Clarke SBR305B User guide

3 IN1 SHEET METAL MACHINE

Model No: SBR305B

PART NO: 6560001

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC12/24

INTRODUCTION

Thank you for purchasing this CLARKE 3 in1 Sheet Metal Machine.

Before attempting to operate the machine it is essential that you read this manual
thoroughly and carefully follow all instructions given. In doing so you will ensure the
safety of yourself and that of others around you, and you can also look forward to the
product giving you long and satisfactory service.

FEATURES

• Shear Table Front Guide

• Shear & Brake Adjustable Rear Stop

• Hardened Steel Brake Fingers

• Precision Ground Hardened Steel Shear Blade

SPECIFICATIONS

Clarke Part Number 6560001

Unpacked Weight 42 kg

Dimensions (W x D x H) 516 x 382 x 385 mm

Bench footprint dimensions 357 x 290 mm

Capacities

Maximum Workpiece Width 305 mm

Maximum Workpiece Thickness 1 mm

Pan/Box Brake Minimum Reverse Bend 9 mm

Pan/Box Brake Maximum Side Height @ 90° 42 mm

Slip Roll Minimum Cylinder Diameter 38 mm

Slip Roll Wire Sizes (L to R) 2.5 mm, 5.0 mm, 6.0 mm

5.5 mm, 4.0 mm, 3.0 mm

NOTE: The details and specifications contained herein, are correct at the time

of going to print. However, CLARKE International reserve the right to
change specifications at any time without prior notice.

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SAFETY INSTRUCTIONS FOR MACHINERY

1. READ THE ENTIRE MANUAL BEFORE USE. Machinery presents serious injury
hazards to untrained users.

2. WEAR PROPER APPAREL. DO NOT wear loose clothing, gloves, neckties, rings,
or jewellery that can catch in moving parts. Wear protective hair covering to
contain long hair and wear non-slip footwear.

3. NEVER OPERATE MACHINERY WHEN TIRED OR UNDER THE INFLUENCE
OF DRUGS OR ALCOHOL. Be mentally alert at all times when in use.

4. ONLY ALLOW TRAINED AND PROPERLY SUPERVISED PERSONNEL TO
OPERATE MACHINERY. Make sure operation instructions are safe and
understood.

5. KEEP CHILDREN AND VISITORS AWAY from the work area.

6. KEEP WORK AREA CLEAN AND WELL LIT. Clutter and dark shadows may
cause accidents.

7. MAINTAIN MACHINERY WITH CARE. Keep blades sharp and clean for best
and safest performance.

8. CHECK FOR DAMAGED PARTS. Check for binding or misaligned parts, broken
parts, loose bolts, and any other conditions that may impair machine operation.
Repair or replace damaged parts before operation.

9. BODY POSITION. To avoid injury due to slipping, ALWAYS maintain secure
footing and a comfortable body position when using this machine. Maintain
stability and balance at all times.

10. OVERLOADING. Attempting to overload this machine beyond the capacities
specified in the “Specifications” on page 2 could cause personal injury or property
damage. DO NOT extend the hand crank to apply additional force.

11. METAL EDGES. Sharp metal edges can cut your fingers. ALWAYS chamfer and
de-burr sharp sheet metal edges before bending and after cutting the workpiece.

12. PINCHING. This machine represents severe pinching and amputation hazards.
ALWAYS keep hands away from the rollers, brake fingers, clamping bar and
shearing blades when operating.

13. GOOD WORKING CONDITION. To reduce the risk of personal injury, ALWAYS
inspect the working parts of this machine for cracks, burrs, loose fasteners, or any
other damage and resolve any issue before beginning operation.

14. WORKBENCH MOUNTING. Personal injury could occur if this machine should
unexpectedly move during operation. ALWAYS make sure the machine is
securely mounted to a stable workbench or stand that can support the weight and
pressures of the operation.

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15. ENTANGLEMENT HAZARDS. The moving parts of this machine represent
entanglement hazards. DO NOT wear jewellery or loose clothing and tie back
long hair when using this machine.

16. SHEARING BLADES/BRAKE FINGERS. If not properly aligned, the shearing
blades or brake fingers can cause machine parts or the workpiece to break up and
fly towards the operator. ALWAYS keep these parts properly adjusted and in
good working condition.

