General International EX-16 Use and Care Manual
Contents
1. 10 P ER URS A 10 OE eee teens 10 11 Choosing amp Installing a Saw 11 EN 01017 2 M VXi ll xc RRRR RRI f 3 cGReRRRRERRIR GHI RR IRI RR 11 ES SPS 11 e 13 Operating Instructions 14 E MM M 14 14 1 a a 14 EMEN M M 14 E 14 M a 15 EES 9 0 15 EN 11M Mu e 17 Maintenance Adjustments amp Servicing 17 Blade clamping thumbscrews set screws 4 17 POL TS Him 18 ps T C S SE D COS a 18 dca DImenBPIODfTeT WOK 18 ike gre _ 18 PA 19 Recommended Optional 1 5 192. FEATURES New Upper and lower blade guard assembly helps prevent unintentional or accidental hand finger contact with the saw blade New Switch protection device to prevent accidental or unintentional start up of the saw New Dust collector table kit for direct dust extraction hook up Head tilts 30 EX 16 38 EX 21 amp EX30 left and 45 right tilting the blade not the table keeping the workpiece level for bet ter control more accurate cuts 2 cutting thickness capacity Quick blade changes with finger operated blade clamps no tools required Easy access speed and tension controls Onboard dust blower EX 16 16 throat capacity Large 12 x 18 1 2 305 x 470 mm table surface 21 throat capacity Large 13 1 2 x 23 1 2 345 x 597 mm table surface Organized blade storage on base 30 throat capacity Large 14 x 32 1 2 358 x 825 mm table surface Organized blade storage on base SPECIFICATIONS LENGTH 27 686 mm 16 32 812 mm EX 21 43 1 4 1100 mm EX 30 WIDTH 15 380 mm EX 16 amp EX 21 15 1 2 394 mm EX 30 HEIGHT 17 432 mm EX 16 15 380 mm EX 21 15 1 4 387 mm EX 30 BLADE TILT RANGE 30 LEFT TO 45 RIGHT EX 16 38 45 21 30 THROAT 16 406 mm EX 16 21 535 mm EX 21 30 762 mm
3. BEFORE REMOVING HANDLING OR CHANGING BLADES 1 Remove an installed worn or broken blade by flip ping the blade tension lever forward position 1 then loosening the thumbscrews A and C on the upper and lower blade mounts B and D Remove the blade 3 Verify that the upper arm is more or less parallel with in 1 8 to the saw table If necessary use the upper arm adjuster below to raise or lower the arm as needed 4 With the blade teeth facing forward and downward slip the bottom of the blade down through the hole in the table Then slip the upper end of the blade into the slot in the upper blade mount and position the top of the blade above the set screw E but no higher than the top of the shoulder F on the blade mount Then tighten the thumbscrew only enough to secure the blade in the mount and prevent it from slipping out 5 The bottom portion of the blade may protrude be yond the bottom of the lower blade mount this is normal and will not affect performance Only the up per portion of the blade requires proper positioning in the upper blade mount Note Overtightening the blade clamp thumbscrews can cause premature wear to the blades gripping surface and result in blade slippage or cause premature wear of the threads in the blade clamp housing To avoid kinking or damaging the blade in the holder G when making adjustments make sure the set screw H opposite the thumbscrew I is threaded into the hol
4. 30 MAXIMUM CUTTING DEPTH 2 51 mm SPEED VARIABLE 400 TO 1400 STROKES MIN EX 16 400 TO 1550 STROKES MIN EX 21 amp EX 30 TABLE SURFACE 12 x 18 1 2 305 x 470 mm 16 13 1 2 x 23 1 2 345 x 597 mm EX 21 14 x 32 1 2 358 x 825 mm EX 30 MOTOR 120V 1 3 A WEIGHT 54 LBS 24 5 kg EX 16 65 LBS 29 5 kg EX 21 97 LBS 44 kg EX 30 SETUP amp OPERATION MANUAL SCROLL SAW GENERAL GENERAL INTERNATI ON Ab MODEL X l SHOWN VERSION 8_ REVISION 2 MAY 05 13 S N EX 16 22018213 EX 21 22053213 EX 30 32231913 COPYRIGHT GENERAL INTERNATIONAL 05 2013 Excalibur BY GENERAL INTERNATIONAL GENERAL INTERNATIONAL 8360 Champ d Eau Montreal Quebec Canada HIP 1Y3 Telephone 514 326 1161 Fax 514 326 5555 www general ca YOU for choosing this Excalibur by General International Scroll Saw modlel This scroll saw has been carefully tested and inspected before shipment and if proper ly 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 opera ting the unit The manual s purpose is to familiarize you with
5. 21 12 AIR NOZZLE 18 EX21 A18 BOLT 1 4 20 X 1 2 2 19 EX21 A19 UPPER amp LOWER TENSION PLATE 20 EX21 A20 HOLD DOWN MOUNT PLATE 21 21 21 ALLEN SCREW 10 32 X 3 8 2 22 21 22 HOLD DOWN CLAMP KNOB 23 2 1 A23 WASHER 1 4 X 16 X 1 8 4 24 EX21 A24 HOLD DOWN CLAMP SCREW 1 25 EX21 A25 HOLD DOWN BAR 26 EX21 A26 CAP SCREW 10 32 X 1 2 27 EX2 1 A27 HOLD DOWN FORKS 28 EX21 A28 DUST BLOWER 29 2 03 SCREW 8 32UNF 3 8 4 30 EX21 A30 VR KNOB 31 EX21 A31 VR 1 32 16 81 CONTROL CABLE EX21 A32 CONTROL CABLE 1 EX30 A32 CONTROL CABLE EX21A 31 32 VR WITH CONTROL CABLE 33 EX21 A33 SCREW 4 X 8 4 34 EX21 A34 MOTOR CONTROL SET CSA 35 EX21 A35 ALLEN SCREW 1 4 20 X 1 2 3 37 EX2 1 A37 LINE CORD SOCKET 38 EX21 A38 FUSE 3 15 AMP 20 X 5 MM GLASS FUSE 40 EX2 1 A40 GEAR COVER 41 2 1 41 NUT 3 8 X 15 5 45 EX21 A45 ALLEN SCREW 10 32 X 2 1 4 4 46 21 46 SCREW 3 8 X 5 8 47 02 05 WASHER 8 4 48 EX02 04 SCREW 8 32 X 1 4 4 49 2 1 A49 MOTOR LABEL 50 EX21 A50 WARNING LABEL 1 51 EXI1 A51 NYLON NUT 10 32 4 52 2 1 52 NYLON NUT 1 4 20UNC 2 53 EX21 A53 LOCK WASHER 1 4 54 EX21 A54 FLAT WASHER 1 4 O D 13 55 EX21 A55 LABEL 2 56 21 56 SCREW 1 4 X 2 1 2 2 57 EX16 A80 UPPER ARM 1 EX2 1 A57 UPPER ARM EX30 A57 UPPER ARM 58 21 58 1 EX21 A58ASSY UPPER RISING KNOB ASSEMBLY 1 59 21 59 NUT 6 1 60 21 60 ADJ
