General International 75-040 M1 Use and Care Manual
Contents
1. Childproof and tamper proof your shop and alll machinery with locks master electrical switches and switch keys to prevent unauthorized or unsupervised use Stay alert Give your work your undivided attention Even a momentary distraction can lead to serious injury Fine particulate dust is a carcinogen that can be haz ardous to health Work in a well ventilated area and whenever possible use a dust collector and wear eye ear and respiratory protection devices Do not wear loose clothing gloves bracelets neck laces or other jewelry while the mortiser is in opera tion Be sure that adjusting wrenches tools drinks and other clutter are removed from the machine and or the table surface before operating Keep hands well away from the mortising chisel bit and all moving parts Use a hold down or clamp to secure the stock and use a brush not hands to clear away chips and dust Be sure that the mortising chisel and bit are securely installed in the chuck before operation Be sure the mortising bit has gained full operating speed before beginning to drill Always use a clean properly sharpened chisel and bit set Dirty or dull chisels and bits are unsafe and can lead to accidents Use suitable work piece support if the work piece does not have a flat surface Do not push or force the chisel and bit into the stock The mortiser will perform better and more safely when working at the rate feed for whic2. SCREW DOWNFEED SHAFT LOCK KNOB SPECIFICATION S 8 M6X 10 4 M5 2 M8 M6 X 10 X X18 S 20 M8 X 10 M8 X 15 AA po po Sw Joo oo in HP ro HP AP A AY Al s s S pl rp J PART NO 75040 58 75040 59 75040 40 SIOPBAR SHOR U 75040 61 75040 62 75040 63 75040 63 1 75040 64 75040 65 75040 66 75040 67 75040 68 75040 69 75040 70 75040 71 75040 72 75040 73 75040 74 75040 75 75040 76 75040 77 75040 78 75040 79 70 910A 70 915 70 916A 70 920A 5 16 REPLACEMENT CHISEL AND BIT SET NOT SHOWN 70 925 70 926A 70 930 70 935 70 936 70 940 70 945 70 946 70 950 70 955 70 956 PARTS LIST 75 040 M1 DESCRIPTION DOWNFEED HANDLE RUBBER HANDLE GRIP LOCK KNOB STOP BAR BLOCK STOP BAR LONG NUT LOCK KNOB WORKPIECE HOLD DOWN LOCKING LEVER WASHER FENCE WORKPIECE HOLD DOWN SHAFT NUT SET SCREW SLIDE BAR SCREW LOCK KNOB WASHER RUBBER ROLLER BUSHING WASHER TSCREW 1 4 REPLACEMENT CHISEL AND BIT SET NOT SHOWN 1 4 REPLACEMENT CHISEL ONLY NOT SHOWN 1 4 REPLACEMENT BIT ONLY NOT SHOWN 5 16 REPLACEMENT CHISEL ONLY NOT SHOWN 5 16 REPLACEMENT BIT ONLY NOT SHOWN 3 8 REPLACEMENT CHISEL AND BIT SET NOT SHOWN 3 8 REPLACEMENT CHISEL ONLY NOT SHOWN 3 8 REPLACEMENT BIT ONLY NOT SHOWN 1 2 REPLACEMENT CHISEL AND BIT SET NOT SH
3. TO THE USER AS WELL AS DAMAGE TO THE MACHINE IF IN DOUBT CONTACT A QUALIFIED ELECTRICIAN BEFORE CONNECTING TO THE POWER SOURCE THIS TOOL IS FOR INDOOR USE ONLY DO NOT EXPOSE TO RAIN OR USE IN WET OR DAMP LOCATIONS GROUNDING INSTRUCTIONS In the event of an electrical malfunction or short circuit grounding reduces the risk of electric shock The motor of this machine is wired for 110V single phase operation and is equipped with a 3 conductor cord and a 3 prong grounding plug A to fit a grounded type recep tacle B Do not remove the 3rd prong grounding pin to make it fit into an old 2 hole wall socket or extension cord If an adaptor plug is used C it must be attached to the metal screw of the receptacle Note The use of an adaptor plug is illegal in some areas Check your local codes If you have any doubts or if the supplied plug does not correspond to your elec trical outlet consult a qualified eletrician before pro ceeding CIRCUIT CAPACITY Make sure that the wires in your circuit are capable of handling the amperage draw from your machine as well as any other machines that could be operating on the same circuit If you are unsure consult a qualified electrician If the circuit breaker trips or the fuse blows regularly your machine may be operating on a circuit that is close to its amperage draw capacity However if an unusual amperage draw does not exist and a power failure still occurs contact a qualified tec