WARNING: LIKE ALL MACHINERY THERE IS POTENTIAL DANGER
WHENOPERATING THIS MACHINE. ACCIDENTS ARE FREQUENTLY
CAUSED BY LACK OF FAMILIARITY OR FAILURE TO PAY ATTENTION.
USE THIS MACHINE WITH RESPECT AND CAUTION TO DECREASE
THE RISK OF OPERATOR INJURY. IF NORMAL SAFETY
PRECAUTIONS ARE OVERLOOKED OR IGNORED, SERIOUS
PERSONAL INJURY MAY OCCUR.

CAUTION: NO LIST OF SAFETY GUIDELINES CAN BE COMPLETE. EVERY
WORKSHOP ENVIRONMENT IS DIFFERENT. ALWAYS CONSIDER SAFETY
FIRST, AS IT APPLIES TO YOUR INDIVIDUAL WORKING CONDITIONS. USE
THIS AND OTHER MACHINERY WITH CAUTION AND RESPECT. FAILURE TO
DO SO COULD RESULT IN SERIOUS PERSONAL INJURY, DAMAGE TO
EQUIPMENT OR POOR WORK RESULTS.

WARNING LABELS

The following symbols may be displayed on the machine or its packaging.

Read this instruction
booklet carefully before
use.

Wear protective gloves Keep fingers clear of

Do not expose to rain.

break, dies, rollers and
blade.

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PARTS IDENTIFICATION

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UNPACKING AND SETUP

Remove the packaging materials from around your machine and make sure that you
have the following items. If you discover the machine is damaged in any way, please
contact your Clarke dealer. You should receive:

• A. Sheet Metal Machine

• B. Shear & Brake Rear Work Stop

• C. Hand Crank

• D. Crank Handle Lock Knobs

• E. Hex Wrenches 5 & 6mm

CLEAN UP

The unpainted surfaces are coated with a waxy oil to prevent corrosion during
shipment. Remove this protective coating with a solvent cleaner or de-greaser.

For thorough cleaning some parts must be removed.

For optimum performance, clean all moving parts or sliding contact surfaces. Avoid
chlorine-based solvents, such as acetone or brake parts cleaner that may damage
painted surfaces.

ALWAYS follow the manufacturer's instructions when using cleaning products.

WARNING: PETROL BASED PRODUCTS HAVE LOW FLASHPOINTS
AND CAN EXPLODE OR CAUSE FIRE IF USED TO CLEAN MACHINERY.
DO NOT USE THESE PRODUCTS TO CLEAN THE MACHINERY.

CAUTION: MANY CLEANING SOLVENTS ARE TOXIC IF INHALED. MINIMIZE
YOUR RISK BY ONLY USING THESE PRODUCTS IN A WELL VENTILATED
AREA.

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SITE CONSIDERATIONS

FLOOR LOAD

Refer to the Specifications for the weight and footprint specifications of your machine.
Some workbenches or stands may require additional reinforcement to support the
machine and the forces applied during operation.

PLACEMENT LOCATION

Consider existing and anticipated needs,
size of material to be processed through
each machine, and space for auxiliary
stands, work tables or other machinery
when establishing a location for your
new machine. See Figure 4 for the
minimum working clearances.

MOUNTING

The base of this machine has holes that
allow it to be mounted to a workbench.
For a safe and smooth operation of this
machine, it MUST be securely mounted
to an appropriate workbench or stand.

The strongest mounting option is a
“Through Mount” (Figure 5) where holes
are drilled all the way through the
workbench, and hex bolts, washers, and
hex nuts are used to secure the machine
to the workbench.

Another option for mounting is a “Direct
Mount” (Figure 6) where the machine is
simply secured to the workbench with a
lag screw.

CAUTION: DUE TO THE CONSIDERABLE FORCES EXERTED ON THIS
MACHINE WHEN IN OPERATION, YOU MUST SECURELY MOUNT TO A STABLE
AND STURDY WORKBENCH OR STAND, OTHERWISE THE MACHINE COULD
TIP OR FALL AND RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.

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PREPARATION

In addition to the assembly procedures below, some disassembly is required to
remove storage grease and re-lubricate the cleaned parts.

ASSEMBLING THE MACHINE

1. Remove one of the cap screws on the
hand crank hub, rotate the end cap
out of the way, then insert the hand
crank into the slot (see Figure 7).

NOTE: It is your preference which side

of the machine you install the
hand crank.

2. Re-install the cap screw removed in
Step 1, then thread and tighten a
lock knob into the centre hole of the
end cap to secure the hand crank in place.

