Excalibur 40-100C Use and Care Manual
Contents
1. a ROUTER b ROUTER LIFT CRANK HANDLE c INSERT RING WRENCH ds STARTER PIN u puan a saus awas Qs as e HEX SOCKET HEAD BOLT f 2 5 MM ALLEN g 3 MM ALLEN KEY h ALLEN KEY i 6 MM ALLEN KEY LIST OF CONTENTS 5555555555 40 130 DUST COLLECTION KIT amp sn 09209 111111 a RIGHT SIDE PANEL E b BOTTOM PANEL Bl qiios INE y e REAR PANEL i d LEFT SIDE PANEL e FRONT PANEL BDSEBOSE I gs DUSI PORT in RR HOSE CLAMP HEX HEAD BOLT LOCK WASHER WESS i MEL x LLL TM Ss 1 FLAT WASHER O Lb ES PHILLIPS HEAD SCREW SHORT al Ju ag m PHILLIPS HEAD SCREW LONG a TOA y UNPACKING CNTD Carefully unpack and remove the components of the following 5 boxes that make up a complete Excalibur Router Table 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 Model 40 1006 LIST OF CONTEN2. 19 X 10 MM 3 8 X 9 32 10 X 7 MM ROUTER INSERT PLATE 9 1 4 X 11 3 4 235 X 298 MM TABLE OPENING SIZES DIAMETER PLATE 3 3 4 95 MM INSERT RING 1 1 2 38 MM 140 IQO NET WEIGHT 40 100C MODEL ASIS 119 LBS 54 KG NS SON GEAN GENERAL y Excalibur 5522 BY GENERAL INTERNATIONAL VERSION 2 _ REVISION 2_DECEMBER 2013 p O Copyright General International 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 THAN K YOU for choosing this Excalibur by General International model 40 100 Deluxe Router Table Kit bench top model This router table has been carefully tested and inspected before shipment and if properly used and maintained will provide you with years of reliable service For your safety as well as to ensure optimum performance and trou ble free operation and to get the most from your investment please take the time to read this manual before assembling installing and operating the unit The manual s purpose is to familiarize you with the safe operation basic function and features of this router table as well as the set up maintenance and identification of its parts and com ponents 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
3. 40130 01 32240001 FRONT BOX PANEL 40 130 02 32240002 RIGHT BOX PANEL 40130 03 906M04006A PHILLIPS HEAD SCREW 40130 04 906M04010A PHILLIPS HEAD SCREW 40130 05 32240003 HINGE 40130 06 32240004 LEFT BOX PANEL 40130 07 32240005 REAR BOX PANEL 40130 08 32240006 POWER CORD CLAMP 40130 09 32240007 BOTTOM BOX PANEL 40130 10 32240008 VENT BASE N Qo 40130 11 32240009 VENT ADJUSTMENT PLATE 40130 12 920040100 RIVET M3 2 40130 13 94800006B AIR HOSE FENCE SIZE 35 M63 X 90CM 40130 14 32240010 DOOR PANEL 40130 15 904M06012 HEX BOLT M X 12 40130 16 915M06000 LOCK WASHER M 40130 17 914M061301 FLAT WASHER M 40130 18 32240011 MAGNET 40130 19 32240012 DUST OUTLET 40130 20 952002034 HOSE CLAMP NO O o0 O8 O MODEL 40 100 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 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
4. The bearing rides along the uncut edge of the board while the cutter removes the wood 1 Follow steps 1 and 2 from previous section Groove Cutting 2 Adjust the fence back and away from the bit only enough to allow the guide bearing to control the depth of cul or use the starting pin as a support for the work piece as shown in B 3 Adjust the fence as close as possible to the bearing The fence will serve as a backup support reducing the chance of an accident TENSIONING THE DRIVE CHAIN Proper tension on the drive chain helps maintain tool bit height in the lift without the need for a locking mechanism If you experience problems with tool creep it may be a sign that tension on the chain needs be tightened If so proceed as follows 1 Lower the lift to its lowest position and then remove it from the table 2 Using a 6 mm allen key loosen the cap screw A Fig 1 SS 1 3 Push the sprocket assembly B Fig 2 further along its slotted opening C Fig 1 by hand to add tension to the chain 4 While holding the sprocket assembly in position tighten the cap screw to secure it in place Note To avoid unnecessary adjustments make sure that the tool creep you are experiencing is not being cause by the router slipping in the reducer collar or in the clamping mechanism on the lift 25 RECOMMENDED OPTIONAL ACCESSORIES We offer some optional accessories available from your loca