4. Tip For added convenience and time savings the table rollers allow you to roll the workpiece left or right l as needed to continue the next cut for the mortise slot 15 Continue cutting the mortise 16 Repeat to complete the mortise overlapping each cut slightly 17 Test the fit of your tenon in the mortise J Re adjust if needed MAINTENANCE MAKE SURE THE MORTISER HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PER FORMING ANY MAINTENANCE PERIODIC MAINTENANCE Keep the machine clean and free of dust and woodchips Vacuum or brush off any loose debris and wipe down the machine and the table occasionally with a damp rag An occasional light coating of paste wax can help protect the table surface and reduce workpiece friction Ask your local distributor for suggestions on aftermarket surface cleaners and protectants based on what is readily available in your area Avoid using silicon based products that may affect wood finishing products such as oil solvent or water based stains varnishes and lacquers Periodically inspect the power cord and plug for damage To minimize the risk of electric shock or fire never operate the mortiser with a damaged power cord or plug Replace a damaged power cord or plug at the first visible signs of damage Periodically inspect chisel and bits for signs of visible damage Replace a chipped or damaged chisel or bit immediately SHARPENING CHISELS AND BITS Workin
5. the unit is safely secured to a work surface uncoil the power cord and plug the power cord into an appropri ate outlet Refer back to the section entitled ELECTRI CAL REQUIREMENTS and make sure all requirements E and grounding instructions are followed When mortising operations have been completed unplug the mortiser from the power source ON OFF POWER SWITCH The mortiser is equipped with a safety ON OFF switch located on the front left hand side of the mortiser head To start the mortiser Push on the red STOP button tab as shown in A to unlock the switch cover then lift the switch cover up B and push on the green START but ton C Close the switch cover To stop the mortiser push on the red STOP button D SETTING THE DEPTH STOP Transfer a reference line showing the desired depth of cut onto the front face of the workpiece and then set the depth stop as follows Lower the chisel to the bottom of your depth refe Note As a time saving convenience the upper stop C rence line A then adjust the depth stop against can be set to control the upward travel of the head This A feature allows you to save time by raising the bit only the stop plate as shown in B fo prevent the chisel enough to clear the workpiece and allow you to reposition from lowering any further the workpiece without having to raise the head fo its max imum TABLE EXTENSIONS The mortiser is equipped with two telescopic
6. M X 75 MM TABLE SIZE 14 1 4 X 11 1 8 362 X 283 MM BASE SEE 75 O40 MI 15 9 16 x 17 1 8 396 x 435 MM OVERALL HEIGHT 24 3 8 620 MM SPINDLE SPEED 1720 RPM MOTOR 1 2 HP 110 V 1 PH A WEIGHT REVISION 2 DECEMBER 2 10 99 LBS 45 KG Copyright General International 12 2010 GENERAL INTERNATIONAL 8360 Champ d Eau Montreal Quebec Canada HIP 1Y3 Telephone 514 326 1161 Fax 514 326 5555 www general ca THANK YOU for choosing this General International model 75 040 M1 5 8 hollow chisel mortiser This mortiser has been carefully tested and inspected before shipment and if properly used and maintained will provide you with years of reliable service For your safety as well as to ensure optimum performance and trouble free operation and to get the most from your investment please take the time to read this manual before assembling installing and operating the unit The manual s purpose is to familiarize you with the safe operation basic function and features of this mortiser as well as the set up maintenance and identification of its parts and compo nents This manual is not intended as a substitute for formal woodworking instruction nor to offer the user instruction in the craft of woodworking If you are not sure about the safety of performing a certain operation or procedure do not proceed until you can confirm from knowledgeable and qualified sources that it is safe to do s