Tip: When needed, extend one end of the hand crank from the hub for greater
leverage.

3. Thread the rods into either the upper
or lower mounting holes, as shown in
Figure 8. Only hand-tighten the rods.

NOTE: Install the rods in the upper

mounting holes to use the work
stop with the brake or in the
lower holes to use it with the
shear.

4. Remove the hex nuts from the ends
of the rods, slide the stop bar onto
the rods and position it for your
operation, then tighten the lock
knobs to secure it as shown in Figure

9.

5. Re-install the hex nuts.

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CLEANING THE MACHINE FINGERS

1. Loosen the two hex bolts securing
the finger receiver/upper shear blade
to the frame (see Figure 10).

2. Move the table back until the upper
shear blade can pass down behind
the table blade by loosening the two
cap screws securing the shear table
to the frame and rotating the table
adjustment screws counter-clockwise
(see Figure 11).

NOTE: Operational adjustment of the

shearing blades is covered in
the “Shearing Blade Gap
Adjustment” on page 25.

3. Make sure the finger receiver and upper shear blade move up and down smoothly,
re-tighten the hex bolts just until they are snug, then back them off approximately
¼ turn.

4. Use the hand crank to position the
brake finger receiver close to the
brake fingers, as shown in Figure 12.

5. Loosen the cap screws to release the
fingers, then remove the fingers from
the side of the finger receiver, as
shown in Figure 12.

6. Use a cloth and de-greaser to remove
the storage grease from the fingers,
screws and receiver. Thoroughly dry
the parts, then apply a thin coat of an anti-rust lubricant.

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7. Place a thin piece of wood on the
finger receiver, as shown in Figure
13, then reinstall the fingers so that
they rest on the wood. Make sure the
tops of the fingers are between the
screw and the casting.

NOTE: Install the widest finger to the

right, then repeat with each
smaller finger.

8. Make sure the fingers are slightly
loose between the screw and the
casting, then use the hand crank to
raise the receiver to fully seat the
fingers up against the casting behind
the screw, as shown in Figure 14.

9. Re-tighten all of the cap screws.

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OPERATION - USING THE SLIP ROLLERS

CAUTION: THE ROLLERS OF THIS MACHINE PRESENT A PINCHING HAZARD.
MAKE SURE NO BODY PART OR CLOTHING IS NEAR THE ROLLERS DURING
OPERATION. FAILURE TO FOLLOW THIS WARNING MAY RESULT IN
FINGERS, HAIR, OR CLOTHING BEING PULLED INTO THE MACHINE,
CAUSING PERSONAL INJURY.

SLIP ROLLER OVERVIEW

The slip roller is used to form cylinders,
cones, and arcs in sheet metal up to 1
mm in thickness and 305 mm wide, as
well as wires and rods. Three steel rollers
are configured to draw the workpiece
through a path that will produce the
desired results (see Figures 15-16).

Fig. 15

Fig. 16

SLIP ROLLING TIPS

• Due to the many variables of different sheet metal types, no single configuration
of the rollers will create the same curve on all materials. Rolling sheet metal to
achieve an exact radius is a trial-and-error process.

• Performing multiple passes through the machine with gradual reductions in the
curve radius produces better results than trying to make the curve in one pass.

• To avoid pitted workpieces and damage to the roller surfaces, always make sure
the workpiece and the rollers are free of grit and any foreign material before every
use.

• Unless the operation requires a cone-type curve, always keep the rear roller
parallel to the front rollers by rotating the diameter adjustment knobs the same
amount.

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CREATING CURVES

Your sheet metal machine can easily create constant radius curves in sheet metal up
to 1 mm thick.

The method of creating a specific radius is a trial and error process. Due to the many
variations among metal workpieces, no single configuration of the rollers will
reproduce the same curve in all materials. We recommend testing your roller
configurations on scrap pieces that are the same dimension and material as your final
workpiece.

TO CREATE A CURVE IN TH5E WORKPIECE

1. Use the diameter adjustment knobs to fully lower the rear roller below the level of
the bottom roller, then rotate the thickness adjustment leaf bolts counter­clockwise until the upper roller can be lifted with enough clearance for the
workpiece.

NOTE: Performing multiple passes through the machine with gradual

reductions in the curve radius produces better results than trying to
make the curve in one or two passes.

2. Insert the workpiece between the
upper and lower rollers and just over
the rear roller, as illustrated in Figure
17, then snug the thickness
adjustment leaf bolts down to hold
the workpiece securely. Make sure
you tighten the leaf bolts exactly the
same amount.

