General International 30-120 M1 Use and Care Manual
Contents
1. HARDWARE ELLIPTICAL JIG IDLER BEARING CAP SCREW 8 X 1 25 110L WASHER BUTTON HEAD SCREW 6 X 1 0 16L 2 TOOLS K SCREWDRIVER L 17 19 MM OPEN END WRENCH M 12 14 MM OPEN END WRENCH N 7 8 MM OPEN END WRENCH 6 MM OPEN END WRENCH P 6 MM ALLEN KEY Q 4 MM ALLEN KEY R 2 MM ALLEN KEY S 4 MM T HANDLE WRENCH ADDITIONAL REQUIREMENTS FOR SET UP e Extra person for help with lifting e Feeler gauge set 0 030 3 mm Allen key Gauge block PLACEMENT WITHIN THE SHOP ESTABLISHING A SAFETY ZONE THIS MODEL 30 120 M1 7 MOLDER IS HEAVY DO NOT OVER EXERT THE HELP OF AT LEAST ONE ASSISTANT OR A HOIST WILL BE AN NEEDED FOR THE FOLLOWING STEP TO LIMIT THE RISK OF SERIOUS INJURY OR DAMAGE TO THE MACHINE ANY EQUIPMENT USED TO LIFT THIS MACHINE SHOULD HAVE A RATED CAPACITY IN EXCESS OF 242 LBS 110 KG PLACEMENT WITHIN THE SHOP This machine should be installed and operated only on a solid flat and stable floor that is able to support the weight of the molder and the operator Using the dimen sions shown as a guideline plan for placement within your shop that will allow the operator to work unencum bered and unobstructed by foot traffic either passing shop visitors or other shop workers or other tools or machinery ESTABLISHING A SAFETY ZONE For shops with frequent visitors or multiple operators it is advisable to establish a safety zone around sh2. amp diagrams RULES FOR SAFE OPERATION help ensure safe operation please take a moment to learn the machine s applications and limitations as well as poten tial hazards General International disclaims any real or implied warranty and holds itself harmless for any injury that may result from improper use of its equipment 10 Do not operate this molder 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 molder is in operation do not permit them to operate the molder Childproof and tamper proof your shop and all ma chinery 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 hazardous to health Work in a well ventilated area and whenever possible use a dust collector Wear face eye ear respiratory and body protection devices Do not wear loose clothing gloves bracelets neck laces or other jewelry while the molder is in operation Wear protective hair covering to contain long hair and wear non slip footwear Be sure that adjusting wrenches tools drinks and other clutter are removed from the machine and or the tabl
3. AND FEEDING NON COMPATIBLE STOCK INTO THIS MOLDER PLANER CAN LEAD TO SERIOUS INJURY TO THE USER OR SHOP BYSTANDERS AND CAUSE DAMAGE TO THE WORKPIECE AND OR THE MACHINE IF THE STOCK YOU WISH TO PLANE MOLD DOES NOT MEET OR COMPLY WITH THE LIMITATIONS LISTED ABOVE FIND ANOTHER SAFER WAY TO PERFORM THE REQUIRED TASK MAXIMUM PLANING WIDTH 7 Planing Max 7 Molding l Max 6 3 4 MAXIMUM MOLDING WIDTH 6 3 4 MAXIMUM WORKPIECE THICKNESS 8 MINIMUM THICKNESS TO WHICH A WORKPIECE CAN BE SAFELY PLANED MOLDED 1 4 MINIMUM WORKPIECE LENGTH THAT CAN BE SAFELY PLANED 8 MAXIMUM DEPTH OF CUT REFERENCE CHART FOR DEPTH OF CUT SELECTION MOLDING PLANING It is recommended that for both hard and soft wood Removing less material per pass and taking multiple OF WOOD passes is always preferred to more aggressive plan ing molding Advantages include longer blade life better finish IE hood of removing too much material causing the work Wile Osis Red Oak The information in this chart is supplied as a general guideline only piece to be too thin for its intended use Note Depth of cut will vary depending on the width of the workpiece density type of wood and moisture content of the stock lity resulting in less time sanding later and less likeli Woite Ene CONNECTING TO A DUST COLLECTOR A dust port with a 4 opening is provided to accommo
4. FENCE RAIL CAP SCREW KEY TABLE COLUMN EXTENSION ROD LONG BELT COVER EXTENSION ROD SHORT SCALE HEX HEAD BOLT SET SCREW SPACER SET SCREW SPROCKET WASHER SPECIFICATION QTY M8X1 25PX16L LH 5 16 18UNCX1 2 L M8X1 25PX25L M8 3 8 16UNC M6X1 0PX35L M6X1 0PX30L M8X1 25PX30L 6X6X40 M6X1 0PX35L M6X1 0PX6L M6X1 0PX30L M 2 2 6 1 1 1 1 1 1 1 4 4 4 4 2 1 1 2 2 4 1 1 1 2 1 1 1 1 2 1 2 1 A A FZ B H B ET PARTS LIST 30 120 M1 PART NO REF DESCRIPTION SPECIFICATION QTY 30120 B01 61012001 STAND LEG 30120 B02 50160012 CARRIAGE BOLT 5 16 X18UNCX5 8 30120 B03 50301085 WASHER 10X20X2 0t 30120 B04 50251023 HEX NUT 3 8 16UNC 30120 B05 24051007 LEVELING FOOT 30120 B06 61012002 STAND CROSS BRACE LONG 30120 B07 61012003 STAND CROSS BRACE SHORT 30120 B08 50301100 WASHER 8X20X1 5t 30120 B09 50101064 HEX HEAD BOLT M8X1 25PX16L 30120 B10 50256002 FLANGED NUT 5 16 18UNC 30120 B11 50107009 BUTTON HEAD SCREW M6X1 0PX10L 30120 B12 50351003 WASHER 1 4 X13X1t 30120 B13 61012010 TABLE EXTENSION ROLLER BRACKET RH 30120 B14 61012008 TABLE EXTENSION ROLLER END CAP 30120 B15 61012007 TABLE EXTENSION ROLLER 30120 B16 61012009 TABLE EXTENSION ROLLER SHAFT 30120 B17 61012015 TABLE EXTENSION ROLLER BRACKET LH 30120 B18 61012101 VARIABLE SPEED CONTROL KNOB 30120 B19 23011029 SAFETV SWITCH 30120 B20 5112
5. date connection to a dust collector not included Be sure to use appropriate sized hose and fittings not included and check that all connections are sealed tightly to help minimize airborne dust If you do not already own a dust collection system consider contacting your General International dis tributor for information on our complete line of dust collection systems and accessories or visit our Web Site at www general ca CHECKLIST BEFORE STARTING VERIFY ALL CHECK POINTS BEFORE STARTING FAILURE TO COMPLY CAN RESULT IN SERIOUS INJURIES Make sure you and any assistants are wearing safe ap propriate workshop attire Roll up long sleeves secure long hair and remove anv jewelrv watches rings bra celets or anything that could become caught in the moving parts potentially causing serious injury To reduce the risk of damage to the planer molder or the workpiece as well as a potential for personal injury after initial set up as well as before each use make sure that everything is securely installed and that all fasten ers and moving parts on this machine are locked in place before starting the machine Make sure that the knives in the cutter head are properly set as explained in section Checking Setting the knives for planing or in section To install molding knives depending on the intended use of the machine Make sure that the feed rollers are properly set as explained in section Adjusting the feed r
6. 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 protectant and dry lubricants based on what is readily available in your area Avoid using silicon based products that may affect or react with 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 planer with a damaged power cord or plug Replace a damaged power cord or plug at the first visible signs of damage The motor and cutter head bearings are sealed and permanently lubricated no further lubrication is required The drive gears chain and elevation screws should be cleaned of woodchips dust debris and old grease after every 10 15 hours of use or as neede depending on frequency of use Affer cleaning re apply a generous coating of any common automotive bearing grease Regularly inspect planed molded workpieces for signs of knife damage or wear and replace damaged or worn knives immediately DRIVE GHAIN GEAR LUBRIGATION Periodicallv the drive chain and gears will need to be cleaned and greased to help maintain smooth feeding and contribute to longer machine life and trouble free operation To clean