6. OFF POSITION AND THAT THE POWER CORD IS UNPLUGGED DO NOT PLUG IN OR TURN ON THE SCROLL SAW UNTIL YOU HAVE COMPLETED THE ASSEM BLY AND INSTALLATION STEPS DESCRIBED IN THIS SECTION OF THE MANUAL INSTALL THE SAW ON STABLE SURFACE xcalibur The unit should be installed on a flat sturdy and stable surface able to support the weight of the machine and the workpiece with ease ATTACHING THE LEVELING FEET Install the leveling feet as shown Loosen the upper A and lower B nuts as needed to adjust the height of the foot Never install the machine over the edge of a table or workbench INSTALLING THE OPTIONAL STAND If you prefer an optional stand item 2185 for EX 16 amp 21 or item EX 30BS for EX 30 is available from your local General International dealer The stand is equip ped with mounting holes allowing the saw after re moving the leveling feet to be bolted directly to the stand FOR YOUR SAFETY IT IS ESSENTIAL THAT THE MACHINE DOES NOT ROCK OR TIP DURING OPERATION UPON START UP OR DURING OPERATION IF YOU NOTICE ANY ROCKING TIPPING OR CHATTERING OF THE BASE TURN THE MACHINE OFF IMMEDIATELY AND READJUST THE LEVELING FEET AS NEEDED TO STABILIZE THE SCROLL SAW ON THE BENCH OR WORK SURFACE MOUNTING TO A WORK SURFACE If a permanent shop placement is practical consider removing the leveling feet on the base and drilling matching through holes in the mounting surface of your
7. Parts lista diagrams 20 25 Rules for Safe Operation To help ensure safe operation please take a moment to learn the machine s applications and limita tions as well as potential hazards General International disclaims any real or implied warranty and hold itself harmless for any injury that may result from the improper use of its equipment 10 11 Be sure read understand and follow all safety warnings instructions in The supplied Operator s Manual Do not operate the saw when tired distracted or under the effects of drugs alcohol or any medica tion that impairs reflexes or alertness Stay alert Give your work your undivided attention Keep the work area well lit clean and free of debris Cluttered areas and benches invite injuries Keep children and shop visitors at a safe distance while operating the saw do not permit them to operate the scroll saw Childproof and tamper proof your shop and machinery with locks padlocks master electrical switches and switch keys or by removing starter keys to prevent unauthorized or unsupervised use Fine particulate dust is a carcinogen that can be hazardous to health Work in well ventilated area and use a dust collector whenever possible Wear approved safety glasses dust mask and non skid footwear Do not wear loose clothing gloves bracelets necklaces or jewellery while operatin
8. any shop is the knowledge and good judgement of the user Use com mon sense and always keep safety considerations as they apply to your individual shop situation first and foremost in mind If you have any doubts about the safety of an operation you are about to perform STOP Do not perform the operation until you have validated from qualified individuals if the operation is safe to perform and what is the safest method to perform it 10 11 Material hold down must be properly set and remain in position during use Never reach under the table when operating or make any adjustments while the scroll saw is run ning Secure the saw to the work bench with clamps or mounting hardware Where possible use clamps or a vice fo secure your workpiece It is safer than using your hand Do not lift or carry the saw by the upper arm Make sure blade tension is properly adjusted Avoid awkward hand positions where a sudden slip could cause a hand to move into the saw blade Do not place fingers or hands in the path of the saw blade When removing short workpieces or cleaning up around the table be sure that the switch is in the OFF position and that the blade has come to a complete stop Never turn the saw ON before making sure that the table is clear except for the workpiece and related feed or support devices for the operation planned Check for proper blade size and type Do not attempt to saw stock that does not have a flat
9. blades so that they are handy and available when needed SKIP TOOTH Regular evenly spaced tooth pattern Considered the most common of scroll saw blades they are available in the widest range of sizes and provide a good combination of fast cutting action with good chip clearance and a relatively smooth finish BLADE WIDTH THICKNESS N For extremely intricate sawing Very tight cuts in 1 16 1 4 wood veneer plastic hard rubber pearl etc TEETH INCH 012 N e N For tight radius work with thin materials 3 32 1 2 wood veneer wood bone fiber plastic etc 2 15 5 12 5 For close radius work in materials 1 8 or thicker Good for sawing hard and soft woods bone horn plastic etc ui 11 5 022 024 029 035 038 045 053 059 Popular sizes for cutting hard and soft woods 3 16 up 2 Also cuts plastic paper felt bone etc 9 5 12 062 024 REVERSE TOOTH seit erred re Reverse teeth at the bottom of the blades prevent splintering to the underside of the workpiece Same 2 0R 28 20 applica 20 3 tionsas 7R 1259 Skip Tooth blades m m 12 DOUBLE TOOTH Fast clean cutting and very efficient chip clearance BLADE WIDTH THICKNESS TEETH INCH Same applica tions as Skip Tooth blades INSTALLING OR CHANGING BLADES ALWAYS TURN OFF AND UNPLUG THE MACHINE