3. Use the diameter adjustment knobs
to raise the rear roller, then use the
hand crank to pass the workpiece
through the machine (see the
illustrations in Figure 18-19).

NOTE: For good results, make the

first bend less than the final
radius, then slightly decrease
the bend with each successive
pass until the final radius has
been reached.

Fig. 17

Fig. 18

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NOTE: If your workpiece has an

undesired initial flat, as
illustrated in Figure 19, you can
remove it by flipping the
workpiece around and pass it
through the front of the
machine so that the initial flat
enters last.

4. Slightly tighten the diameter
adjustment knobs the same amount, then pass the workpiece through the rollers
again.

NOTE: To make a cone, tighten one adjustment knob more than the other.

5. Repeat Step 4 until you have produced the desired curve.

Fig. 18

CREATING CYLINDERS

If you know the diameter of the cylinder you want to create, use the formula below to
calculate the length of material needed.

C = πD

C = Circumference (Length of Material Needed)

π = Pi (Approximately 3.142)

D = Diameter

Example

You would use the above formula as follows:

C = πD

C = (3.142) x 150 mm

C = 471.3 mm

The result of 471.3 mm indicates that you need to start with a piece of sheet metal
that is approximately 471.3 mm in length in order to create a 150 mm diameter
cylinder.

: Suppose you want to create a 150 mm diameter cylinder.

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You can use the slip roll to create a bend
with the correct radius so that the two

Fig. 20

ends meet, forming a 150 mm diameter
cylinder (Figure 20).

NOTE: Performing multiple passes

through the machine with
gradual reductions in the curve
radius produces better results
than trying to make the curve
in one or two passes.

TO CREATE A CYLINDER

1. Use the diameter adjustment knobs to fully lower the rear roller below the level of
the bottom roller, then rotate the thickness adjustment leaf bolts counter­clockwise until the upper roller can be lifted with enough clearance for the
workpiece.

2. Insert the workpiece between the
upper and lower rollers and just over
the rear roller, as illustrated in Figure
21, then snug the thickness
adjustment leaf bolts down to secure
the workpiece. Make sure you tighten
the leaf bolts the same amount.

3. Turn the hand crank clockwise to
feed the workpiece through the
machine until it is approximately half
way through the upper and lower
rollers.

4. Turn the diameter adjustment knobs
clockwise knobs to lift the rear roller
until the desired radius bend is
reached, as illustrated in Figure 22.
Make sure to turn the knobs equal
amounts so the rear roller is always
parallel with the other rollers. Failure
to do so will create a larger radius on
one end than the other, resulting in a
cone shape.

NOTE: Always err on the side of

making the radius too large rather than too small. It is easy to decrease
the radius but very difficult to increase the radius later.

Fig. 21

Fig. 22

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5. Turn the hand crank to process the
material through the slip rollers.
Continue turning until the workpiece
is completely through the upper and
lower rollers as illustrated in Figure

23.

6. Rotate the workpiece 180°, insert the
curved end into the rollers, then
process it through the machine, as
illustrated in Figure 24.

7. Reduce the radius of the curve by
raising the rear roller, then repeat
Steps 4-7 until you have produced
the desired cylinder (see the
illustration in Figure 25).

Fig. 23

Fig. 24

• If the ends of the cylinder do not
meet, lift the rear roller equally at both ends, then process the entire cylinder
through the slip roller again. Repeat as necessary.

• If the ends of the cylinder overlap,
remove the cylinder as described in
“Removing the workpiece from the
rollers” on page 16. Then, either
attempt to increase the radius by
manually bending it, or scrap the
workpiece and start this procedure
again with a new blank.

8. When the cylinder is complete, refer
to “Removing the Workpiece from the
Rollers” on page 16 for detailed
instructions on removing the cylinder from the top roller.

Fig. 25

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REMOVING THE WORKPIECE FROM THE ROLLERS

CAUTION: THE SHARP EDGES OF SHEET METAL CAN QUICKLY CUT YOUR
HANDS. ALWAYS USE CAUTION AND HEAVY LEATHER GLOVES WHEN
HANDLING SHEET METAL.

1. Insert the supplied hexagon key into
the retainer pin and rotate the
retainer pin until the flat portion of
the pin is facing toward the roller or
to the right, as shown in Figure 26.