7. NG RAISE THE MORTISER HEAD Y IN This mortiser is shipped from the factory with the head lowered to it s lowest position as shown in A 1 Loosen the upstroke lock knob B to allow the head to raise to its highest position as shown in C ATTACH THE WORKPIECE STOP The workpiece stop can be installed on either side of the mortiser A to suit your needs or personal work pre ferences 1 Thread the long stop bar into the threaded hole in the base and secure with the lock nut B 2 Install the stop bar block and short stop bar as shown in C INSTALL THE DOWN FEED HANDLE lt A The four holes in the down feed shaft A allow you to reposition the handle in the holes for better comfort and con venience 1 Loosenlock knob B 2 Position the downfeed handie choosing the hole that provides the most comfortable handle angle 3 Re tighten the lock knob to secure the down feed handle in position C Note If desired the entire handle assembly can be removed by loosening the two set screws D and re installed for use on the left hand side of the machine as shown in E ATTACH THE TOOL AND CHISEL HOLDER A convenient tool holder is supplied for chuck key allen keys and chisels storage A 1 Install the tool and chisel holder to the left side of the machine using the two screws and washers already mounted as shown in B INSTALL A CHISEL AND BIT SET TURN OFF AND UNPLUG THE MORTISER FROM THE POWER SOURCE BEF
8. ORE PERFORMING ANY MAINTENANCE ADJUSTMENTS OR BIT CHANGES CHISEL AND BIT TIPS ARE VERY SHARP HANDLE WITH CARE TO AVOID PERSONAL INJURY USE A PIECE OF CARDBOARD PLASTIC OR OTHER MATERIAL BETWEEN YOUR FINGER AND THE TIP OF THE BIT WHENEVER HOLDING OR HANDLING THE CHISEL AND BIT BY THE TIP Note The 5 8 shank diameter bushing is already intalled at the factory A This unit is supplied with a set of four different sized chi The unit is also supplied with 2 different sized chisel sel and bits to help the user cut mortises of varying support bushing adapters allowing the user to install widths to suit the application chisel and bit sets of either 5 8 or 3 4 shank dia meter to accommodate bit sizes some of which are available as optional accessories ranging from a mi nimum of 1 4 up to a maximum of 5 8 1 Select the appropriate size of chisel and bit 2 Select the appropriate bushing and if not already installed unscrew and remove the locking lever A then slip the bushing into the quill assembly as shown B 3 Loosen the two lock knobs C on either side of the mortiser head and slide the corresponding slide plate out of the way 4 Insert the supplied chuck key D and turn counterclockwise to open the chuck jaws and allow a drill bit to fit in E 5 With a piece of plastic carboard or wood held between the tip of the bit and your finger F install the chisel and bit with the chip clearing slot facing either left or r
9. OWN 1 2 REPLACEMENT CHISEL ONLY NOT SHOWN 1 2 REPLACEMENT BIT ONLY NOT SHOWN 5 8 REPLACEMENT CHISEL AND BIT SET OPTIONAL ACCESSORY NOT INCLUDED NOT SHOWN 5 8 REPLACEMENT CHISEL ONLY NOT SHOWN 5 8 REPLACEMENT BIT ONLY NOT SHOWN SPECIFICATION QTY M8 X 15 M10 X 70 SFO O Ns NI INI N Ns hh NID INI NFeoa jill l5l lI Uu WTINs eojojojojol ojol o o MODEL 75 040 M1 8360 Champ d Eau Montreal Quebec Canada HIP 1V3 Tel 514 326 1161 Fax 514 326 5565 Parts amp Service Fax 514 326 5555 Order Desk orderdeskGgeneral ca www general ca IMPORTANT When ordering replacement parts always give the model number serial number of the machine and part number Also a brief description of each item and quantity desired