10. surface unless a suitable support is used 20 21 Turn off motor if the material resists being backed out of an incomplete cut Use appropriate speed for applications CAUTION Some wood contains preservatives such as copper chromium arsenate CCA which can be toxic When cutting these materials extra care should be taken to avoid inhalation and to mini mize skin contact Always use a dust mask and safety glasses when sawing Everyday eyeglasses only have impact resistant lenses they are NOT safety glasses Keep guards in place and in working order Make sure your fingers do not contact the terminals of the power cord plug when plugging in or unplug ging the saw Never overfeed or force work into the blade Check for alignment and binding of all moving parts broken parts mounting and any other con ditions that may affect the saw s operation Keep handles dry and free from oil and grease MAINTAIN TOOLS WITH CARE Keep tools sharp and clean for best and safest performance Follow instructions for lubricating and changing acces sories DIRECTION OF FEED Feed work into a blade or cut ter against the direction of rotation of the blade or cutter only TO AVOID ELECTRICAL SHOCK ENSURE MACHINE IS PROPERLY GROUNDED DO NOT OPERATE IN DAMP CONDITIONS DISCONNECT FROM POWER SUPPLY BEFORE SERVICING REPLACE FUSE WITH THE SAME TYPE AND RATING ONLY 3 AMP BE SURE TO READ AND UNDERSTAND O
11. the safe operation basic function and features of this scroll saw 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 per forming a certain operation or procedure do not proceed until you can confirm from know ledgeable and qualified sources that it is safe to do so 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 commit ted to making constant improvements General Inter national reserves the right to make changes to compo nents parts or features of this unit as deemed necessary without prior notice and without obligation to install any such changes on previously delivered units Reasonable care is taken at the factory 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 model of sroll saw and several versions of this manual be in circulation if you own an earlier o
12. to the drill press To prolong blade life by limiting unnecessary cutting drill your guide holes as close as possible your reference lines D 3 Release tension on the blade by flipping the blade tension lever forward 4 Loosen the thumbscrew on the lower blade mount located under the table to release the blade from the mount 5 Raise the upper arm assembly which will lift the blade up through the hole and above the table 6 Position the workpiece on the table so that the guide hole lines up with the hole in the table 7 Lower the arm assembly with one hand while guiding the blade through the hole in the workpiece and table 8 Re install the bottom end of the blade in the lower blade mount and tighten the thumbscrew only enough to secure the blade in the lower blade clamp and prevent it from slipping Note Overtightening the blade clamp thumbscrews can cause premature wear to the blades gripping surface and result in blade slippage or cause premature wear of the threads in the blade clamp housing added this sincd Norm s copy 9 Flip back the blade tension lever to re tension the blade and test the blade tension as described in Installing or Changing Blades section of this manual 10 To begin cutting follow the same steps as described in Basic 90 straight or curved cuts section on page 14 of this manual TO REDUCE THE RISK OF INJURY ALWAYS TURN OFF THE SAW AND WAIT FOR THE BLADE TO COME TO A COMPLET
13. 08 SCREW M X 16 4 09 21 09 BEARING 60877 1 10 21 10 1 11 21 11 NUT 8 X P1 25 LH 12 EX21 C12 BEARING 810 3 14 21 14 1 15 21 15 LOCK NUT M5 17 EX21 C17 BEARING 0609 10 18C EX21 C18C BEARING INNER SLEEVE SHORT 26 03 X 21MM 2 19 21 19 SCREW 5 X 28 1 20 21 20 BEARING COVER 2 21 21 21 BEARING 1412 2 22 EX21 C22 MAIN ROCKER PIVOT 014 04 X 35 5MM 23 EX21 C23 NUT MA 12 24 EX21 C24 CAP SCREW 4 X 25 2 26 EX21 C26 AIR PUMP BELLOWS 2 27 EX21 C27 FRONT ROCKER 2 27 EX21 C27C UPPER AND LOWER ROCKER ASSEMBLY 28 EX21 C28 WASHER M8 X 15 X 0 6 4 29C EX21 C29C INNER BEARING SLEEVE ROCKER 8 03 X 18 40MM 2 30C EX21 C30C BEARING INNER SLEEVE LONG 20 03 X 37MM 2 31C EX21 C31C ROCKER MOUNT 2 32C EX21 C32C CAP SCREW M4 X 45 2 33C EX21 C33C CAP SCREW MA X 25 4 35 EX21 C35 STRUT 2 36C EX21 C36C BLADE CHUCK 36 55 EX21C 36ASSY BLADE CHUCK BOTTOM ASSEMBLY 37 EX21 C37 SET SCREW M X8 2 38 EX21 C38 BLADE CLAMP THUMB SCREW 2 39 EX21 C39 BLADE 40 EX21 C40 ALLEN KEY 3MM 41 EX21 C41C CLAMP BRACKET 1 42 EX21 C42 SET SCREW 1 4 20UNC 43 EX21 C43 SPRING 44 21 44 TENSION LEVER FOR EX 16 EX 21 5MM 1 EX30 C44 TENSION LEVER FOR EX 30 7MM 1 45 21 45 SCREW POST 5 18 1 46 21 46 SLIDING BRACKET 46A EX21 C46A UPPER BLADE TENSION ASSEMBLY FOR EX 16 amp EX 21 1 EX30 C46A UPPER BLADE TENSION ASSEMBLY F
14. 10 16 EX21 B16 ANGLE FOLLOWER 2 17 21 17 SCREW 10 32 X 5 16 8 18 21 18 WASHER 10 X 12 X 8 19 EX21 B19 NUT 1 4 20UNC 12 20 21 20 ANGLE INDICATOR 21 21 21 ALLEN SCREW 1 4 20 X 1 2 22 2 1 22 E RING ETW 3 23 21 23 DETENT BARREL 24 21 24 SPRING 25 21 25 DETENT PLUNGER 26 2 1 26 HANDLE 1 27 21 27 WASHER 1 4 16 X 3 28 EX2 1 28 BLADE TILT LOCKING LEVER 29 21 29 FLAT HEAD SCREW 1 4 20 X 3 4 4 35 EX21 B35 LEVELING FOOT 3 8 16 X 1 1 4 4 36 EX16 B45 TILT LOCK DRAW ROD 1 EX2 1 36 LOCK DRAW ROD EX30 B36 TILT LOCK DRAW ROD 37 21 37 NUT 3 8 16UNC 8 38 EX21 B38 POINTER 39 21 39 ROUND HEAD SCREW M4 X 6MM 40 21 40 WASHER 4 1 45 EX16 DCT DUST COLLECTOR TABLE KIT EX21 DCT DUST COLLECTOR TABLE KIT 1 EX30 DCT DUST COLLECTOR TABLE KIT 45 1 21 45 1 PLASTIC SHROUD 45 2 EX2 1 B45 2 DUST CHUTE 45 3 21 45 3 ROUND HEAD SCREW 8 32UNC 5 16 4 45 4 2 1 45 4 WASHER 8 32UNC 4 e 45 O SL a e Li gt oV X A 1 Je PARTS LIST EX 16 21 30 REF PART DESCRIPTION SPECIFICATIONS 02 21 02 BALANCE BLOCK 03 EX21 C03 SET SCREW 6 X 6 04 21 04 ALLEN SCREW 1 4 20 X 1 2 3 05 21 05 WASHER 1 4 3 06 21 06 FLAT WASHER 1 A X 16 X 1 8 3 07 EX21 C07 MOTOR COVER PLATE 08 21