2. Rotate the thickness leaf bolts
anticlockwise until they no longer
apply pressure to the top roller.

3. Protect your hands from the sharp
edges of the workpiece, then grasp
the top roller and use moderate force
to pull it forward, as shown in Figure

27.

Fig. 26

4. Remove the workpiece, slide the top
roller back into place, then secure the
roller by rotating the retainer pin until
the flat side is no longer visible.

BENDING WIRE

Your sheet metal machine can bend
wires, rods, and small-diameter tubing
between the diameters of

1

/

” and

8

(see Figure 28).

To ensure even pressure on the material,
place the workpiece in the smallest
possible groove on either side of the
rollers. Although a

7

/

” rod would fit into

64

any of the wire grooves, you would use

1

the

/

” groove since it is the smallest

8

possible groove the rod will fit into.

Process the material through the machine in the same manner described on the
previous pages for sheet metal.

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/

”

64

Fig. 27

Fig. 28

NOTE: The wire grooves can also be used when rolling sheet metal that has a

wire bead on the side.

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OPERATION - ANGLE BENDING

BENDING BRAKE OVERVIEW

The brake of the SBR305B is used to
make bends of 0°-90° in sheet metal up
to 1 mm in thickness and 305 mm in
width. When you use the hand crank, the
brake fingers force the workpiece into
the groove of the finger receiver to make
the desired bend (see Figures 29-30).

BEND ALLOWANCE

When metal is bent, the outside overall
dimension increases from its original
length-this amount is called the bend
allowance. A typical bend allowance for a
90° bend in a 1 mm mild steel workpiece
is approximately 1.27 mm. That means
you need to start with a workpiece that
is approximately 1.27 mm shorter than
the desired outside length of the finished
workpiece, as illustrated in the example
of Figure 31.

Fig. 29

Fig. 30

Calculating the bend allowance for your
operation requires many variables, such
as metal thickness, type of material,
radius of the bend, etc. Detailed
information for calculating the bend
allowance can be found in metalworking
handbooks and on the internet.

An easy way to find the correct
dimension of your initial blank is to
measure a piece of scrap of the same
material as the workpiece, make the
bend, then measure the piece again. The
difference between the two
measurements is the bend allowance,
which you subtract from the dimension
of the workpiece blank before the bend.

Fig. 31

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BENDING SHEET METAL

Tip: To reduce the chance of scoring your workpiece when using the brake, always
keep the fingers and receivers clean and lubricated (refer to Steps 1-9 beginning on
pages 9 & 10 for detailed instructions), and free of burrs or other blemishes. Also,
apply a strip of sturdy tape along the top and bottom of the bend line.

WARNING: THE BRAKE FINGERS ON THIS MACHINE PRESENTS A
PINCHING HAZARD. MAKE SURE NO BODY PART OR CLOTHING IS
NEAR THE AREA WHERE METAL BENDING OCCURS. FAILURE TO
FOLLOW THIS WARNING MAY RESULT IN SEVERE PERSONAL
INJURY.

1. Mark a line along the width of the workpiece where the bend is to take place.

2. Use the hand crank to lower the
finger receiver until you can position
the workpiece underneath the fingers
with the bend line aligned with the
tips, as shown in Figure 32.

NOTE: When performing the same

bending operation on multiple
parts, use the rear work stop to
save time positioning the
workpieces.

Fig. 32

3. While holding the workpiece steady,
use the hand crank to raise the finger
receiver to perform the desired bend
(see Figure 33 for an example), then
lower the receiver and remove the
workpiece.

4. If a reverse bend is required, re­install the workpiece upside-down, as
shown in Figure 34, and repeat Steps
2-3.

5. The minimum reverse bend possible
is 9 mm.

NOTE: When performing a pan and

box bending operation, loosen
the cap screws on the brake
finger gib and configure the
fingers for your operation.
Remove the fingers you do not
need.

Fig. 33

Fig. 34

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PAN FORMING

The hand brake roller can be used to make various sizes of pans. The maximum lip
(side) height supported by this tool is 1”.

To form a pan;

1. Pre-measure and cut your material
before bending. Notch the corners
according to the desired lip height as
shown in Fig 35.

2. Insert material between the fingers
and the moving cutter plate. Bend
the material until a 90 degree angle
has been formed.

3. Rotate the material 90 degrees
counter-clockwise. Allow the
completed side to extend just beyond
the dies. Bend the second side.