7. parts always give the model number serial number of the machine and part number Also a brief description of each item and quantity desired
8. require less time spent sanding later Once all the boards have been passed through the machine once set them aside and turn off the machine Measure the workpiece s thickness Inspect the profile and if more material needs to be removed repeat the steps of section Planing or Molding accordingly Take as many passes as needed to achieve final workpiece thickness profile stopping the machine after each pass to reset the cutter head height as well as the feed rollers height if needed MOLDING CURVED PIECES USING THE ELLIPTICAL JIG The elliptical jig allows you to mold profiles into the face of curved workpieces Molding curved workpieces generally requires the work piece to be mounted and secured to a template that rides against the inner and outer guide bearings of the jig A For full width profile cuts both the workpiece and the tem plate must be of the exact same width as the top of the profile B Note this is not required when using a profile that is designed to cut only a portion of the entire width of the workpiece Ideally templates should be made from 3 4 thick MDF C and should be made roughly 4 longer than the work piece at each end D The minimum length of curved workpiece that can be safelv molded is 9 To secure the workpiece to a template pre drill and counter sink mounting holes into the template from below E The placement of the mounting holes will depend on the size of th
9. the adjustment knob L to align the bearings with the knife and then tighten the jam nut to secure them in place With the workpiece flush against the inner guide bear ings M loosen the button head screws N on the outer idler guide bearing and adjust the bearing flush against the outside face of the workpiece O Then tighten the screws to secure the bearing in place In preparation for the first pass raise the cutter head just enough to remove the workpiece and then re adjust the cutter head downward by one full turn on the handwheel to take than a 3 32 depth of cut BEFORE STARTING THE MACHINE AND FEEDING THE WORKPIECE INTO THE CUTTER MAKE SURE THAT THERE IS NO INTERFERENCE IN THE KNIFE AREA THAT COULD CAUSE THE KNIVES TO MAKE CONTACT WITH ANYTHING OTHER THAN THE WORKPIECE SERIOUS INJURY TO THE USER AND OR BYSTANDERS AS WELL AS DAMAGE TO THE MACHINE WORKPIECE AND KNIVES CAN OCCUR IF DURING THE MOLDING PROCESS THE KNIVES COME INTO CONTACT WITH GUIDES BEARINGS SCREWS OR ANY OBJECTS OTHER THAN THE WORKPIECE MAINTENANCE MAKE SURE THE PLANER MOLDER HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORMING ANY MAINTENANCE PERIODIC MAINTENANCE Inspect test the ON OFF switches before each use Do not operate the planer molder with a damaged switch replace a damaged switch immediately Keep the machine as well the table clean and free of saw dust woodchips pitch or glue Vacuum or brush off any
10. the chip deflector towards the cutter head I so there s a space of roughly 1 8 between the chip deflector and knife edges J 10 14 16 17 Place a perfectly squared block of wood approx 1 x 1 x 5 on the table and against the right fence With the head positioned low enough move the fence and the block over until the block touches the side of the knife and then lock the fence in place using both lock Knobs To ensure that the second knife is aligned with the first rotate the head 180 and verify that the side of knife lightly rubs against the block O If needed loosen the bolts P slightly and apply inward or out ward pressure to the knife to reposition it as needed while retightening the bolts Rotate the head 180 Loosen the 2 button head screws on the curved chip deflector then draw the chip deflector to wards the cutter head so there s minimum space of 1 4 between the chip deflector and knife edges J OPERATING INSTRUGTIONS BASIC PRINCIPLES OF PLANING MOLDING This planer molder is designed to remove material from the top face of a board in order to bring the board or a series of boards down to a specific desired shape or pro file and thickness To obtain uniform results across the length of a board the stock being planed molded must have one face that has already been machined perfectly flat usually on a jointer and the stock should be fed with this flat face agains
11. thermal relay circuit breaker protects the feed motor from power surges or spikes in line voltage In the event of a power surge the thermal relay will be automatically tripped thereby cutting off the power to the feed motor To reset the thermal relay after it has been tripped set the feed motor switch to the off position and press the thermal relay re set button I then restart the feed motor The feed motor speed ranges from 3 to 20 FPM Feet Per minute The feed speed adjustment knob is located on the feed motor control panel on the right hand side of the machine Turn the knob Clockwise to increase the feed rate Counterclockwise to decrease the feed rate Select appropriate feed speed for the stock being planed molded high speed for softwood and slow for hardwoods Experiment with feed speeds based on the workpiece material and its width as well as the depth of SWITCH OFF Decrease Increase speed speed cut to find which setting work best for your needs As a general guideline however for best results more aggressive cuts or wider materials should be planed at slower speeds and lighter cuts or narrow materials can be planed at higher speeds GHEGKING SETTING THE KNIVES FOR PLANING Accurate results can only be achieved when the two knives are properly installed and set to the exact same height in the cutter head The planer knives have been factory set to the exact same height in the cutter h
12. 0 V 1 PH 12 OVERALL DIMENSIONS L X W X H 32 X 27 1 2 X 51 813 X 699 X 1295 MM WEIGHT 242 LBS 1 10 KG REVISION 1 MARCH 08 10 Copyright International 03 2010 GENERAL INTERNATIONAL 8360 Champ d Eau Montreal Quebec Canada HIP 1V3 Telephone 514 326 1161 Fax 514 326 5555 www general ca THANK VOU for choosing this General International model 30 120 MI 7 Molder This molder has been carefully tested and inspected before shipment and if properiv used and maintained will provide vou with vears of reliable service For vour safetv as well as to ensure optimum performance and trouble free operation and to get the most from vour 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 molder 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 vou are not sure about the safetv of performing a certain operation or procedure do not proceed until vou can confirm from knowledgeable and qualified sources that it is safe to do so Once you ve read through these instructions keep this manual handy for future reference Disclaim