15. E STOP BEFORE REACHING IN TO REMOVE WASTE MATERIAL FROM A FRET CUT 16 ANGLE OR BEVEL CUTTING One of the unique features of the Scroll Saw is the ability to tilt the head of the saw in order to make angle or bevel cuts The table and the workpiece always stay horizontal parallel to the floor while the blade tilts keeping your hands in the same comfortable cutting position as they would normally be for regular right angle cuts Because you are not fighting gravity or working with your hands or wrists bent in awkward positions it can be a huge advantage and makes it easier and safer to make accurate bevel cuts The blade tilt controls are located under the table at the front saw To tilt the blade for bevel cutting 1 Release the locking lever A by turning counter clockwise 2 Turn the tilting handle B left or right to set the blade to the desired angle Note Push and hold the spring loaded indexing pin C to locate the following common angles 90 45 30 amp 22 5 both left and right When tilting the blade to the left at extreme angles it may nec essary to remove and reverse the lower blade mount thumbscrew assembly in order to maximize clearance under the table D shows the lower blade mount in default position and E shows it reversed 3 Tighten the locking lever A to secure the blade at the desired angle 4 To begin cutting follow the same steps as described in Basic 90 straig
16. OR EX 30 1 57 EX21 C57 WASHER 4 10 1 4 58 21 58 INNER BEARING SLEEVE LONG 6 02 X 16 50MM 4 59 EX21 C59C BEARING INNER SLEEVE 28 03 X 21 50MM 1 60 EX21 C60 WASHER M5 2 61 21 61 SCREW 4 27 2 62 21 62 WASHER MA X 14 12 04 16 64 DRIVE LINK ASS Y FOR EX 16 2 21 64 DRIVE LINK ASS Y FOR 21 EX30 C64 DRIVE LINK ASS Y FOR EX 30 64A EX16 C64A COMPLETE DRIVE LINK ASS Y FOR EX 16 EX21 C64A COMPLETE DRIVE LINK ASS Y FOR EX 21 EX30 C64A COMPLETE DRIVE LINK ASS Y FOR EX 30 NIN 65 21 65 1 66 21 66 SPACER 67 EX21 C67 BEARING INNER SLEEVE SHORT 26 03 X 16MM 2 68 EX21 C68 CAP SCREW MA X 30 2 69 EX21 C69 WASHER 4 8 1 8 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 MODELS EX 16 EX 21 EX 30 MODEL X l SHOWN Excalibur BY GENERAL INTERNATIONAL 8360 Champ d Eau Montreal Quebec Canada HIP 1Y3 Tel 514 326 1161 Fax 514 326 5565 Parts amp Service Fax 514 326 5555 Order Desk orderdesk general ca www general ca
17. ROVIDED If it will not fit your receptacle have the proper receptacle installed by a qualified electrician CHECK with a qualified electrician or service person if you do not completely understand these grounding instruc tions or if you are not sure the tool is properly grounded EXTENSION CORDS USE ONLY 3 WIRE EXTENSION CORDS THAT HAVE 3 PRONG GROUNDING PLUGS AND 3 POLE RECEPTACLES THAT ACCEPT THE TOOLS PLUG REPAIR OR REPLACE A DAMAGED OR WORN POWER 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 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 EXTENSION CORD LENGTH AMPERES 5 16 6b a4 2 588 16 6 8 l2 4 9 10 __ 15 0 10 0 NR 21430 10 NR ONR Based on limiting the line voltage drop to 5V at 150 of the rated amperes NR Not Recommended l6 9 NR 10 ONR l0 NR NR ONR SCHOLL SAW EX 16 EX 21 EX 30 OPPOSITE SIDE VIEW UPPER ARM ADJUSTER VARIABLE BLADE SPEED CONTROL KNOB ON OFF SWITCH WITH SAFETY DEVICE BLADE TEN
18. SION LEVER BLADE GUARD BLADE WORKPIECE HOLD DOWN TABLE BLADE TILT LOCKING LEVER TILT HANDLE ANGLE INDICATOR ANGLE ADJUSTMENT SCALE MOUNTING HOLES 4 BLOWER UPPER ARM MOTOR BLADE HOLDER SOCKETS EX 21 amp EX 30 ONLY UNPACKING amp HANDLING Carefully unpack and remove the scroll saw and its components from the box and check for damaged or missing 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 As SCROLL SAW POWER CORD u Z uu HERR 1 CS 8 D LEVELING 4 E 3 MM ALLEN Fe BLADE aiena 1 NOTE Unscrew the 4 shipping bolts and remove the saw from the protective plywood shipping base Never liff the saw by the upper arm assembly as this will Rather lift the saw by the front of the table and by the result in damage to the drivetrain motor INSTALLATION amp ASSEMBLY For your convenience this scroll saw is shipped from the factory partially assembled and requires only minimal assembly and set up before being put into service ATTACHING THE POWER CORD Plug the female end of the power cord into the socket at the rear of the saw as shown BEFORE STARTING THE ASSEMBLY MAKE SURE THAT THE SWITCH IS IN THE
19. USTING LEVER 61 21 61 CONTROL BOX 62 EX21 A62 CROSS BLOCK RETAINER 63 21 63 HOUSING CROSS BLOCK 64 21 64 FLAT WASHER M X 1 X 2 65 2 1 65 NYLON NUT 1 66 EX21 A66 ALLEN SCREW 67 2 1 67 R FASTENER 68 21 68 WASHER 69 2 1 69 NYLON NUT 1 70 21 70 ALLEN SCREW 7 71 21 71 1 72 EX21 A72 SET SCREW 77 21 77 LABEL 82 EX02 01 UPPER BLADE GUARD 83 02 02 LOWER BLADE GUARD 84 EX21 A84 SWITCH SAFETY GUARD 85 EX21 A85 STRAIN RELIEF 86 EX21 A86 GROUND LABEL PARTS LIST EX 16 EX 21 EX 30 PARTS LIST EX 16 21 30 REF PART DESCRIPTION SPECIFICATIONS 01 21 01 2 02 16 41 SIDE PANEL 2 EX2 1 02 SIDE PANEL 2 EX30 B02 SIDE PANEL 2 03 21 03 REAR TRUNNION PLATE 04 EX21 B04 FRONT TRUNNION PLATE 05 16 42 TABLE WITH HOLES 21 05 TABLE WITH HOLES 0 05 TABLE WITH HOLES 06 21 06 GROUND JUMPER 07 21 07 POWER CORD CSA 08 21 08 SPONGE BLOCK 10 21 10 SCREW 1 4 20UNC X 1 2 11 21 11 WASHER 1 4 3 12 16 43 WASHER 8 21 12 WASHER 9 EX30 B 12 WASHER 1 4 9 13 21 13 BLADE TILT WASHER 2 14 21 14 BLADE TILT DRIVE GEAR 2 15 16 44 SCREW 1 4 20UNC X 3 4 10 21 15 SCREW 1 4 20UNC X 3 4 8 EX30 B15 SCREW 1 4 20UNC X 3 4