Fig. 34

4. Repeat step 3 for the 3rd side.

5. Rotate to the final side and insert the
workpiece between your dies. Your
formed sides will be on the outside of
the dies.

6. Before bending, tap one corner
nearer to the middle of the machine.
This will allow the material to clear
the fingers when raised.

7. Bend the fourth side.

8. Using a block or piece of wood, tap
the corner of the material back into
place.

Fig. 34

Fig. 34

Fig. 34

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OPERATION - SHEARING SHEET METAL

SHEARING OVERVIEW

The SBR305B has a set of reversible
blades that shear mild steel up to 1 mm
in thickness and 305 mm in width. When
you use the hand crank to perform a
shear, the upper movable blade is
lowered past the fixed table blade,
creating a shearing action (see Figures
39-41). For repetitive cuts, use the
adjustable rear work stop.

Fig. 39

CUTTING SHEET METAL

WARNING: THE SHEARING BLADES ON THIS MACHINE PRESENT A
HAZARD. KEEP BODY PARTS OR CLOTHING AWAY FROM THE AREA
WHERE METAL SHEARING OCCURS. FAILURE TO FOLLOW THIS
WARNING MAY RESULT IN SEVERE PERSONAL INJURY.

TO CUT SHEET METAL

1. Mark the cut line across the width of
the workpiece.

2. Make sure the gap between the
shearing blades is correct for the
workpiece material (refer to
“Shearing Blade Gap Adjustment” on
page 25 for detailed instructions).

Fig. 40

Fig. 41

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3. Position the workpiece up against the guide block on the right side of the table,
then align the cut mark with the upper shear blade, as shown in Figure 41.

NOTE: The shearing action begins on the right side of the workpiece and

moves to the left.

NOTE: If you need to adjust the gap between the shearing blades to

accommodate your workpiece, refer to the “Shearing Blade Gap
Adjustment” on page 25 for detailed instructions.

NOTE: If you are using the rear work stop, adjust the stop so that at least one

square edge of the workpiece is against it.

4. Use the hold down adjustment bolts to adjust the hold-down bar so that it firmly
holds the workpiece in place without marking or denting it.

5. Keeping all body parts away from the blades, rotate the hand crank with an even
and steady pressure to complete the cut.

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MAINTENANCE

SCHEDULE

For optimum performance from your machine, follow this maintenance schedule if in
regular use and refer to any specific instructions given in this section.

DAILY MAINTENANCE

• Clean the machine.

• Tighten any loose mounting bolts.

• Check/replace any damaged rollers.

• Check/replace any cracked or damaged brake fingers or receiver.

• Sharpen/replace any dull or nicked shearing blades.

• Address any other unsatisfactory condition.

MONTHLY MAINTENANCE

• • Lubricate the gears and hand crank bushes.

6-MONTHLY MAINTENANCE

• Lubricate the roller bushes.

CLEANING & PROTECTING

Cleaning the SBR305B is relatively easy. Use a cloth and de-greasing spirit if required
to wipe down the machine.

LUBRICATION

Keep your SBR305B properly lubricated to help ensure long life and smooth operation
of the machine.

GEARS

Clean away grease and any built-up
grime from the top and bottom roller
gear teeth as shown in Figure 42, with a
stiff brush and de-greasing spirit.

When dry, apply a small amount of
grease to the teeth, then use the hand
crank to rotate the rollers and distribute
the lubricant.

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HAND CRANK BUSHES

Wipe off the grease fittings next to each
hand crank hub (see Figure 43), then use
a grease gun to add a small amount of
multi-purpose grease to the hand crank
bushes.

ROLLER BUSHES

Remove the top roller from the machine,
then remove the bushes from the ends
of the roller (see Figure 44). Use a cloth
and de-greasing spirit to clean the
bushes and the ends of the roller, then
apply a thin coat of multi-purpose grease
to the roller ends and re-install the
bushes.

Use a stiff brush and degreasing spirits
to clean the rear roller bushes, then
apply a small amount of multi-purpose
grease to them. Reinstall the top roller and close the cover.

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SERVICING

SHEARING BLADE REVERSAL/REPLACEMENT

The shearing blades are reversible, so when the first cutting edge becomes dull, the
blades can be rotated to use the second cutting edge.

When both cutting edges of the blade become dull, use wet grinding techniques for
SK-4 metal or better to sharpen the cutting face of the blade.

The upper shearing blade uses a 5° relief edge and the lower table blade does not.
However, if you are not comfortable performing the sharpening procedure or do not
have access to a professional sharpening service, replacement blades are available
through the Clarke spares department.