13. 012 50107018 50302007 61011011 50107009 61011501 50303003 50201013 50351003 61011026 61011032 61011029 61011016 50501020 61011036 61011008 34022017 61011004 50202012 34022027 61011028 50107019 50403003 61011030 61011005 61011038 50104014 51110001 61011022 61011031 61011039 61011006 61011007 50151115 50301112 61011002 50402003 50501051 50201011 50103049 61011001 50604022 50501050 50402005 61011003 50103041 50301084 PARTS LIST 30 120 M1 DESCRIPTION BUTTON HEAD SCREW LOCK WASHER CAP SCREW SET SCREW CHAIN WHEEL CHAIN CHAIN WHEEL CHAIN CHAIN COVER BUTTON HEAD SCREW LOCK WASHER FEED MOTOR BRACKET BUTTON HEAD SCREW FEED MOTOR SPROCKET WASHER HEX NUT WASHER CHAIN WHEEL BRACKET SPRING ADJUSTMENT SCREW BEARING SHAFT BEARING SPRING CHAIN WHEEL BRACKET SHAFT SHORT FEED ROLLER BRACKET FEED ROLLER LOCK NUT HEX NUT ADJUSTMENT BUSHING BUTTON HEAD SCREW E RING CHAIN WHEEL BRACKET SHAFT LONG HEAD CASTING BUSHING PHILLIPS HEAD SCREW CORD SNAP RING CABLE PROTECTOR REAR CHIP DEFLECTOR PLATE FRONT CHIP DEFLECTOR PLATE DUST COVER DUST CHUTE HEX HEAD BOLT WASHER KNIFE C RING BEARING HEX NUT SET SCREW CUTTER HEAD KEY BEARING C RING PULLEY SET SCREW WASHER SPECIFICATION QTY M6X1 0PX12L 5 M5X0 8PX10L M5X0 8PX5L 25X52P 25X76P M6X1 0PX50L M M6X1 0PX10L M5 M6X1 0P 1 4 X13X1t M10X1 5P M6X1 0PX25L ETW 10 M5X0 8PXTOL ACC 2
14. 170 amp of top quality dust collec 50 167S tors to suit all your shop We offer a selection needs Dust collectors con of roller stands for tribute to a cleaner more added in feed or healthful out feed support workshop environment when working with longer stock CUTTER HEAD REPLACEMENT KNIVES 301 20 44 TABLE ALIGNMENT BLOCK hi 30 040 Set of two 7 hi speed steel re Aluminum guide block used to align the cutter head parallel to the table SET OF 2 MOLDING KNIVES FOR MODEL 30 120 ONLV Hi speed steel H S S molding knives to create a varietv of different moldings 18498 17 MA 92 177 DIE 221123 DERESE metin 492108 MiB Gi mm 234818 12121 221121 AH IBA 024 138 mi OFS MAIN ASSEMBLY PART NO 30120 A01 30120 A02 30120 A03 30120 A04 30120 05 30120 A06 30120 A07 30120 A08 30120 A09 30120 A10 30120 A11 30120 A12 30120 A13 30120 A14 30120 15 30120 A16 30120 A17 30120 A18 30120 A19 30120 A20 30120 21 30120 A22 30120 A23 30120 A24 30120 25 30120 26 30120 A27 30120 A28 30120 A29 30120 A30 30120 A31 30120 A32 30120 A33 30120 A34 30120 A35 30120 A36 30120 A37 30120 A38 30120 A39 30120 A40 30120 A41 30120 A42 30120 A43 30120 A44 30120 45 30120 46 30120 47 30120 48 30120 49 30120 50 30120 A51 30120 A52 30120 A53 30120 A54 30120 55 50107004 50302006 50102003 50103011 61011035 50802008 61011025 50802009 61011
15. 3003 FUSE 1A 250V 6 35X32mm 30120 B21 61012016 FUSE BLOCK 30120 B22 61012014 CONTROL PANEL 30120 B23 61012012 CONTROL BOX 30120 B23 1 CONTROL BOX SCREW M3X0 5PX15L 30120 B24 51101004 PLASTIC CLAMP SB7R 3 30120 B25 61012004 STAND TABLE 30120 B26 50102031 CAP SCREW M8X1 25PX25L 30120 B27 61012011 MOTOR COVER PANEL 30120 B28 34011029 RUBBER PROTECTOR 30120 B29 50103015 SET SCREW M6X1 0PX10L 30120 B30 61012651 MAGNETIC SAFETY SWITCH ASSEMBLY 30120 B30 1 61012601 MAGNETIC SAFETY SWITCH 30120 B30 2 61012801 POWER CORD 30120 B30 3 61012701 MOTOR CORD 30120 B30 4 51104005 STRAIN RELIEF 30120 B30 5 51104003 STRAIN RELIEF 30120 B30 6 61012901 MAGNETIC SWITCH TO SAFETY SWITCH CORD 30120 B31 50104068 PHILLIPS HEAD SCREW M6X1 0PX16L 30120 B32 61012018 SWITCH MOUNTING PLATE 30120 B33 61012501 MAIN MOTOR 30120 B34 51104003 STRAIN RELIEF PG 13 5 30120 B35 51121001 PLASTIC PROTECTOR NB 1216 30120 B36 61012005 MOTOR PULLEY 30120 B37 50604020 KEY 6X6X30L 30120 B38 50801011 V BELT A46 30120 B39 61012013 MOTOR BRACKET ROD 30120 B40 61012006 MOTOR MOUNTING BRACKET 30120 B41 50302008 LOCK WASHER M8 30120 B42 50101034 HEX HEAD BOLT M8X1 25PX25L 30120 B43 61012951 MAIN SWITCH TO FUSE BOX CORD 30120 B44 61012017 FUSE BOX TO SAFETY SWITCH CORD 30120 B45 51119001 WIRE CONNECTOR SW P3 30120 B46 50104014 PHILLIPS HEAD SCREW M5X0 8PX10L 30120 B47 51110001 CORD SNAP RING ACC 2 5 7 8mm NO NI Co CO CO OX NI NI BY CO Co Cop gt STAND
16. 5 7 8mm 4 3 8 16UNCX3 4 L 10X20X1 5t RTW 35 6003 2NK M4X0 7P M4X0 7PX10L OXOX25L 6204 2NK RTW 47 M6X1 0PX6L 8X30X3t o RD o n HPA Ay Ap A ffm Ay Alp lo gt in gt gt MAWISSY MAIN ASSEMBIV GNTD PART NO 30120 A56 30120 A57 30120 A58 30120 A59 30120 A60 30120 A61 30120 A62 30120 A63 30120 A64 30120 65 30120 65 1 30120 A65 2 30120 A65 3 30120 A66N 30120 A67 30120 A68 30120 A69 30120 A70 30120 A71 30120 A72 30120 A73 30120 A74 30120 75 30120 76 30120 A77N 30120 A78 30120 A79N 30120 A80N 30120 A81 30120 A82N 30120 A83 30120 A84 30120 85 30120 86 30120 87 30120 88 REF 50101062 61011015 50172003 34023021 61011017 50102031 50302008 61011013 61011014 34013101 34013024 34013021 50251006 61011023 50111014 50404008 61011037 61011019 50103057 61011034 50114040 61011020 61011018 50102013 50604038 61011010 61011009 61011024 61011021 61011027 61011033 50101063 50103054 61011041 50103023 50303004 PARTS LIST 30 120 M1 DESCRIPTION HEX HEAD BOLT COLLAR SET SCREW HANDWHEEL HANDWHEEL SHAFT CAP SCREW LOCK WASHER SCREW MOUNT BRACKET LEAD SCREW HANDWHEEL HANDLE BOLT HANDLE HEX NUT SLIDE PLATE LOCK KNOB O RING LOCK KNOB SHAFT FENCE BRACKET SET SCREW POINTER LOCK LEVER
17. LIMIT THE POTENTIAL FOR INJURY FROM A KICKBACK ALWAYS MAKE SURE THAT THE FEED ROLLERS ARE SET LOWER THAN THE LOWEST POINT OF THE CUTTER HEAD BEFORE ENGAGING A BOARD IN THE CUTTER HEAD Q Out feed roller In feed roller f f Place vour gauge block on the table under the cut Tighten the cutter head lock lever to secure the ter head cutter head in position Place a 0 030 feeler gauge C on top of the gauge Place your gauge block on the table under the in block then lower the cutter head until the knife light feed roller E ly touches the feeler gauge D when manually rock ing the cutter head back and forth 5 needed adjust the height of the in feed roller by 6 Place vour gauge block onto the table under the out loosening the lock nuts F on the in feed roller adjust feed roller If needed adjust the height of the out ment screws H and then turning adjustment screws feed roller bv loosening the lock nuts on the out G until the in feed roller lightly touches the top of feed roller adjustment screws I and then turning the the gauge block then re tighten lock nuts F adjustment screws until the out feed roller lightiv touches the top of the gauge block then re tighten the lock nuts Note To avoid overtensionning the drive chains which may result in drive chain breakage do not lower the feed rollers too much Use the number of threads on the adjustment screws as a visual referen