10. SETUP amp OPERATION MANUAL FEATURES 3 8 HOLLOW CHISEL MORTISER Heavy duty cast iron head column and base built for steady vibration free per formance Head slides on precision machined cast iron dovetail ways stroke is controlled by a gas head cylinder for smooth operation Dual depth stop for complete control of both down stroke depth and upstroke tra vel Left of right mount large feed handle with multi position arm for better leverage and increased feed control Includes an adjustable workpiece stop and hold down Totally enclosed fan cooled motor with start capacitor for smooth start up and longer running life Dust protected switch with large mush roomstyle stop button and lock out safety feature to prevent unintentional start up Includes adapter bushings to accommo date both 5 8 and 3 4 sized chisel shanks Large table with telescopic extensions for enhanced workpiece support Non marking rubber table rollers hold the workpiece firmly to the fence Convenient tool holder 1 4 5 16 3 8 and 1 2 mortising chisel and bit set included ad SPECIFICATIONS ie Ix E CHISEL CAPACITY z 1 4 TO 5 8 6 TO 16 MM MAXIMUM CHISEL STROKE c HR 5 127 MM 1 m I DISIANCE FROM FENCE TO CHISEL CENTER 7 4 101 mm MA DISTANCE FROM CHISEL TO TABLE CHISEL 1 4 5 127 MM CHUCK CAPACITY 12 13 MM FENCE SIZE 13 15 16 X 2 15 16 355 M
11. completion of assembly Limited Lifetime Warranty Because of our commitment to quality and customer satisfaction General and General International agree to repair or replace any part or component which upon examination proves to be defective in either workmanship or material to the original purchaser for the life of the tool However the Limited Lifetime Warranty does not cover any product used for profes sionnal or commercial production purposes nor for industrial or educational applications Such cases are covered by our Standard 2 year Limited Warranty only The Limited Lifetime Warranty is also subject to the Conditions and Exceptions as listed below Standard 2 Year Limited Warranty All products not covered by our lifetime warranty including products used in commercial industrial and educational applications are warranted for a period of 2 years 24 months from the date of purchase General and General International agree to repair or replace any part or component which upon examination proves to be defective in either workmanship or material to the original purchaser during this 2 year warranty period subject to the conditions and exceptions as listed below To file a Claim To file a claim under our Standard 2 year Limited Warranty or under our Limited Lifetime Warranty all defective parts components or machinery must be returned freight or postage prepaid to General International or to a nearby distribu
12. e Lower the workpiece hold down until slightly above the workpiece H and tighten VERIFY ALL FOLLOWING CHECK POINTS BEFORE TURNING ON THE MORTISER FAILURE TO COMPLY CAN RESULT IN SERIOUS INJURIES MAKE SURE THE TWO SLIDE PLATES OF THE CHUCK COVER ARE CLOSED AND THEIR LOCK KNOBS ARE TIGHTENED SECURELY MAKE SURE THE CHISEL AND BIT ARE PROPERLY INSTALLED AND THAT THE BIT CHUCK AND CHISEL LOCK LEVER ARE TIGHTENED SECURELY WHEN THE MORTISER IS RUNNING CHECK TO SEE IF IT RUNS WITHOUT VIBRATION OR SHAKING Turn on the machine Lower the chisel into the workpiece using a steady even pressure until it bottoms out on the depth stop FEED RATE Note To prevent burning the tip of the bit a steady feed rate is required The machine may stall or slow down if the feed rate is too fast Tip To allow chips to discharge when cutting deeper mortises or through mortises cut the mortise to its full depth in several steps by backing off periodically at roughly 3 8 1 2 intervals Raising the bit back out of the mortise briefly before plunging back in allows the chips to discharge and can contribute to longer chisel and bit life and cleaner sharper mortises When cutting through mortises place a piece of scrap wood under the workpiece fo help prevent tear out as the bit cuts its way through the opposite or exit face of the workpiece 13 Raise the chisel 14 Reposition the workpiece against the fence to continue the cut