20. WNER S MANUAL BEFORE OPERATING L M L M M M ELECTRICAL REQUIREMENTS BEFORE CONNECTING THE MACHINE TO THE POWER SOURCE VERIFY THAT THE VOLTAGE OF YOUR POWER SUP PLY CORRESPONDS WITH THE VOLTAGE SPECIFIED ON THE MOTOR 1 0 NAMEPLATE A POWER SOURCE WITH GREATER VOLTAGE THAN NEEDED CAN RESULT IN SERIOUS INJURY TO THE USER AS WELL AS DAMAGE 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 120V single phase opera tion and is equipped with a 3 conductor cord and a 3 prong grounded plug to fit a grounded type recepta cle A Cover of Ground Do not remove the 3rd prong grounding pin to make outlet box il fit into an old 2 hole wall socket If an adaptor plug is used B it must be attached to the metal screw of the receptacle Note The use of an adaptor plug is illegal in some areas including Canada Check your local codes Grounded cord connected tools intended for use on a supply circuit having a nominal rating less than 150 volts This tool is intended fo use on a circuit that has an outlet that looks like the one i
21. bearings in the drive mechanism are sealed and permanently lubricated and do not need be oiled or greased RECOMMENDED OPTIONAL ACCESSORIES Underside View We offer some optional accessories available from your local General International dealer for increased con venience productivity accuracy and safety when using your scroll saw For more information about our products please visit our website at www general ca FOOT SWITCH 01 Enjoy hands free on off control of your scroll saw with this simple design easy to use momentary style foot switch Features a 1 2 Ft 16 gauge grounded power cord with a standard 110V 3 prong plug Constant off mode design press and hold down switch to turn the saw on and simply lift foot from switch to turn the saw off STAND 21 5 EX 30BS Heavy duty adjustable height flared steel stand designed specifically to fit your EX 16 EX 21 EX 21BS or EX 30 EX 30BS scroll saw Wide stance design with sturdy cross bracing for stable vibration free operation NS o 2 REF PART DESCRIPTION SPECIFICATION QTY 01 EX16 A78 MAIN BODY 21 01 MAIN BODY EX30 A01 MAIN BODY 1 16 79 1 21 TOP COVER EX30 A03 TOP COVER 04 EX21 A04 ALLEN SCREW 10 32 X 1 4 4 05 EX21 A05 SWITCH COVER 06 EX21 A06 SWITCH 12
22. best results based on the type and thick ness of material and type of blade being used The blade speed control knob D is located on the top of the machine e To increase blade speed turn the control knob clockwise decrease blade speed turn the control knob counterclockwise Blade speed selection is subjective and is dependant on a variety of factors type and thickness of material being cut type of blade being used feed rate required finish quality as well as experience personal preference and com fort level of the user There are no hard and fast rules Be patient practice and experience will be your best teacher Here are some general guidelines to consider when selecting adjusting blade speed For best results and smoothest most efficient cutting always select the highest speed that you are comfortable using based on your experience skill level Generally speaking harder or denser workpiece material requires slower blade speeds Slower speeds also work better with very thin blades or when cutting most metals as well as for brittle or delicate material such as fine veneers Some wood species will have a tendency to burn quicker at higher blade speeds To avoid additional sanding later reduce blade speed and feed speed at the first signs of burn marks on the workpiece ADJUSTING THE BLOWER and on any reference lines Adjust the blower tube A as needed fo point the nozzle at the blade fo set i
23. der to protrude slightly beyond the blade slot J 6 Push the blade tension lever back position 2 to apply tension on the blade Helpful Hints on blade tension Determining correct blade tension is somewhat sub jective It is learned through experience and is some what dependant on personal preference A properly tensioned blade will last longer and be much less like ly to break prematurely If the blade fension is too loose you will notice that the blade will have a ten dency drift or slip off line when cutting and you may also experience excessive vibration or unusual noise A blade that is too tight will break prematurely Assuming the blade has been properly installed in the blade mounts when the blade tension lever is pushed Upper arm must be parallel approx 1 8 to the table fully back towards the rear of the saw the blade should be properly tensioned Test the blade tension by lightly plucking on the blade like you would a guitar string with your finger If the blade is tight and tensioned correctly you will get a clear and even note If so you are ready to proceed operating and cutting with The saw If not for some cases after double checking that the blade is properly installed in the blade mounts further blade tension fine tuning can be made by adjusting the rear knob lo raise the upper arm slightly Note this is not the main function of the adjustment knob see follo
24. e time of claim Warranty does not include failures oreakage 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 CONTENTS Rules for safe 0 5 Additional Safety Instructions for Scroll Saw 6 Electrical requirements 7 BR PARA A S P S eee eee eee A A s a 7 M fF JPP AAA RR I P IIR s s GA RR 7 Identification of main parts and components 8 Unpacking amp Handling 9 EN MM MR _ 9 EE M RR 9 Installation amp Assembly 9 SR 9 On SID SUICO 10 Ci SI i E