18. NS GROUNDING INSTRUCTIONS In the event of an electrical malfunction or short circuit grounding reduces the risk of electric shock to the ope rator The motor of this machine is wired for 220V single phase operation and is equipped with a 3 conductor cord A and a 3 prong grounded plug B fo fit a match ing grounding type receptacle C DO NOT MODIFY THE PLUG PROVIDED If it will not fit your recepta cle have the proper receptacle installed by a quali fied electrician CHECK with a qualified electrician or service person if you do not completely understand these grounding instructions or if you are not sure the tool is properly grounded 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 technician or our service department EXTENSION CORDS The use of an extension cord is not generally recom mended for 220V equipment If you find it necessary use only 3 wire extension cords that have 3 prong grounding plug and a matching 3 pole receptacle that accepts the tool s plug Repair or re
19. SETUP amp OPERATION MANUAL 7 MOLDER cast iron table and head for smooth vibra tion free performance Heavy duty cast iron dovetailed column precision machined for smooth cutter head height adjustment Precision high speed sealed pre lubricated bearings Independent variable speed feed motor provides added control for precision tear out free performance with hardwoods and stock with figured grain Jackscrew style cutter head adjustment system Triple guide bearing design allows for curved moldings Easily adjustable guide fence system sim ple lock knob design to keep stock in line through the cut In feed and out feed table extension rollers for added support with longer work pieces Magnetic 2 step safety switch to prevent unwanted or unintentional start up is equipped with an extra large easy access stop panel and a lock out key to prevent unauthorized use of the molder Built in dust hood with 4 dust outlet Variable feed speed SPECIFICATIONS MAXIMUM PLANING WIDTH 7 178 MM MAXIMUM MOLDING WIDTH 6 3 4 171 mm MAXIMUM THICKNESS OF STOCK 8 203 mm MINIMUM THICKNESS OF STOCK 1 4 6 mm MINIMUM LENGTH OF STOCK 8 203 mm MAXIMUM DEPTH OF CUT PLANING 1 8 3 mm MAXIMUM DEPTH OF CUT MOLDING 3 4 19 MM NUMBER OF KNIVES 2 ces ex sen 30 I20 MI 7000 RPM FEED SPEED VARIABLE 3 20 FPM 0 9 6 1 MPM MOTOR 2 22
20. amp MOTOR ASSEMBLY ND of n ni n SH rtm A ELLIPTICAL JIG ASSEMBLY ELLIPTICAL JIG ASSEMBLY PART NO 30120 CO1 30120 02 30120 03 30120 04 30120 05 30120 06 30120 07 30120 08 30120 09 30120 C10 30120 C11 30120 C12 30120 C13 30120 C14 30120 C15 30120 C16 30120 C17 30120 C18 30120 C19 REF 50204002 50602004 61013003 50201025 50351003 50501020 61011016 50102055 50301102 61013004 61013006 61013002 50301077 50102003 61013005 50501012 50301116 61013001 50107003 PARTS LIST 30 120 M1 DESCRIPTION KNOB SPRING PIN SCREW HEX NUT WASHER BEARING BEARING SHAFT CAP SCREW WASHER SCREW BRACKET SPRING BEARING BRACKET WASHER CAP SCREW BEARING SHAFT BEARING WASHER BEARING BRACKET BUTTON HEAD SCREW SPECIFICATION QTY 3X20L M16X2 0P 1 4 X13X1t 608 27 M8X1 25PX110LX25L 8 2X16XIt 5 4X13X1 5t M5X0 8PX10L 6203 77 6X20X1t M6X1 0PX16L i ionini pol pol nli wW 35 MODEL 30 120 M1 GENE f INTERNATI 8360 Champ d Eau Montreal Quebec Canada H1P 1Y3 Tel 514 326 1161 Fax 514 326 5565 Parts amp Service Fax 514 326 5555 Order Desk orderdesk general ca www general ca IMPORTANT When ordering replacement
21. and grease the drive chain and gears 1 Turn off and unplug the machine from the power source To access the chain and gears unfasten the screw A holding the front panel in place and remove the front panel B Remove old grease and dust deposits bv wiping with a dry rag Applv generous dabs of anv common automotive bearing grease to the gears C chains D and eleva tion screws E and F Re install the front panel and tighten down the screw INSPECTING REPLACING CUTTER HEAD KNIVES There are 2 cutter head knives blades installed in the planer at the factory With usage and normal wear over time it will eventually become necessary to replace the knives When needed replacement knives sold in sets of 2 can be ordered through your local General International dis tributor under part 30120 44 Tip Hint To avoid potentially costly downtime consider having a spare set of replacement knives on hand and ready for use when needed Observing planed workpieces as they come out of the machine and looking for signs of knife damage or wear is the best method to help you to determine when knives are due to be changed Signs to look for include EFFECT EXAGGERATED EFFECT EXAGGERATED gt FOR CLARITY FOR CLARITY A raised ridgeline in the workpiece that runs a straight line from beginning to end of the board A This is ge nerally an indication that one or both of the knives has been nicked or damaged by a foreign object su
22. andwheel B to adjust the cutter head height to the desired depth of cut turning Clockwise to raise the cutter head Counterclockwise to lower the cutter head Note the depth gauge C on the front of the machine can be used as a reference but it is not intended for high pre cision measurements 3 Re tighten lock lever A to secure the cutter head in position NOTE 1 3 of a clockwise rotation of the crank handle will raise the cutter head by 1 32 1 3 of a counter clockwise rotation will lower the cutter head by 1 32 GONNEGTING TO A POWER SOURGE TO REDUCE THE RISK OF SHOCK OR FIRE DO NOT OPERATE THE UNIT WITH A DA MAGED POWER CORD OR PLUG REPLACE DAMAGED CORD OR PLUG IMMEDIATELV TO AVOID UNEXPECTED OR UNINTENTION AL STARTUR MAKE SURE THAT BOTH OF THE POWER SWITCHES ARE IN THE OFF POSITION BEFORE CONNECTING TO A POWER SOURCE Once the assembly steps have been completed uncoil the power cord and plug the power cord into an appropri ate outlet Refer back to the section entitled Electrical Requirements and make sure all requirements and grounding instructions are followed When operations have been completed unplug the molder from the power source ON OFF POWER SWITCHES This molder is equipped with 2 different ON OFF power switches one magnetic switch equipped with a lock out key for the drive motor and one independant on off switch with a safety key and thermal re set br
23. be plan ed facing up aligning the board laterally so that it will be fed through the planer in the general direc tion of the grain d Note the depth gauge B can be used as a reference but it is 1 8 O 1 32 not intended for high preci sion measurements Slide the workpiece up to the cutter head and using the depth of cut adjustment handwheel lower the cutter head as needed to obtain the desired depth of cut KEEP HANDS AWAY FROM THE ROTATING CUT TER HEAD AND FEED ROLLERS DO NOT FORCE THE WORKPIECE TOWARDS THE CUTTER HEAD LET THE IN FEED ROLLER FEED THE WORKPIECES AVOID HAVING TO STEP OR REACH IN FRONT OF THE MACHINE EVENT OF A KICKBACK AVOID STANDING DIR ECTLY IN LINE WITH THE FRONT OR BACK OF THE MACHINE WHENEVER A BOARD IS ENGAGED IN THE CUTTER HEAD 9 Slowly slide the workpiece forward until the in feed 10 Step to the rear of the machine and recover the roller grips the board Release the board allowing planed board on the table once it has cleared the the feed roller to automatically feed the board out feed roller and has stopped advancing through the planer NEVER PUSH PULL OR OTHERWISE TRV TO MOVE OR RE POSITION THE WORKPIECE ONCE IT IS IN THE CONTROL OF THE AUTOMATIC FEED ROLLERS MOLDING 1 Turn off and unplug the machine from the power source 2 If only the face is to be profiled Cut your workpiece to it s final width If the edges are to be trimmed by th