13. g with properly sharpened chisel and bits will greatly increase the quality of your work and allow you to obtain clean crisply cut mortises with minimal effort With use over time chisels and bits will need to be re sharpened The frequency of use type of workpiece material and the size and depth of the mortises you cut will affect how often or infrequently re sharpening will be required You will find there are a variety of aftermarket sharpening tools made by third party sources that are available on the market for both the chisels and the bits for your mortis er Your local distributor or tool retailer will be able to advise you of any sharpening tool options based on what is readily available in your area Take note that chisels should only be sharpened on their inside edges as any material removed from the outside edge will affect and change the overall dimensions of the chisel An example of a typical chisel sharpening cone is shown in A Such cones are usually made available in sets or individually by size and should be matched to the size of the chisel your local tool distributor or sharpening sup plies specialist will be able to advise you further For best results follow the instructions supplied with the sharpening tool or accessory being used LUBRICATION Keep both sides of the dovetail way B well lubricated and free of dust or debris Clean and remove dust debris and old lubricant as needed depending on frequency of u
14. h it was designed Avoid working from awkward or off balance positions Do not overreach and keep both feet on floor Never leave the machine unattended while it is run ning or with the power on Use of parts and accessories NOT recommended by GENERAL INTERNATIONAL may result in equipment malfunction or risk of injury Never stand on machinery Serious injury could result if the tool is tipped over or if the mortiser chisel and bit are unintentionally contacted Always disconnect the tool from the power source before servicing or changing accessories such as chisel and bit sets or before performing any mainte nance cleaning or if the machine will be left unat tended Make sure that the switch is in the OFF position before plugging in the power cord Make sure the tool is properly grounded If equipped with a 3 prong plug it should be used with a three pole receptacle Never remove the third prong Do not use this mortiser for other than its intended use If used for other purposes GENERAL INTERNA TIONAL disclaims any real implied warranty and holds itself harmless for any injury which may result from that use GX ELECTRICAL REQUIREMENTS A BEFORE CONNECTING THE MACHINE TO THE POWER SOURCE VERIFY THAT THE VOLTAGE OF YOUR POWER SUPPLY CORRESPONDS WITH THE VOLTAGE SPECIFIED ON THE MOTOR I D NAMEPLATE A POWER SOURCE WITH GREATER VOLTAGE THAN NEEDED CAN RESULT IN SERIOUS INJURY
15. hnician or our service department EXTENSION CORDS If you find it necessary to use an extension cord with your machine use only 3 wire extension cords that have 3 prong grounding plug and a matching 3 pole recepta cle that accepts the tool s plug Repair or replace a damaged extension cord or plug immediately Make sure the cord rating is suitable for the amperage listed on the motor I D plate An undersized cord will cause a drop in line voltage resulting in loss of power and overheating The accompanying chart shows the correct size extension cord to be used based on cord length and motor I D plate amp rating If in doubt use the next heavier gauge The smaller the number the heavier the gauge NR z Not Recommended 5 8 HOLLOW CHISEL MORTISER 75 040 M1 IDENTIFICATION OF MAIN PARTS AND COMPONENTS LEFT AND RIGHT SIDE VIEW A DOWNFEED HANDLE B MOTOR C ON OFF SWITCH D DUAL DEPTH STOP E CHISEL LOCKING LEVER F FENCE LOCKING LEVERS G FENCE H BASE l TABLE ROLLERS J WORKPIECE STOP K WORKPIECE HOLD DOWN L TABLE EXTENSIONS M TOOL AND CHISEL HOLDER N GAS HEAD CYLINDER O SLIDE PLATE LOCK KNOB P CHUCK BASIC FUNCTIONS This hollow chisel mortiser is designed to cut 90 mortises in solid wood as well as other wood based stock This mor tiser is designed to tackle a wide range of mortising applications suited to both hobbyist and professional users Ideal for use in any furniture making or cab