TO REVERSE OR REPLACE THE SHEARING BLADES:

CAUTION: THE SHEARING BLADES ARE SHARP AND CANQUICKLY CUT YOUR
HANDS. ALWAYS WEAR HEAVY LEATHER GLOVES WHEN HANDLING THE
SHEARING BLADES TO AVOID THIS CUTTING HAZARD.

1. Remove the hex bolts and springs
that secure the shear hold-down bar
(see Figure 45).

2. Remove the four cap screws that
secure the blade, then carefully
remove it from the machine (see
Figure 46).

Tip: When removing or installing the

upper shear blade, remove the cap screw
at one end, then insert a small hex
wrench or similar tool through the hole
to keep the blade in place as you remove
the rest of the cap screws.

3. Inspect the blade cutting edge that was in use, for wear, nicks, or burrs.

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• If the cutting edge shows wear or nicks and the other cutting edge has not been
used, rotate the blade and re-install it.

• If both cutting edges are worn or nicked, either properly sharpen the cutting face
or replace the blade.

4. Re-install the hold-down bar, then check that the shearing blade gap adjustment is
correct as instructed in “Shearing Blade Gap Adjustment” below.

SHEARING BLADE GAP ADJUSTMENT

The shearing blade gap adjustment determines the accuracy of the cut.

Follow the procedures below to make sure this adjustment is correct for the
workpiece material being processed.

PERFORMING THE SHEAR TEST

1. While keeping your fingers clear of
the shear blades, shear a piece of
scrap material that is the same as
your workpiece along the full length
of the blade, as shown in Figure 47,
then inspect the cut.

• If the machine correctly cuts to your
satisfaction along the length of the
blades no adjustments are needed.

• If the cut is clean at one end and not
the other, perform the following ADJUSTING THE SHEAR TABLE procedure
that follows.

• If the condition of the cut on the ends is different from the cut in the middle,
perform the following “Adjusting the Blade Bow” on page 26.

ADJUSTING THE SHEAR TABLE

1. Loosen the cap screws on either end
of the shear table that secure it to
the machine (see Figure 48).

2. Evenly rotate the table adjustment
screws to adjust the position of the
shearing table until the blade gap is
even, then re-tighten the cap screws
to secure the table in place.

NOTE: Rotating the table adjustment

screws clockwise moves the
table toward the upper shear blade.

3. Perform the previous shear test.

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

4. If necessary, repeat Steps 1-3 until you are satisfied with the shear test cut.

ADJUSTING THE BLADE BOW

The adjustment bolt of the blade bow is
used to remove any slight bow in the
cast iron cross beam that the brake
finger receiver and upper shear blade are
attached to (see Figure 49).

TO ADJUST THE BLADE GAP WITH THE BLADE BOW

1. Hold the adjustment bolt still, then turn the jam nut to adjust the centre of the
cross beam in or out (see Figure 49).

• If the shear test cut was clean on the ends of the shear table but not in the
middle, turn the jam nut counter-clockwise to force the adjustment bolt against
the cross beam, moving it in toward the front.

• If the shear test cut was clean in the middle but not on the ends, rotate the jam
nut clockwise to allow the cross beam to move back.

2. Perform the previous shear test.

3. If necessary, repeat Steps 1-2 until you are satisfied with the shear test cut.

BRAKE ALIGNMENT

CAUTION: OPERATING THE BRAKE WITH CRACKED OR DAMAGED BRAKE
FINGERS OR RECEIVER COULD CAUSE THESE PARTS TO SHATTER AND FLY
APART, WHICH COULD RESULT IN PERSONAL INJURY.

During the life of your machine, you may need to align the brake fingers with the
finger receiver from side-to-side.

TO ALIGN THE BRAKE

1. Remove, clean, and de-burr all of the finger tips and the receiver groove, then
inspect the fingers and receiver for any cracks or damage.

• If any of the brake fingers or the receiver are damaged in any way, DO NOT use
the brake until you have replaced these parts with new ones.

2. Replace the fingers, follow the procedure on page 9 (Cleaning the Machine
Fingers).

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

3. Place a piece of heavy flat bar stock
or a heavy metal ruler approximately
12" long across the finger receiver, as
shown in Figure 50.