24. ce You should not count more than 5 threads on fheses screws If vou have lowered the feed rollers to their lowest point and thev still do nof touch the top of the gauge block you then will have to adjust the depth of cut to remove the thickness of material equivalent to the distance between the feed rollers and gauge block when the rollers are adjusted to their lowest point FOR EXTENDED FEED ROLLER LIFE The infeed and outfeed rollers will have to be lowered for most molding operations The amount of adjustment required will vary depending on the size and style of the cutter For larger profiles and deeper cuts re adjust the height of the feed rollers after a few passes bv loosening the screws G 2 turns approx to correct the height of the rollers vs the depth of the stock that was removed from the workpiece To prevent the top of the workpiece from damaging the feed rollers make sure that the workpiece never exceed 1 4 of the height of the rollers J o Out feed i In feed roller ik Make sure the feed rollers are never set lower than this point ADJUSTING THE FEED ROLLER PRESSURE The feed rollers are factorv set to provide a proper amount of downward pressure to the workpiece However We re commend that you verify that the feed rollers are properly set prior to first use Then with use and normal wear over time it may periodi cally become necessary to make minor adjustments to pressure of the feed
25. ch as a nail staple or other hard object hidden or embedded in the workpiece A slight washboard or chatter effect B which can be an indication of uneven knife wear causing one knife to cut slightly deeper than the other 3 Rough irregular torn or fuzzy grain on a freshly planed surface may be a sign of worn or dull blades causing the wood fo tear out Sharp blades cut crisply and leave a relatively smooth finish Note Fuzzy grain can also be a sign of high moisture content in the workpiece If knives have recently been chan ged or if you suspect that moisture content and not dull knives is the cause set the workpiece aside and test by planing other boards with known or acceptable moisture content If the planed results using a different workpiece are smooth then moisture content in your wood is the problem no adjustments can be made to the machine for this Set the wet stock aside and simply work with drier wood To maintain even knife wear always replace both Knives each time knife replacement is required REGOMMENDED OPTIONAL AGGESSORIES We offer a large variety of products for increased convenience productivity accuracy and safety when using your planer molder Here s a small sampling of optional accessories available from your local General International dealer For more information about our products please visit our website at www general ca DUST COLLECTORS ROLLER STANDS We offer a wide selection 50 150 50
26. cords Identification of main parts and components Unpacking List of contents Additional requirements for set up Placement within the shop Establishing a safety zone Preparation amp Clean up Install the cutter head height adjustment handwheel Remove the styrofoam block Remove the protctive plastic sheet Clean up Assembly instructions Mount the magnetic safety switch Attach the leveling feet to the stand Install the belt on the drive pulley Basic adjustments amp controls Raising Lowering the cutter head for depth of cut Connecting to a power source On off power switches On off magnetic power switch Feed motor switch with safety key Thermal relay circuit breaker Changing feed speed Checking Setting the knives for planing 13 15 Setting one knife parallel to the table Setting the height of the second knife Adjusting the feed rollers Adjusting the feed roller height Adjusting the feed roller pressure To install molding knives Operating instructions Basic principles of planing molding Selecting boards suitable for planing molding 20 Rated limits of this molder planer Connecting to a dust collector Checklist before starting Planing Molding Repeat multiple passes for planing amp molding 23 Molding curved pieces using the elliptical jig 24 Maintenance Periodic maintenance Drive chain gear lubrication Inspecting replacing cutte head knives Recommended optional accessories Parts list
27. e knives Cut your workpiece to 1 32 wider than it s final width It is also recommended that all workpieces are planed to the final mold width and height before setting up the molder for any given profile 3 Position the fences against each edge of the work piece A without pinching the workpiece between the fences make sure the workpiece can be fed MAKE SURE THE PLANER MOLDER HAS BEEN between the fences without binding TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORMING ANY Loosen the cutter head lock lever B and lower the MAINTENANCE cutter head until the knife barely makes contact with the workpiece Check that the workpiece is properly aligned with the knife and if needed adjust the fence positioning left or right to align the workpiece then raise the cutter head just enough to remove the workpiece Adjust the cutter head downward by one full turn on the handwheel to take a 3 32 depth of cut Proceed to steps 5 to 10 of previous section Planing REPEAT MULTIPLE PASSES FOR PLANING AND MOLDING In most cases several passes through the machine will be required to bring the workpiece s down to final thickness dimension or specific profile In fact it is generally preferable to remove less material per pass and achieve final thickness dimension specific profile by taking multiple passes This can extend blade life place less strain on the motor and provide better workpiece finish quality that will
28. e surface before operating Keep hands well away from knives and all moving parts Use a push stick to feed stock and a brush not hands to clear away chips and dust Be sure that the knives are securely installed in the cutter head 11 Always use clean properly sharpened Knives Dirty or 12 dull knives are unsafe and can lead to accidents Inspect stock and remove all foreign objects before planing Make sure that any stock you plane is clean and free of any dirt nails staples tiny rocks or any other foreign objects that may damage the molder knives Only process natural solid wood boards Never plane MDF particle board plywood laminates or other syn thetic materials Do not push or force stock into the cutter head The molder will perform better and safer when working at the rate for which it was designed Kickback is when the workpiece is ejected at high speeds by the force of the cutter head To minimize the risk of injury from kickback use proper feeding tech nique and stand to one side out of the path of a po tential kickback Select appropriate feed speed for the stock being planed high speed for softwood and slow for hard woods Place stock firmly against the table and use suitable in feed and out feed support if stock is too long Keep guards in place and in working order If a guard must be removed for maintenance or cleaning make sure it is properly attached before using the
