Clarke SBR305 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
LS0620 - ISS 3
3 IN1 SHEET METAL MACHINE
MODEL NO: SBR305
PART NO: 6560000

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INTRODUCTION
Thank you for purchasing this CLARKE 3 in1 Sheet Metal Machine.
Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safety of yourself
and that of others around you, and you can look forward to your purchase
giving you long and satisfactory service.
GUARANTEE
This product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt which will be
required as proof of purchase.
This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.
Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.
This guarantee does not effect your statutory rights.
FEATURES
• Shear Table Front Guide
• Shear & Brake Adjustable Rear Stop
• Hardened Steel Brake Fingers
• Precision Ground Hardened Steel Shear Blade

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SAFETY INSTRUCTIONS FOR MACHINERY
1. READ THE ENTIRE MANUAL BEFORE USE. Machinery presents serious injury
hazards to untrained users.
2. ALWAYS USE APPROVED SAFETY GLASSES WHEN OPERATING MACHINERY.
Everyday eyeglasses are NOT safety glasses.
3. ALWAYS USE HEARING PROTECTION WHEN OPERATING MACHINERY.
Machinery noise can cause permanent hearing loss.
4. 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.
5. NEVER OPERATE MACHINERY WHEN TIRED OR UNDER THE INFLUENCE OF
DRUGS OR ALCOHOL. Be mentally alert at all times when in use.
6. ONLY ALLOW TRAINED AND PROPERLY SUPERVISED PERSONNEL TO OPERATE
MACHINERY. Make sure operation instructions are safe and understood.
7. KEEP CHILDREN AND VISITORS AWAY from the work area.
8. MAKE WORKSHOP CHILDPROOF. Use padlocks, master switches, and
remove start switch keys.
9. DO NOT USE IN DANGEROUS ENVIRONMENTS. DO NOT use machinery in
damp, wet locations, or where any flammable or noxious fumes may exist.
10. KEEP WORK AREA CLEAN AND WELL LIGHTED. Clutter and dark shadows
may cause accidents.
11. MAINTAIN MACHINERY WITH CARE. Keep blades sharp and clean for best
and safest performance.
12. MAKE SURE GUARDS ARE IN PLACE AND WORK BEFORE USING MACHINERY.
13. REMOVE ADJUSTING KEYS AND WRENCHES. Make a habit of checking for
keys and adjusting wrenches before turning machinery ON.
14. CHECK FOR DAMAGED PARTS BEFORE USING MACHINERY. 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
15. USE RECOMMENDED ACCESSORIES. Refer to the instruction manual for
recommended accessories. Improper accessories increase risk of injury.
16. DO NOT FORCE MACHINERY. Work at the speed for which the machine or
accessory was designed.
17. DO NOT OVER REACH. Maintain stability and balance at all times.

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ADDITIONAL SAFETY INSTRUCTIONS FOR 3-IN-1
SHEET METAL MACHINES
1. OVERLOADING. Attempting to overload this machine beyond the
capacities specified in the “Specifications” on page 35 could cause
personal injury or property damage. DO NOT extend the hand crank to
apply additional force.
2. USAGE. To avoid injury or property damage, always use the machine for its
intended purposes, DO NOT modify the machine in any way.
3. 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.
4. 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.
5. PERSONAL PROTECTION. To avoid personal injury, ALWAYS wear heavy
leather gloves, eye protection, and leather boots with extra toe protection
when using this machine.
6. BODY POSITION. To avoid injury due to slipping or falling, ALWAYS maintain
secure footing and a comfortable body position when using this machine.
7. 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.
8. 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.
9. ENTANGLEMENT HAZARDS. The moving parts of this machine represent
entanglement hazards. DO NOT wear jewelry, or loose clothing, and tie
back long hair when using this machine.
10. 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..

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WARNING LABELS
Read this manual before use.
Wear eye protection when using the machine.
Keep fingers clear of break, dies, rollers and blade.
WARNING: LIKE ALL MACHINERY THERE IS POTENTIAL DANGER WHEN
OPERATING 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.

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PARTS IDENTIFICATION
Fig. 1

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SETUP
UNPACKING
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.
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 degreaser.
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.
A. Sheet Metal Machine 1
B. Shear & Brake Rear Work Stop 1
C. Hand Crank 1
D. Crank Handle Lock Knobs 2
E. Hex Wrenches 5, 6mm 1 Each
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.
Fig. 2 Fig. 3

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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, workpiece, 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 IT TO A
STABLE AND STURDY WORKBENCH OR STAND. OTHERWISE, THE MACHINE
COULD TIP OR FALL AND RESULT IN PERSONAL INJURY OR PROPERTY
DAMAGE.
Fig. 4
Fig. 5
Fig. 6

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ASSEMBLY
In addition to the assembly procedures below, some disassembly is required to
remove storage grease and re-lubricate the cleaned parts.
TO ASSEMBLE YOUR 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 center 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.
6.
Fig. 7
Fig. 8
Fig. 9

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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
counterclockwise (see Figure 47).
NOTE: Operational adjustment of
the shearing blades is
covered in the “Shearing
Blade Gap Adjustment” on page 26
3. Make sure the finger receiver and upper shear blade move up and down
smoothly, retighten 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 gib 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 degreaser to
remove the storage grease from the fingers, gib, and receiver. Thoroughly
dry the parts, then apply a thin coat of an anti-rust lubricant to all the parts.
Fig. 10
Fig. 11
Fig. 12

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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 gib 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 gib and the
casting, then use the hand crank
to raise the receiver to fully seat
the fingers up against the casting
behind the gib, as shown in Figure
14.
9. Re-tighten all of the gib cap
screws.
Fig. 13
Fig. 14

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OPERATING - SLIP ROLLERS
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).
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.
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.
Fig. 15
Fig. 16

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CREATING CURVES
Your sheet metal machine can easily create constant radius curves in sheet
metal up to 1 mm in thickness.
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.
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: Suppose you want to create a 150 mm diameter cylinder. 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.
Fig. 19

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You can use the slip roll to create a
bend with the correct radius so that
the two 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. 20
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).
• 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 17. 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 17 for detailed
instructions on removing the cylinder from the top roller.
Fig. 23
Fig. 24
Fig. 25

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REMOVING THE WORKPIECE FROM T H E R OLLERS
TO REMOVE THE WORKPIECE FROM THE TOP ROLLER:
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.
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.
CAUTION: THE SHARP EDGES OF
SHEET METAL CAN QUICKLY
CUT YOUR HANDS. ALWAYS USE
CAUTION AND HEAVY LEATHER
GLOVES WHEN HANDLING
SHEET METAL.
Fig. 26
Fig. 27

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BENDING WIRE
Your sheet metal machine can bend
wires, rods, and small-diameter
tubing between the diameters of 1/8”
and 13/64” (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 7/64” rod
would fit into any of the wire grooves,
you would use the 1/8” groove since it
is the smallest 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.
NOTE: The wire grooves can also be used when rolling sheet metal that has a
wire bead on the side.
Fig. 28

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OPERATING - BRAKE
BRAKE OVERVIEW
The brake of the SBR305 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.
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. 29
Fig. 30
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 8-
13 beginning on page 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.
TO BEND SHEET METAL:
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.
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.
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.
Fig. 32
Fig. 33