4. Lower the brake fingers until one just
rests on the metal bar, as shown.

5. Starting at one end, visually check
the gap between the brake fingers
and the metal bar.

6. If you find a gap at one end of the
brake, loosen the cap screw shown in Figure 50 on that end, then turn the
adjustment bolt counter-clockwise until the gap disappears.

7. Re-tighten the cap screw, remove the metal bar and use the hand crank to cycle
the machine 2-3 times.

8. Repeat Steps 3-7 until the brake fingers rest evenly on the metal bar along its
entire length.

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

TROUBLESHOOTING

SLIP ROLLER OPERATION.

PROBLEM CAUSES SUGGESTIONS

Slip roller creates
cones when trying
to make a
cylinder.

Creases or
wrinkles in the
workpiece.

Workpiece is
pitted or
scratched.

Top and rear rollers not
parallel.

Excessive pressure applied
when rolling.

Workpiece or rollers are dirty
or damaged.

Use the diameter adjustment
knobs to make the rollers
parallel.

Reduce the radius and perform
the bend in several light
passes.

Thoroughly clean the
workpiece and rollers. Polish

out any nicks/ burrs in the

rollers, or replace them.

BENDING BRAKE OPERATION

PROBLEM CAUSES SUGGESTIONS

Heavy resistance
during bending

Machine capacities are
exceeded.

Operate within the listed
capacities of the machine.

Bend radius is not
consistent across

workpiece.

Tips of brake
fingers are

chipping or rolling

Workpiece has
scoring marks

Machine capacities are
exceeded

Fingers and receiver not
aligned.

Fingers and receiver not
aligned.

Workpiece is too thick.

Fingers or receiver scratched Polish out scratches, and apply

Operate within the listed
capacities of the machine

Properly align the fingers and
receiver

Properly align the fingers and
receiver

Operate within the listed
capacities of the machine

tape at the bend locations for
further protection

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

SHEAR BLADE OPERATION

PROBLEM CAUSES SUGGESTIONS

Machine will not
cut workpiece.

Cuts are not
square

Poor quality of
cuts with ripping

or tearing

Cut exceeds machine
capacities.

Not enough gap between
blades.

Uneven contact with guide or
work stop

Blade gap unequal across
length

Too much bow in blade Properly adjust blade bow

Inadequate hold-down
pressure

Dull blades Reverse/sharpen/replace

Incorrect blade gap setup

Loose blades

Operate within the listed
capacities of the machine

Increase blade gap.

Maintain proper contact with
guide and work stop

Properly adjust blade gap for
material

Properly adjust hold-down
pressure

blades

Properly adjust blade gap for
material

Remove blades, clean
thoroughly and re-install

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 effect your statutory rights.

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

COMPONENT PARTS DIAGRAM

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

COMPONENT PARTS LIST

No Description No Description No Description

1 Left wall 24 Back pressure roller 47 Bolt M8 x 16

2 Workbench 25 Roller adjustment knob 48 Washer 8mm

3 Cross beam 26 Handle knob 49 Nut M8

4 Crank arm 27 Adjustable screw 50 Bolt M10 x 16

5 Right wall 28 Roller bushing 51 Screw M8 x 30

6 Bare frame 29 Washer 52 Screw M6 x 25

7 Cover 30 Gear 53 Screw M8 x 20

8 Press plate bracket 31 Lower pressure roller 54 Washer 8mm

9 Spring 32 Upper pressure roller 55 Screw M6 x 45

10 Pressing plate 33 Cover 56 Screw M6 x 8

11 Moving cutter plate 34 PVC hose 57 Screw M6 x 10

12 Fingers 35 Eccentric shaft 58 Screw M6 x 8

13 Pressing plate 36 Washer 59 Screw M8 x 20

14 Bolt M8x40 37 Key 60 Clamp bolt

15 Rolling wheel 38 Screw M6 x 12 61 Stop stick

16 Guide 39 Screw M6 x 16 62 Grease cap

17 Adjustable bolt 40 Bolt M6x50 63 Nut M10

18 Handle 41 Nut M8 64 Bolt M10 x 125

19 Positioning bar 42 Adjustable bolt 65 Stop Stick

20 Positioner 43 Screw M6 x 8 66 Hex key wrench 5mm

21 Positioning plate 44 Screw M8 x 40 67 Hex key wrench 6mm

22 Support plate 45 Washer 8 mm

23 Blade 46 Bolt M8 x 40

FINGERS

• 25mm/1” Finger

• 50mm/2” Finger

• 76mm/3” Finger

• 102mm/4” Finger

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]