29. e workpiece and the shape of the curve as well as the profile and depth of cut required Use appropriate length flathead woodscrews screwed into the workpiece from below to a minimum depth and keep the final depth of the intended cut of the profile in mind to avoid having the molder knife contact the tips of the screw imbedded into the workpiece as the knives cut deeper into the workpiece from above F Also make sure that the heads of the screws are seated below the coun tersink in the underside of the template to allow the tem plate to slide flat against the table and avoid damaging or scratching the tables surface with an exposed screw head G ALWAVS EXERCISE EXTREME CAUTION WHEN RE USING A TEMPLATE FOR A DIFFERENT PROFILE AS A DIFFERENT LOCATION OF CUT AND DEPTH OF THE CUT IN THE WORKPIECE MAV REQUIRE RELOCATING THE MOUNTING SCREWS IN ORDER TO AVOID SCREW TIP CONTACT WITH THE KNIVES FROM ABOVE AS THEV CUT INTO THE WORK PIECE 1 Turn off and unplug the machine from the power source 2 If installed remove the two fences 3 If needed raise the cutter head to give yourself unimpeded access to the table 4 Install the elliptical jig inner guide bearings as 5 To align the guide bearings with the profile knife shown using 2 cap screws with washers H and lower the head fo lightly pinch the workpiece J install the outer idler guide bearing as shown using 2 button head screws I 6 Loosen the jam nut on the inner guide turn
30. ead However we suggest that you ver ify the knives prior to first use To verify if the knives are set properly use a gauge block not included following the steps below for each knives Gauge block You may use a home made gauge block made of hardwood The gauge block can be made by fol lowing the dimensions in A If you prefer precision aluminum gauge blocks are available from General International under item 30 040 ALWAYS DISCONNECT THE MACHINE FROM THE POWER SOURCE BEFORE MAKING ANY ADJUSTMENTS FAILURE HEED THIS WARNING CAN LEAD SERIOUS PERSONAL INJURV KNIVES ARE VERV SHARP USE CARE WHEN HANDLING KNIVES Make sure that the the machine is disconnected from 3 Turn the upper pullev D bv hand until anv one of the power source the knives is at it s lowest point To give vourself unimpeded access to the cutter head and knives remove the top cover B bv loosening and removing the 3 screws C Place vour gauge block onto the table under one Loosen the cutter head lock lever G by turning it extremitv of the cutter head as shown in E and F counterclockwise then lower or raise the cutter head as needed until the knife lightly touches the top of the gauge block as shown in H when vou manualiv rock the cutter head back and forth Tighten the cutter head lock lever G to secure the cutter head in position SETTING ONE KNIFE PARALLEL TO THE TABLE ry 7 Place your gauge block onto tab
31. eaker for the feed motor TO PREVENT UNAUTHORIZED USE OR UNINTENTIONAL START UP REMOVE THE SAFETY KEY AND LOCK OUT KEY AND STORE THEM IN A SAFE PLACE OUT OF THE REACH OF CHILDREN WHENEVER THE MOLDER IS NOT IN USE ON OFF MAGNETIC POWER SWITCH This model 30 120 M1 is equipped with a Magnetic 2 step safety switch to prevent unwanted or unintentional start up and unauthorized use of the planer molder The switch assembly is equipped with a GREEN START but ton A an extra large easy access RED stop panel B and a lock out key C To start the molder Insert the lock out key C and press on the GREEN START button A To stop the molder Press on the RED STOP panel B Once the RED STOP panel has been pressed the plan er molder can oniv be started bv pressing once again on the RED STOP panel to release the green button then bv pressing on the green button FEED MOTOR SWITGH WITH SAFETV KEV FEED MOTOR MOTEUR ON This model 30 120 MI is also equiped with a simple ON To start the feed motor insert the safety key F and lift OFF switch D for the feed motor featuring a removable the switch up G lock out safetv kev E To stop the feed motor push down on the switch H THERMAL RELAY CIRCUIT BREAKER TO AVOID UNEXPECTED OR UNINTENTIONAL START UP BE CERTAIN THAT THE SWITCH HAS BEEN SET TO THE OFF POSITION BEFORE RE SETTING THE THERMAL RELAV The
32. er The information and specifications in this manual pertain to the unit as it was supplied from the factorv at the time of printing Because we are commit ted to making constant improvements General International reserves the right to make changes to components parts or features of this unit as deemed necessarv without prior notice and without obligation to install anv such changes on previousiv delivered units Reasonable care is taken at the factorv to ensure that the specifications and information in this manual corres ponds with that of the unit with which it was supplied However special orders and after factorv modifica tions may render some or all information in this manual inapplicable to your machine Further as several gene rations of this model of molder 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 ques tions contact your retailer or our support line with the model and serial 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 completion of assembly Limited Lifetime Warranty Because of our commitment to quality and customer satisfactio
33. he table CLEAN UP The protective coating on the table K prevents rust from forming during shipping and storage Remove it bv rubbing with a rag dipped in kerosene mineral spirits or paint thinner Important Dispose of potentially flammable solvent soaked rags according to manfacturer s safety recom mendations A putty knife held flat to avoid scratching the surface may also be used to scrape off the coating followed by clean up with solvent Note Avoid rubbing the molder s painted surfaces as many solvent based products will remove paint ASSEMBLY INSTRUCTIONS Tip To prevent rust apply a light coating of paste wax or use regular applications of any after market surface protectant or rust inhibitor For your convenience this molder is shipped from the factory partially assembled and requires only minimal assem bly and set up before being put into service MOUNT THE MAGNETIC SAFETY SWITCH SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COM PLETED THE INSTALLATION AND ASSEMBLY STEPS DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED TO DO SO Attach the magnetic safety swith to the right side of the molder using the 2 button head screws already mouned fo the stand A as shown in B ATTACH THE LEVELING FEET TO THE STAND Attach the 4 leveling feet A to the stand using 2 nuts and 2 washers C in the assembly order shown in D Note Af