25. en dis connecting one end of the blade which is fit through the pilot hole and re connected essentially using the pilot hole as the starting point to cut out the piece from within A typical example of fret cutting would be removing the center portion of lettering A remove portion saw is great tool for fret cutting because unlike most scroll saws it allows you to raise the upper arm with the blade attached B line up the guide hole in your workpiece with the hole in the table and then lower the arm while guiding the blade through the hole from above see step by step instruc W tions below This can be a very useful time saving feature par Excalibt A ticularly for intricate or complex fret designs that can involve dozens or even hundreds of holes 1 With the saw turned off and unplugged install the appro priate blade for the type of material to be cut and the type of cut to be made Refer to the section Choosing and Installing a Saw Blade on page 11 of this manual 2 With your pattern or design transferred onto the workpiece drill a guide hole in The inside waste portion of the work piece C Make sure that the hole is large enough for the blade to fit through Helpful hints on drilling guide holes If multiple fret cuts are required on fhe same workpiece drill all of your required guide holes before taking the workpiece the scroll saw This will keep you from going back and forth from the saw
26. f at a com fortable distance so as not to obstruct your hand move ment as you work The workpiece hold down B can be adjusted to assist in preventing the blade from lifting the workpiece up from the table during the cut Loosen the thumbscrew C to set the height to your convenience based on the thickness of the workpiece Before cutting test to make sure that the hold down is not adjusted too tightly to the workpiece or that it obstructs the movement of the workpiece 14 BASIC 90 STRAIGHT OR CURVED CUTS All cuts made with the blade at 90 to the table follow the same basic principals Start by marking or transferring your pattern or reference lines onto you workpiece Maximum workpiece size from blade to rear of saw EX 16 has 16 throat that allows for a workpiece of up to 16 of clearance to swing completely around without hitting the back of the saw If necessary rough cut the workpiece down a workable size before star ing intri cate work on the scroll saw The EX 21 has a 21 throat that allows for a workpiece of up to 21 of clearance swing completely around without hitting the back of the saw If necessary rough cut the workpiece down fo a workable size before starting intri cate work on the scroll saw The EX 30 has a 30 throat that allows for a workpiece of up to 30 of clearance swing completely around without hitting the back of the saw If necessary rough cut the work
27. g the saw Keep long hair contained by wearing pro tective hair covering Be sure all adjustment tools wrenches or other clut ter are removed from the machine and or the table surface before operation When not in use tools should be locked up in a dry place out of children s reach and away from flammable sub stances Keep hands well away from saw blade and all moving parts Use a brush not hands to clear away chips and sawdust Be sure that saw blade is properly installed and in proper cutting direction before operation Always use a clean properly sharpened blade Dirty or dull blades are unsafe and can lead to accidents Also be sure the blade has gained full operating speed before beginning to cut Do not push or force stock into the blade The saw will perform better and more safely when working at the rate for which it was designed Do not use for purposes not intended 12 Avoid working from awkward or off balance posi 20 21 tions Do not overreach while cutting keep both feet on floor Never lean over or reach behind the blade and never pull the workpiece through the cut from behind Never stand or lean on the saw Serious injury could occur if the unit is tipped over or if the blade is unin tentionally contacted Use of parts and accessories NOT recommended by General International may result in equipment malfunction or risk of injury Never leave the machine unattended while r
28. h to determine which blade works best for you with different materials Replacement and specialty blades can be purchased from a variety of sources Ask your local tool or scroll saw dealer for suggestions for unpinned 5 scroll saw blades based on what is available in your area Some general guidelines to consider when choosing blades Wide thick blades with coarse teeth are suited to cutting straight lines and sweeping curves but will not turn tight corners They will cut aggressively and leave a fairly smooth finish but may leave burn marks if the work piece is turned too tightly e Narrower thinner blades with finer teeth will cut more slowly but will turn much tighter corners for cutting very intricate work They will impart a very smooth burnished finish that requires no sanding e Consider material thickness when selecting blades Ensure that a minimum of two or three teeth are in con tact with the workpiece at all times For example when cutting 1 8 thick material use a blade with a mini mum of of 16 20 teeth per inch Blade Storage for models EX21 amp EX 30 only There are sockets mounting holes on either side of the base of the saw to hold blade storage test tubes tubes not supplied Most blade retailers sell blades either already in the tubes or will be able to sell spare tubes separately Storing your spare blades in tubes by size right on the base of the machine can be a great way to organize your spare
