................................................................................. 3.22Kg

Package Contents:Biscuit Jointer: ................................................................................................. x1Dust Extraction Adaptor: ............................................................................... x1Dust Bag: ........................................................................................................ x1Moulded Plastic Carry Case: ........................................................................ x1

- 6 - - 11 -

PARTS DESCRIPTION

SETUP

ALWAYS Switch the tool OFF and unplug from the power supply BEFORE makingany 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 adjustmentknob to the cutting depth, material thickness and the associated biscuit.

ADJUSTING THE CUTTING DEPTH

Handle

Fence

SightWindow

Kerf Guide

Depth Adjustment Knob

Bevel Adjustment Lever

Fig.1

Lock ‘ON’ SwitchSpindle Lock

BaseDustExtractionPort

BLADE REPLACEMENTALWAYS switch off and isolate from the mains supply by removing the plug fromthe mains socket BEFORE changing the blade.

1. Remove the kerf guide by unscrewing thetwo screws with a cross head screwdriver.(circled in fig.3).

2. Place the biscuit jointer upside down on aworkbench and remove the screw securingthe steel disc in the base plate (arrowed inFig 4), then remove the disc.

3. Depress the spindle lock, and usinga peg spanner in the holes circledin fig.5 undo the flange nut byturning the spanner anticlockwise.

4. Push the body of the jointer forwardto expose the blade allowing it tobe removed.

5. When inserting a new blade push thebody of the jointer forward to allowthe blade to be passed over the spindle.

6. To ensure the blade is in the correct position over the spindle, manually turnthe blade (blade should rotate freely) the arrow on the case indicates thedirection of rotation.

7. Replace the flange nut by pushing down on the spindle lock button andtightening the flange with a peg spanner.

8. Replace the plastic insert disc making sure that it is firmly in position and isflush with the outer base housing.

9. Replace the kerf guide and tighten the two cross head screws making surethat the slot in the kerf guide lines up with the blade and the guide does notprotrude beyond the base plate.

Fig.3

Fig.4

Fig.5

:gnikraMbonK :htpeDgnittuC :ssenkcihTlairetaM :tiucsiB0 mm0.8 mm21-8 0:oN01 mm0.01 mm51-21 01:oN02 mm0.21 mm51> 02:oN

- 7 -- 10 -

ADJUSTING THE CUTTING HEIGHT

NOTE: Always unplug the biscuit jointer before making any adjustments.

• The height can be set by unlocking both of the bevel adjustment leversand sliding the fence to the desiredlevel with the aid of the scale.(refer to fig.1).

• Normally the height set correspondsto half the material’s thickness(biscuit grooves are cut in thecentre of the piece). Note: athicker piece may have more thanone biscuit across it’s thickness i.e.one at 1/3rd and one at 2/3rds.

• If the bevel adjustment levers are inthe way when working, pull the leverout and turn to a new position.

SETUP CONTINUED

MOUNTING THE DUST EXTRACTION

• For dust extraction connect either avacuum to the dust extractionadaptor or the included dust bag.

• Regularly empty the dust bag tomaintain dust extractionperformance.

ADJUSTING THE CUTTING ANGLE

• The cutting angle can be set byunlocking both bevel adjustmentlevers and moving the fence tothe required angle. (refer to fig.1).

OPERATION CONTINUEDMAKING ‘T’ JOINTS

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, atypical application would be connecting the shelves of a bookcase to thevertical 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 andvertical centre lines on each piece.

NOTE: measure carefully to ensurethe centre lines on both pieces line up.

3. Securely clamp a piece of timber9.5mm below the centre linesquarely across the width of theboard (‘B’ on fig.2). This will beused as a guide for the base of thejointer.NOTE: The centre of the cuttingblade 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 themotor body.

7. Rest the base of the jointer up against the edge of the guide piece oftimber ‘B’, with the cutter pointing down towards board ‘A’. Align thecentre 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 theswitch, (the motor will run continuously).

9. Maintaining a downward pressure, plunge the blade into the work piece bypushing 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 isclear of the work piece. Switch the tool OFF by pressing on the back of theON/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 slotsare cut.

13. Once all biscuit slots have been cut into the faces of the boards follow thecutting instructions (2-14) on page 8 for cutting slots into the end of theboards which will form the shelves.

9.5mm

A

B Fig.2

- 8 - - 9 -

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 jointlocation ‘B’, space additional joints along the timbers edge approx. 100mmapart.

2. Clamp the work piece securely sothat it will not move during the cut.

3. Set the plunge depth to the size ofbiscuits to be used. No.20 biscuits aregenerally suitable for mostapplications. If you are using stockwhich is 15mm or less in thicknessthen smaller biscuits will be required.

4. Unlock the bevel adjustment leversand adjust the angle of the fenceto 90°. Set the height of the fenceas required and re-lock the beveladjustment levers.

5. Hold the tool with one hand on the handle and the other hand on the motorbody.

6. Rest the fence on the work piece and align the centre marking on the toolwith 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 theswitch, (the motor will run continuously).

8. Maintaining a downward pressure on the fence, plunge the blade into thework piece by pushing the whole tool forwards up to the stop until the cut iscomplete.

9. Release the forward pressure and allow the tool to return so the blade isclear of the work piece. Switch the tool OFF by pressing on the back of theON/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 dryassemble 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, alsospread glue over the entire surface of the joint.

14. Reassemble the work pieces and clamp together until the glue has set.

MAKING EDGE TO EDGE JOINTSOPERATION

A

B

OPERATION CONTINUED

NOTE: Always unplug the biscuit jointer before making any adjustments.

1. Using a combination square draw areference mark ‘A’ through thecentre point of each jointperpendicular to the mitred edge ‘B’.

2. Follow the cutting instructions (2-14) foredge to edge jointing on page 8.

MAKING MITRE JOINTS

MAKING BUTT JOINTS

1. Position the mating pieces togetherand draw a reference mark ‘A’ at 90°to the centre point of each proposedjoint location ‘B’,.

2. Follow the cutting instructions (2-14) foredge to edge jointing on page 8.

A

B

A

B

MAKING CORNER JOINTS

1. Position the pieces together and draw a reference line on the outside face ofone piece and the end of the second piece.

2. Follow the cutting instructions (2-11)on page 8 and cut a slot intothe end of piece ‘A’.

3. Clamp piece ‘B’ that it protrudesabove your work bench.

4. Without changing any of the settingson the jointer. Follow the cuttinginstructions (5-14) on page 8 and cuta slot into the face of piece ‘B’.

A

B