34. le under 8 Turn the upper pullev bv hand until vou can fit the other extremitv of the cutter head to check for knife supplied T handie wrench into the holes in the cut parallelism with the table ter head shaft as shown in 1 and J to keep the Should the knife not be set properly follow next steps If cutter head from turning the knife is parallel to the table skip ahead to step 15 Loosen the 3 button head screws K using the supplied 4 mm Thandle wrench and draw the chip deflector away L from the cutter head as shown then secure it in 10 Fully loosen the 2 middle locking bolts M using the supplied 14 mm wrench then slightly loosen the end locking bolts N so that thev still hold the knife position Loosen the nut O located on top of the knife the one on the side of the knife that need to be adjusted then adjust the set screw P to raise or lower the knife until it lightly touches the top of the gauge block Re tighten nut O then re check the height setting on the other extremitv of the knife and re set if neces sarv until the knife is parallel to the table 13 Re tighten the locking bolts M and N SETTING THE HEIGHT OF THE SEGOND KNIFE UNDERSIDE VIEW 15 Place vour gauge block onto the table under one extremity of the second knife If the second knife is set higher or lower than the first knife follow steps 10 and 11 14 Remove the T handle wrench from the cutter head rotate the head 180 a
35. machine again Use of parts and accessories NOT recommended by GENERAL INTERNATIONAL may result in equipment malfunction or risk of injury Never stand or lean on machinery Serious injury could result if the tool is tipped over or if the cutting tool is unin tentionally contacted Always disconnect the tool from the power source before servicing or changing accessories such as knives or before performing any maintenance or cleaning or if the machine will be left unattended Make sure that the switch is in the OFF position before plugging in the power cord Make sure the fool 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 molder for other than its intended use If used for other purposes GENERAL INTERNATIONAL disclaims any real implied warranty and holds itself harmless for any injury which may result from that use N ELECTRICAL REQUIREMENTS Z 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 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 LOCATIO
36. n 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 sional 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 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 distributor repair center or other location designated by General International For further details call our service de
37. nd re install the wrench to lock the opposite side of head in place 16 Place vour gauge block under the other extremitv of second knife and check for knife parallelism with the table Should the knife not be set properly follow steps 11 to 13 If the second knife is parallel to the table re tighten nut and locking bolts and N ADJUSTING THE FEED ROLLERS ADJUSTING THE FEED ROLLER HEIGHT The feed rollers have been factorv set at 0 030 below the lowest point of the knives However we recommend that vou verify that the feed rollers are properly set prior to first use Importanti Alwavs verifv that the two knives are properiv installed and set to the exact same height in the cutter head before checking and adjusting the height of the feed rollers FAILURE TO FOLLOW THESE RECOMMENDATIONS WILL LEAD TO POTENTIAL SERIOUS INJURY CAUSED BY STOCK KICKBACK Make sure that the feed rollers are set 0 030 inches below the lowest point of the cutter knives as shown in A so that they can grip the board If the feed rollers are set higher than the lowest point of the knives as shown in B they won t be able to grip the workpiece which will be ejected at high speeds by the force of the cutter head cutter head Out feed roller In feed roller FS N f ALWAYS DISCONNECT THE MACHINE FROM THE POWER SOURCE BEFORE MAKING ANY ADJUSTMENTS FAILURE TO HEED THIS WARNING CAN LEAD TO SERIOUS PERSONAL INJURY TO
38. ollers Make sure the board has been inspected and is suitable for planing molding as explained in section Selecting boards suitable for planing molding l f multiple boards are to be planed collect all workpieces together and set them nearby on a table or bench within easy reach To limit the potential for injury in the event of a kickback avoid having to step or reach in front of the machine to pick up the next workpiece A Make sure to have on safety glasses as well as hearing amp respiratory protection at all times when using the machine PLANING Dancen GENERAL UNTERNATIGNAL With the planer turned off position the workpiece on the table with the flat face down and the face to be planed facing up Position the fences A against each edge of the work piece without pinching the workpiece between the fences make sure the workpiece can be fed between the fences without binding Set the board aside and tighten the cutter head locking lever C to lock the cutter head in position Turn on your dust collector ALWAYS TURN ON THE DUST COLLECTOR BEFORE STARTING THE PLANER MOLDER Press the green ON button D on the magnetic switch to start the cutter head motor Set the feed speed to minimum before starting the feed motor then lift the switch E up to start the feed motor Gradually increase the speed until you reach the desired feeding speed back on the infeed table with the face to
39. ond knife on the opposite side of the cutter knife u p 7 Clean any dust or wood chips from the cutter head BEFORE INSTALLING MOLDING KNIVES MAKE SURE THAT G and knives and carefullly store the knives in THE SET SCREWS DO NOT PROTRUDE FROM mE ne FACE OF THE CUTTER HEAD AS SHOWN IN H LETTER a safe and dry place if thev will be re used or dis SHOWS A PROTRUDING SET SCREW AND THAT THE NUTS pose of them safelv if thev are worn or damaged ARE FIRMLY FASTENED SO THAT THE KNIVES SIT FLUSH ONTO THE LIP FAILURE TO HEED THIS WARNING CAN RESULT IN SERIOUS INJURIES AND OR DAMMAGE TO THE MACHINE 8 Place the molding knife against the cutter head lip with the beveled side of the knife facing up J Use the holes in the cutter head that allow the knife to be installed as close to center as possible and secure the knife in place with a bolt L in each of the mounting holes in the knife Make sure the knife is sitting flush against the bottom lip and while tightening the bolts applv light outward pressure against the knife to push it towards the pulley 12 Remove the T handle wrench from the cutter head rotate the head 180 and re install the wrench to lock the opposite side of head in place 13 Install the second molding knife using the same pro cedure in corresponding holes in the opposite side of the head a _ 15 Loosen the 3 button head screws H on the flat chip deflector then draw