29. ht or curved cuts section on page 14 of this manual Letter F shows the scroll saw in position for bevel cutting BLADE CLAMPING THUMBSCREWS SET SCREWS Over time with normal use and wear especially when doing a lot of internal cutting where one end of the blade is frequently disconnected then reconnected to fit into a hole the contact end of the thumbscrews A will wear and can become smooth to the point were it will no longer clamp the blade properly To avoid potentially costly downtime consider keeping a spare set of replacement thumbscrews and set screws on hand for use if needed Note If you begin to experience frequent blade slippage it may be a sign that it is time to replace the blade clamp thumb screw B and or the set screws opposite the thumbscrews C Note Overtightening to compensate for blade slippage may damage or in extreme cases strip the threads in the blade clamping block Note Before replacing either always double check visually to make sure that the blade is being held between the set screw and the thumbscrew as shown D and is not being bent or kinked into the opposite side of the blade clamping block because of a set screw that is adjusted too far back in the holder as shown 17 BLADE TENSION LEVER LUBRICATION A regular application of white grease or petroleum jelly to the friction point bottom of the tension lever is recommended This will allow for smoother operation a
30. ir 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 amp International or to a nearby distributor 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 amp 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 th
31. llustrated in A The tool has a grounding plug that looks like the plug illustrated in A A temporary adapter which looks like the addapter illustrated in B and C may be used to connect this plug to 2 pole receptacle as shown in B if a properly grounded outlet is not available The temporary adapter should be used only until a properly grounded outlet can be insalled by a qualified electrician This adapter is not permitted in Canada The green colored rigid ear lug and the like extending from the adapter must be connected to per manent ground such as a properly grounded outlet box This tool is equipped with an electric cord having an equipment grounding conductor and a grounding plug The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances Improper connection of the equipment grounding conductor can result in a risk of electric shock The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipment grounding con ductor If repair or replacement of the electric cord or plug is necessary do not connect the equipment grounding conductor to a live terminal uter surface that is green with or without yellow stripes is the equipment grounding con ductor If repair or replacement of the electric cord or plug is necessary do not connect the equipment grounding conductor to a live terminal DO NOT MODIFY THE PLUG P
32. o your saw SQUARING THE BLADE TO THE TABLE Depending on frequency of use and how much the tilting mech anism is used normal wear will over time cause the blade to come slightly out of alignment with the table Periodically check the blade for square with the table When needed adjust as described in the following steps to re align the blade square to the table 1 Turn off and unplug the saw 2 Using the blade tilt controls at the front of the saw set the blade angle to read 0 which is 90 vertical to the table 3 Sef a machinists square on the table and against the blade to verify the blade angle C 4 If the blade angle requires adjustment loosen the 4 bolts in the front trunnion D as well as the 4 bolts on the rear trunnions E 5 By hand move the entire head to bring the blade square to the table 6 With the blade square to the table hold the head in position and re tighten the bolis on the front and rear trunnions 18 MAINTENANCE Always release tension on the blade when the saw is not in use Clean the saw regularly with a soft bristle brush or by vac uuming to keep cutting dust from accumwulating An occasional application of a light dab of grease on the front and rear trunnions F will keep the tilting mecha nism working smoothly If you find the tilting mechanism becoming more difficult to operate thoroughly wipe off any built up cutting dust on the trunnions and re apply a little grease The
33. piece down fo a workable size before starting intri cate work on the scroll saw EX 21 shown 1 With the saw turned off and unplugged install the appropriate blade for the type of material to be cut and the type of cut to be made Refer to the section Choosing and Installing a Saw Blade on page 11 2 Adjust the workpiece hold down and the blower nozzle to your liking 3 Turn on the saw and set the speed controller to the desired blade speed 4 With your fingers holding the piece firm to the ta ble and using your thumbs for directional control feed the workpiece into the blade using steady even pressure 5 Make sure that the blade is cutting on the waste side of your reference line and adjust feed direc tion slightly as needed to compensate for blade drift Cutting Tips To stay in control on tight curve cuts slow down your feed rate as needed fo allow the blade teeth time make the cul Avoid coming a complete stop whenever possible as this can leave burn marks on the workpiece and also makes it more difficult to get the piece re started and moving through the cut again Avoid forcing through a curve cut as this can cause the blade to twist and cut off track or may even cause the blade to break FRET CUTTING Fret or inside cutting is an operation that can only be performed on a scroll saw Fret cutting involves drilling a small pilot hole through the interior of your pattern on the workpiece th
34. r later ver sion of this unit this manual may not depict your unit 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 insoected 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 satisfaction General amp and General amp 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 amp and General amp International agree to repa