16. ight and tighten the bit in the chuck so that the tip of the bit juts out approximately 1 16 to 3 16 2 mm to 5 mm from the tip of the chisel G 6 While still holding the chisel in place tighten the locking lever h to secure the chisel in the bushing Note Do not overtighten the locking lever as this can damage your mortiser TO SQUARE THE CHISEL TO THE FENCE 1 Lower the head to its maximum A 2 Place a piece of taller stock minimum 3 against the fence B Note Make sure you are using a piece of planed and squared stock that has an even thickness 3 Loosen the fence locking levers C and slowly advance the fence with the piece of wood towards the chisel i If the face of the chisel sits flusn against the stock as If the chisel does not sit flush shown in D the chisel is square Tighten the chisel lock 1 l Loosen the chisel lock lever E and manually turn ing lever E and proceed with normal operation the chisel F until its face sits flush against the stock 2 Lock lever E to secure the chisel in position BASIC ADJUSTMENTS amp CONTROLS CONNECTING TO A POWER SOURCE TO REDUCE THE RISK OF SHOCK OR FIRE DO NOT OPERATE THE UNIT WITH A DAMAGED POWER CORD OR PLUG REPLACE DAMAGED CORD OR PLUG IMMEDIATELY TO AVOID UNEXPECTED OR UNINTENTIONAL START UP MAKE SURE THAT THE POWER SWITCH IS IN THE OFF POSI TION BEFORE CONNECTING TO A POWER SOURCE Once the assembly steps have been completed and
17. inet making applications that require mortise and tenon joinery the unit is supplied with a set of 4 different sized chisel and bits to help the user cut mortises of varying widths to suit the appli cation The unit is also supplied with 2 different sized chisel bushings allowing the user to install chisel and bit sets of either 5 8 4 supplied or 3 4 commonly available from other aftermarket sources shank diameter This mortiser is designed to acommodate chisel and bit set sizes ranging from a minimum of 1 4 up to a maximum of 5 8 Carefully unpack and remove the mortiser and its com ponents from the box and check for damaged or miss ing items as per the list of contents below NOTE Please report any damaged or missing items to your General International distributor immediately LIST OF CONTENTS MORTISER DOWNFEED HANDLE TABLE ROLLERS STOP BAR BLOCK STOP BAR SHORT STOP BAR LONG W NUT TOOL amp CHISEL HOLDER 1 4 6 MM CHISEL AND BIT 5 16 8 MM CHISEL AND BIT 3 8 10 MM CHISEL AND BIT 1 2 13 MM CHISEL AND BIT CHUCK KEY 3 4 SHANK BUSHING ADAPTER 3 MM ALLEN KEY 4 MM ALLEN KEY 5 MM ALLEN KEY Already installed on the mortiser table CLEAN UP Clean all rust protected surfaces by rubbing with a rag dipped in kerosene mineral spirits or paint thinner Dispose of potentially flammable solvent soaked rags according to manufacturer s safety recommendations Avoid rubbing any painted surfaces as many solve
18. mp bit set 5 8 16 mm shank ITEM 70 950 5 8 16 mm mortising chisel amp bit set 5 8 16 mm shank PART NO 75040 01 75040 02 75040 03 75040 04 75040 05 75040 06 75040 07 75040 08 75040 09 75040 10 75040 11 75040 12 75040 13 75040 14 75040 15 75040 16 75040 17 75040 18 75040 19 75040 20 75040 21 75040 22 75040 23 75040 24 75040 25 75040 26 75040 27 75040 28 75040 29 75040 30 75040 31 75040 32 75040 33 75040 34 75040 35 75040 36 75040 37 75040 38 75040 39 75040 40 75040 41 75040 42 75040 43 75040 44 75040 45 75040 46 75040 47 75040 48 75040 49 75040 50 75040 51 75040 52 75040 53 75040 54 75040 55 75040 56 75040 57 PARTS LIST 70 040 M1 DESCRIPTION BASE OPEN RETAINING RING EXTENSION BAR SET SCREW TABLE EXTENSION SCALE COLUMN FLAT WASHER LOCK WASHER HEX HEAD BOLT TOOL amp CHISEL HOLDER PAN HEAD SCREW GEAR COVER PAN HEAD SCREW GAS HEAD CYLINDER RACK CAP SCREW SLIDE BAR PAN HEAD SCREW WASHER CORD CLAMP HEX NUT CAP SCREW PAN HEAD SCREW SWITCH BOX CABLE TERMINAL POWER CORD PAN HEAD SCREW CONDENSER COVER CONDENSER PACKING MOTOR SCREW SWITCH CHUCK HEAD SLIDE PLATE LOCK KNOB WASHER LOCKING LEVER BUSHING ADAPTER LOCK WASHER CAP SCREW PAN HEAD SCREW NUT LOCK KNOB DEPTH STOP DEPTH STOP BAR HEX NUT SET SCREW GEAR KEY OPEN RETAINING RING PINION SHAFT SET