5. if unintentional contact is made with spin ning router bit Keep all guards and safety devices in place and in good working order If a guard must be removed for maintenance or cleaning make sure it is properly re installed before using the machine again Hold the workpiece firmly against the table and use suitable support if the workpiece does not have a flat surface Feed the stock into the bit against the rotation direc tion of the bit Never run the stock between the fence and the bit Do not operate with a damaged bit in the router Always disconnect the router from the power source before changing accessories or before performing any maintenance and adjustments or if the machine will be left unattended Be sure that all adjustment tools wrenches or other clutter are removed from the table surface and safely stored before routing Make sure the routers switch is in the OFF position before plugging in to a power source Avoid working from awkward or off balance positions Do not overreach and always keep both feet firmly on the floor Never leave the router unattended while running or with the power on Do not use this router table for any purpose other than its intended use If used for other purposes GENERAL INTERNATIONAL disclaims any real or implied warranty and holds itself harmless for any injury which may result from such use INSTALLATION THE MACHINE IS HEAVY 119 LBS 54 KG DO NOT
6. motor into the clamping area as shown above using shim or reducers if necessary For installation with reducer collar 1 Install the collar onto the router as shown in F and then fit the router with collar into the lift G making sure that the collar flange sits flush against the clamping bracket m mt FW ud 3 With the router in position tighten clamping bolt J securely using a using a 8 mm Allen key but do not over tighten Important Test that the router is se curely clamped in the reducer collar by trying to twist the router in the collar by hand 4 The routers collet should now be protruding out from the top plate This will facilitate tool router bit changing from above the table eliminating the need to remove the router lift system from the table to access the collet 3 With the router plate leveled to the table lock the plate in place using the two supplied hex socket head screws C in the threaded holes on both sides of the plate INSERT RING REMOVAL Insert the two pins of the wrench in the two holes on the insert ring then turn clockwise to unlock the ring A and lift the insert ring up and out of the table inser tion B LEVELING AND LOCKING THE ROUTER PLATE 1 Using a straightedge check that the router plate is level with the main table A 2 Adjust the 10 leveling screws B in the table opening as needed to level the plate on all four sides lf needed ref
7. ouuu 9 Mounting hardware for 40 047 MDF table for model 40 100M e j e LUTTE ASSEMBLY INSTRUCTIONS Y SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COMPLE TED THE INSTALLATION AND ASSEMBLY STEPS DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED TO DO SO 40 060 ROUTER TABLE STAND Note Do not tighten the stand bolts until after you have fastened the stand to the router table top See step 3 on page 14 1 Attach a rubber foot to each leg using a phillips 2 Lay the stand braces and legs on the floor as screw flat washer and hex nut A in the assembly shown This will help you to rapidly locate the order shown in B braces and know what to attach where Note Bottom brace C goes on the rear of the stand and bottom brace D goes on the front Put middle cross brace E aside for now 3 Using 4 carriage bolts with flat washers and hex nuts 4 Using the same hardware attach a second leg to F attach one leg to one top brace and one top the top cross brace I then attach the second top cross brace as show in G in the assembly order brace J to this leg as shown shown in H 5 Attach a third leg K to the top brace J then attach 6 Attach the rear bottom cross brace N and the front second top cross brace L then fourth leg M bottom cross brace O as shown 11 7 Attach the two bottom sid
8. prevent rust apply a light coating of paste wax or use regular applications of any aftermarket surface protec tant or rust inhibitor Tip With a screw driver push a solvent saturated rag into the T slots fo remove the grease INSTALL THE TABLE CAST IRON TABLE 40 100C AND PHENOLIC TABLE 40 100P ONLY For 40 047 MDF table for 40 100M only thread in all leveler screws and nuts as shown below You will use the wood screws supplied with your table in the upcoming steps to attach the table and dust collection box to the stand and the fence mounting rails to the table 5 As a precaution thread in all fasteners as shown to make sure there are no filings in any of the threaded holes and leave the fasteners in the underside of the table Only remove as assembly is taking place Note 1 The leveler screws need be inserted from the bottom of the table The nut will sit on the top side of the flange that the router lift plate will rest on A Note 2 There are 3 holes on each side of the table open ing C The two outside holes are for the leveling screws A and the middle hole is used to secure a plate or the lift to the table ATTACH THE TABLE TO THE STAND CAST IRON TABLE 40 100C AND PHENOLIC TABLE 40 100P ONLY For 40 047 MDF table for 40 100 use the wood screws supplied with your table to attach the stand to the table 1 With the table upside down remove the 4 mounting 2 Attach the stand