35. s well as prolong the life of the tension lever Apply a small dab of grease after every 10 15 hours of use or as needed depending on the frequency of use of the saw BLADE TENSION LEVER REPLACEMENT Over time with normal wear the blade tension lever will need to be replaced 1 Flip the lever forward as shown to release tension from the blade and remove the blade completely 2 Loosen the barrel bolt using two phillips screwdrivers and remove the binding screw and worn blade tension lever 3 Install a new tension lever using the barrel bolt and binding screw UPPER ARM ADJUSTMENT FOR FRET WORK Over time and with normal wear the upper arm adjustment screw A may require slight adjustment in order to hold the arm in the raised position when the arm is lifted by the operator To reset the adjustment screw 1 Remove the blade and with the upper arm down set the arm more or less parallel to the saw table 2 Loosen the lock nut B 3 Turn the adjuster screw clockwise 1 4 turn at a time B until there is just enough resistance to hold the arm in the raised position 4 Re tighten the lock nut and check again to make sure the upper arm will now stay up when lifted If not repeat these steps using slight 1 4 turn adjustments on the screw Note Do not over tighten the adjustment screw Over tightening the adjust ment screw will apply too much tension and prevent the free movement of the arm during operations causing damage f
36. un ning or with the power ON Don t leave tool until it comes to a complete stop Always turn off and disconnect from power source before servicing or changing accessories blades bits and cutters or before performing any mainte nance or adjustments Reduce the risk of unintentional start up Make sure that switch is in the OFF position before plugging in the power cord Do not use the saw if the power switch is defected Have defective switch es replaced by an authorized service center Make sure saw is properly grounded If equipped with a 3 prong plug it should be used with a three pole receptacle Never remove the third prong Avoid body contact with grounded surfaces e g pipes radiators stoves refrigerators Repairs to the saw should only be carried out by qualified people using original spare parts A guard or other damaged part should be properly repaired or replaced by an authorized service center Inspect power cords and extension wires periodi cally If damaged have them repaired by an authorized service facility Never yank cords and wires and keep away from heat oil and sharp edges This tool is for indoor use only Do not expose fo rain or use in wet or damp locations Additional Safet Instructions TN Specific to this Scroll Saw Because each shop situation is unique no list of safety guidelines can ever be complete The most important safety feature in
37. wing paragraph and using this knob as the primary blade tensioner will cause premature wear and damage the machine This saw has an adjustment knob the rear that can raise the blade mount up to 1 25 mm This allows you to fine tune blade tension when needed as well as to reposition The saw blade at a point where you can use a different part of the blade in the cutting area This also allows you to use a piece of band saw blade cut to a length of 5 6 127 150 in your saw and gives you up 3 inch cutting capacity when needed Note Do over tension the knob as this can cause premature wear and damage the machine OPERATING INSTRUCTIONS ON OFF SWITCH The saw is equipped with a simple dust protected rocker style on off switch A featuring a protection device B to prevent unwanted or unintentional start up ON OFF SWITCH PADLOCK To avoid accidental starting by young children or others not qualified to use the tool the use of a padlock C is required 1 Open the padlock 2 Insert through holes in the on off switch 3 Close the padlock 4 Place the key in a safe place out of the reach of chil dren ADJUSTING THE BLADE SPEED The Scroll Saw is equipped with a variable speed control which allows you to select or fine tune to the exact blade speed required from 400 1400 strokes per minute for the EX 16 model amp from 400 1550 strokes per minute for EX 21 amp EX 30 models for
38. workbench or stand to bolt the saw in place hardware not included on your workbench If a permanent installation is not practical clamps can also be used to secure the saw to a bench or work table 10 ORDER OF ASSEMBLY A Saw B Hex head bolt C Flat washer D Workbench or stand E Flat washer F Lock washer G Hex nu DUST COLLECTOR OUTLET The dust collector outlet on this saw allows for hook up to a user supplied shop vacuum or dust collector Note 1 The dust collector outlet reduces clearance under the table and limits the left tilt capacity of the saw to 30 for model EX 16 and to 38 for models EX 21 and EX 30 Note 2 If desired the dust collector outlet can be removed to recover a maximum left tilt capacity of 452 Proceed as follows With the saw turned off and unplugged loosen and remove the 4 screws and washers A that attaches the dust colllector outlet to the underside of the table ALWAYS TURN OFF AND UNPLUG THE MACHINE BEFORE REMOVING OR INSTALLING COMPONANT CHOOSING amp INSTALLING A SAW BLADE BLADE SELECTION Blade selection is dependent on the type and thickness of the material being cut but is also a matter of experi ence and personal preference There are numerous types of blades available on the market specifically suited for various cutting applications such as metal cutting and spiral blades which cut in all directions Try test cutting with a sample of eac
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