19. nt based products will remove paint To prevent rust apply a light coating of paste wax or use regular applications of any aftermarket surface protec tant or rust inhibitor ASSEMBLY INSTRUCTIONS For your convenience this mortiser is shipped from the factory partially assembled and requires only minimal assembly and set up before being put into service SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COMPLE TED THE ASSEMBLY STEPS DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED TO DO SO INSTALLATION This machine should be installed and operated only on a flat sturdy and stable surface able to support the weight of the machine 99 Ibs 45 kg and the work piece with ease Note Never install the machine over the edge of a table or workbench A MOUNTING TO A WORK SURFACE o HEX HEAD BOLT FLAT WASHERS LOCK WASHER Q HEX NUT If a permanent shop placement is practical consider drilling matching through holes in the mounting sur face of your workbench or stand s platform to bolt the mortiser in place using hex bolts flat washers lock washers and hex nuts A fasteners not included in the assembly order shown in B FOR YOUR SAFETY IT IS ESSENTIAL THAT THE MORTISER DOES NOT ROCK OR TIP DURING OPERATION MAKE SURE THAT THE MORITSER IS FIRMLY SECURED TO THE WORK SURFACE OR STAND S PLATFORM AND THAT THERE IS NO ROCKING TIPPING OR CHATTERI
20. nty TABLE OF CONTENTS Rules for safe operation Basic Operations Electrical requirements Maintenance Grounding instructions Periodic maintenance Circuit capacity Sharpening chisels and bits Extension cords Lubrication Required maintenance Identification of main parts l and components Recommended optional accessories Basic functions Diagram Unpacking Parts list List of contents Clean up Contact info Assembly instructions Installation Mounting to a work surface Raise the mortiser head Attach the workpiece stop Install the down feed handle Attach the tool and chisel holder Install a chisel and bit set To square the chisel to the fence Basic adjustments amp controls Connecting to a power source On off power switch Setting the depth stop Table extensions RULES FOR SAFE OPERATION To help ensure safe operation please take a moment to learn the machine s applications and limitations as well as poten tial hazards Generale International disclaims any real or implied warranty and holds itself harmless for any injury that may result from improper use of its equipment Do not operate the mortiser when tired distracted or under the effects of drugs alcohol or any medication that impairs reflexes or alertness The working area should be well lit clean and free of debris Keep children and visitors at a safe distance when the mortiser is in operation do not permit them to ope rate the mortiser
21. o Once you ve read through these instructions keep this manual handy for future reference Disclaimer The information and specifications in this manual pertain to the unit as it was supplied from the factory at the time of printing Because we are committed to making constant improvemenis General Internatio nal reserves the right to make changes to components parts or features of this unit as deemed necessary with out prior notice and without obligation to install any such changes on previously delivered units Reasonable care is taken at the factory to ensure that the specifica tions and information in this manual corresponds with that of the unit with which it was supplied However spe cial orders and after factory modifications may render some or all information in this manual inapplicable to your machine Further as several generations of this mo del of mortiser and several versions of this manual may be in circulation if you own an earlier or later version of this unit this manual may not depict your machine exactly If you have any doubts or questions contact your retailer or our support line with the model and seri al number of your unit for clarification GENERAL amp GENERAL INTERNATIONAL WARRANTY All component parts of General General International and Excalibur by General International products are carefully inspected during all stages of production and each unit is thoroughly inspected upon