40. op machinery A clearly defined no go zone on the floor around each machine can help avoid accidents that could cause injury to either the operator or the shop vis itor It is advisable to take a few moments to either paint using non slip paint or using tape define on the floor the limits or perimeter of each machines safety zone Take steps to ensure that all operators and shop visitors are aware that these areas are off limits whenever a machine is running for everyone but the individual operating the unit PREPARATION amp CLEAN UP INSTALL THE CUTTER HEAD HEIGHT ADJUSTMENT HANDWHEEL REMOVE THE STYROFOAM BLOCK To limit the potential for damage in transport this mold is shipped from the factory with the molder s head sit ting on a styrofoam block for support dang a 3 MM Allen key loosen the set screw A on 1 Loosen the cutter head lock lever D by turning it the handwheel counterclockwise important Attempting to adjust the Fit handwheel shaft onto the shaft height of the cutter head with it s lock lever tightened will cause premature wear of the locking mechanism Tighten the set screw to secure the handwheel in place 2 Rotate the handwheel counterclockwise to raise the cutter head enough to remove the styrofoam block E REMOVE THE PROTECTIVE PLASTIC SHEET 1 Loosen the fence lock knobs F and remove the fences G and H Remove the protective plastic sheet I from t
41. partment 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 copy of original sales invoice 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 warranty TABLE OF GONTENTS Electrical requirements Grounding instructions Circuit capacitv Extension
42. place a damaged extension cord or plug immediately If you find it necessary to use an extension cord with your machine make sure the cord rating is suitable for the amperage listed on the motor 1 D plate An under sized 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 TABLE MINIMUM GAUGE FOR CORD TOTAL LENGTH OF CORD IN FEET 220 VOLTS 25 FEET 50 eet 100 eet 150 FEET AMPERE RATING NR Not Recommended 7 MOLDER 30 120 1 _ CUTTER HEAD HEIGHT ADJUSTMENT HAND WHEEL BELT COVER DUST HOOD FEED MOTOR TABLE EXTENSION ROLLERS FENCES FENCE LOCK KNOBS H FEED SPEED CONTROL KNOB l FEED MOTOR SWITH WITH SAFETY KEY J THERMAL RELAY K DRIVE MOTOR L MAGNETIC SWITCH WITH LOCK OUT KEY M DRIVE MOTOR COVER PANEL N STAND O LEVELING FOOT Carefully unpack and remove the molder and its com ponents from the box and check for damaged or mis sing items as per the list of contents below NOTE Please report anv damaged or missing items fo your General International distributor immediately LIST OF CONTENTS MOLDER HANDWHEEL LEVELING FOOT amp HARDWARE HEX NUT FLAT WASHER LEVELING FOOT ELLIPTICAL JIG amp
43. rollers If you notice snipe which is a small depression in the sur face of a workpiece across its width either at one or both ends of your workpiece the pressure on the feed rollers must be reduced Refer to the following symptoms to determine which roller need to be adjusted If snipe occurs at the beginning of the board reduce the amount of pressure on the in feed roller by turning lock nut K on adjusting screws L counterclockwise If snipe occurs at the tail end of the board reduce the amount of pressure on the out feed roller by turning the lock nut K on adjusting screws M counterclockwise NOTE Some experimentation may be necessary to achieve an ideal adjustment TO INSTALL MOLDING KNIVES ALWAVS DISCONNECT THE MACHINE FROM THE POWER SOURCE BEFORE CHANGING KNIVES OR MAKING ANV ADJUSTMENTS FAILURE TO HEED THIS WARNING CAN LEAD TO SERIOUS PERSONAL INJURV KNIVES ARE VERV SHARP USE CARE WHEN HANDLING KNIVES Make su Turn the upper pullev by hand until you can fit the from the power source supplied T handle wrench into the holes in the cut To give vourself unimpeded access to the cutter ter head shaft as shown in C and D to keep the cut head and knives remove the top cover A by loos ter head from turning while changing knives ening and removing the 3 screws B 1 mia 4 Using the supplied 14 mm wrench loosen and 5 Carefully remove the knife F remove all 4 locking bolts E 6 Repeat steps 4 and 5 with the sec
44. t the table A SELECTING BOARDS SUITABLE FOR PLANING MOLDING ALWAYS PLANE MOLD IN THE GENERAL DIRECTION OF THE GRAIN PLANING MOLDING AGAINST THE GRAIN OR PLANING END GRAIN IS DANGEROUS AND MAY CAUSE THE WORKPIECE TO SHATTER This planer molder is intended for use with solid woods or MDF only and should not be used to plane or mold any other materials The workpiece should always be fed through the ma chine in the general direction of the grain in the wood B Before being fed through the planer molder all lumber should be inspected for debris and foreign objects such as staples or nails Foreign objects stuck to or embedded in your workpiece can be ejected from the machine at high speed and cause serious injury or damage cutter knives Make sure to remove all such foreign objects from the wood before running it through the planer molder Select lumber carefully and avoid workpieces with loose or protruding knots Workpieces that are twisted severely deformed or warped should also be avoided Warped twisted damaged or fragile stock runs an increased risk of jamming in or damaging the machine or cutters There is also a much greater risk of injury to the operator or bystanders from kickback where the workpiece is forcefully or violently ejected from the machine due to a jam whenever working with such damaged or warped wood RATED LIMITS OF THIS MOLDER PLANER RESPECT THE RATED LIMITS OF THIS MACHINE IGNORING THESE LIMITS
45. ter the stand is placed in its final location level the feet by loosening the top nut adjusting lower nut up or down on the screw stem as needed then tightening down the top nut Note To limit the potential for damage in transport this molder is shipped from the factory with the motor mount ing plate secured to the stand with a cap screw E 1 Using the supplied 6 mm allen key loosen and remove the cap screw and flat washer E that se cures the motor mounting plate to the stand 2 Using the supplied 4 mm T handle wrench loosen and remove the 3 Allen screws F then remove the upper pullev cover G Note The drive belt is alreadv installed on the upper pullev H Remove the motor cover panel to access the motor J With the help of an assistant lift the motor up and install the other end of the belt in the slot on the lower pullev K Re install the motor cover panel and upper pul ley cover 3 Using the supplied 4 mm T handle wrench unscrew and remove the 4 button head screws 1 that secure the motor cover panel to the stand BASIC ADJUSTMENTS amp CONTROLS RAISING LOWERING THE CUTTER HEAD FOR DEPTH OF CUT The depth of cut is set by raising or lowering the cutter head 1 Loosen the cutter head lock lever turning it counterclockwise Important Attempting to adjust the height of the cutter head with it s lock lever tightened will cause premature wear of the locking mechanism 2 Use h
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