22. se After cleaning reapply a verly light coating of lubricant Note Use any all purpose oil available at any hardware store REQUIRED MAINTENANCE With use and normal wear over time the motor assem bly may loosen slightly If you notice abnormal noise or vibrations tighten the cap screws A accessible behind the slide plates on both sides of the chuck using the supplied 5 mm allen key With use over time some slight play may develop in head on the dovetail way due to wear To eliminate play between the head and the dovetail way loosen the lock nuts B and adjust the individual set screws C as needed Re tighten the lock nut s once the adjustment has been completed NOTE Adjust only enough to eliminate play do not over tighten as this can stiffen or restrict head travel requiring more effort to complete the feed stroke and cause prema ture wear of the dovetail way RECOMMENDED OPTIONAL ACCESSORIES Here are some of the optional accessories available from your local General International dealer For more information about our products please visit our website at www general ca REPLACEMENT CHISEL amp BIT SETS ITEM 70 910A 1 4 6 mm mortising chisel amp bit set 5 8 16 mm shank ITEM 70 920A 5 16 8 mm mortising chisel amp bit set 5 8 16 mm shank ITEM 70 930 3 8 10 mm mortising chisel amp bit set 5 8 16 mm shank ITEM 70 940 1 2 13 mm mortising chisel a
23. table exten sions for enhanced workpiece support when working with longer stock BASIC OPERATIONS Layout and mark workpieces for the mortises to be cut Install the appropriate chisel and bit in the chuck Place the stock on the table against the fence A Set the depth stop Loosen the fence locking levers B and adjust the fence until the workpiece is positioned with the mortise to be cut centered on the chisel C Note If necessary lower the chisel onto the workpiece to make sure the layout lines of the mortise are aligned with the bit 6 With the fence now set to the correct front to back position tighten the two fence locking levers to hold the fence in place So that the chips are discharged into the part of the mortise which is already cut and that the part to be cut remains well visible set the workpiece on the table with the bit aligned with either The left end of the mortise if the chip clearing slot is facing left D The right end of the mortise if the chip clearing slot is facing right E Note To avoid overheating or damage fo the chisel or bit do not position the slot against the blind end of the mortise as this would prevent the chips from discharging from the chisel 8 If multiple workpieces are to be mortised in an identi cal manner adjust the workpiece stop F to allow to position the next workpiece at the exact same loca tion Tighten the table rollers G to hold the workpiece securely against the fenc
24. tor repair center or other location designated by General International For further details call our service department at 1 888 949 1161 or your local distributor for assistance when filing your claim Along with the return of the product being claimed for warranty a copy of the original proof of purchase and a letter of claim must be included a warranty claim form can also be used and can be obtained upon request from General International or an authorized distributor clearly stating the model and serial number of the unit if applicable and including an expla nation of the complaint or presumed defect in material or workmanship CONDITIONS AND EXCEPTIONS This coverage is extended to the original purchaser only Prior warranty registration is not required but documented proof of purchase i e a copy of original sales invoice or receipt showing the date and location of the purchase as well as the purchase price paid must be provided at the time of claim Warranty does not include failures breakage or defects deemed after inspection by General or General International to have been directly or indirectly caused by or resulting from improper use or lack of or improper maintenance misuse or abuse negligence accidents damage in handling or transport or normal wear and tear of any generally considered con sumable parts or components Repairs made without the written consent of General International will void all warra
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