9. router lift to the highest or maximum upward position turn the crank handle clockwise BN k P 3 3 Haba Am MR gu on ja M A 2 uk P 3x Clean packing lubricant from the lift posts screws F and the chain G Clean it by spraying with a solvant which will dilute the grease and then wipe clean or use compressed air to blow dry After degreasing reapply some dry lubricant 3 Remove the crank handle and flip the lift over in the table Fr a y a re zi a a Wa GE 4 Turn Allan screw counter clockwise to loosen clamp body B The two threaded nuts C are there to help spread the clamp body Note Spread clamping mechanism only as needed Nuts C have no other purpose and you will notice that they are locked together and will sit in a neutral position when the router motor is secured into place _ Note Some motors have pins protrusions E on the housing You will need to turn twist the motor as you slide it into the clamping area or onto the reducer collar m Close but nottouching 2 Adjust the height of the router in the collar H to ensure that the router is as close as possible to the underside of the plate without touching I 20 he JE APA E Note When mounting the Milwaukee model 5625 5626 motor please ensure that a shim D is between the router and the clamping surface of the lift 5 Slide the router
10. your final piece USING THE SPACER BARS FOR JOINTING Two spacer bars A are supplied with the fence system cutting router bit to remove material from the edge to facilitate jointing by offsetting the outfeed fence B face of a board The result is a perfectly flat and square to the infeed fence and providing a straight path for edge the workpiece to follow as it is machined fully support ed at its start and end Eh Note both spacer bars should be used in the top and bot tom f slots in the fence body as shown Take care to install them in matching offset positions both at 0 7mm or both at 1 5mm Each spacer bar has two sides which allow you to off Note when not in use the spacer bars can be stored on set the outfeed fence by either 0 7 mm or 1 5 mm stag the t track on the back of the fence body as shown gering JOINTING 1 Loosen but do not remove the outfeed fence face and install the soacer bars between the outfeed fence and the fence body 2 With the router unplugged and the safety switch in the off position follow the instructions supplied with your router and install a straight cutting bit in the router 3 Adjust the height of the lift to raise or lower the bit as need until the bit is slightly higher than the workpiece 4 Loosen the fence locking knobs and using a straightedge position the outfeed fence aligned flush with the bit A Rotate the bit by hand to validate alignmen
11. 009 60700010 912M14000 60500012 60700017 60700002 914M061301 9140381902 60700009 60800005 60800018 908M06006 60800002 9236805Z0 901M08020 903M06018 903M04012 9180404018A 9236804Z0 60700009B 9236900Z0 903M06030 60800020 919501000 912M06000 60100018 60800003 901M10070A 910M10005 901M06060A 901M10055 94300002 PARTS LIST 140 125 DESCRIPTION ALUMINUM CARRIAGE BRACKET MAIN GEAR SHAFT LEAD SCREW INSERT RING GEAR SHAFT CARRIAGE PLATE CLAMP POST TOP PLATE STARTING PIN PHILLIPS HEAD SCREW CAM GEAR ELLIPTICAL WHEEL NYLON NUT GEAR SPROCKET LOCK GUIDE NUT UPPER GUIDE NUT BASE FLAT WASHER FLAT WASHER LIFT CRANK HANDLE SLEEVE SCALE PLATE SET SCREW BUSHING BEARING CAP SCREW FLAT HEX SOCKET HEAD SCREW FLAT HEX SOCKET HEAD SCREW KEY BEARING CRANK HANDLE SLEEVE BEARING FLAT HEX SOCKET HEAD SCREW CHAIN C RING NYLON NUT INSERT WRENCH BACK LASH LOCK CAP SCREW HEX NUT CAP SCREW CAP SCREW O RING SPECIFICATIONS 1 1 2 M X 25 MIA M M10 M X 680572 8 20 M X 18 MA X 12 M4 X 4 X 12 680477 6900ZZ M X 30 S10 M M10 X 70 M10 M X 0 M10 X 55 12 42 X 1 78 QTY s co e ol Dust Collection Kit 40 130 PARTS LIST 40 130 PART NO REF NO DESCRIPTION SPECIFICATIONS QTY
12. B MDF TABLE 400 X 600 MM 40049 02 903M06030 FLAT HEX SOCKET HEAD SCREW M X 30 40049 03 907M06013 WOOD NUT M X 13 40049 04 907007004 WOOD SCREW 7 X 40 40047 05 60700030A TSLOT GUIDE RAIL 40049 06 905316058 SELF TAPPING SCREW 3 16X 5 8 40049 07 907316058 SELF TAPPING SCREW 3 16 X 5 8 Router Fence 40 065 PARTS LIST 40 065 PART NO REF NO DESCRIPTION SPECIFICATIONS QTY 4006501 27160032A FENCE BODY 780 MM 40080 02 60100001A LOCK HANDLE 9 16 2 40065 03 12716002 SCALE 780 MM 40080 04 32240052A T BOLT 6 40080 05 9145162302 FLAT WASHER M8 2 40080 06 939M08000B LOCK KNOB M8 8 40080 07 32240034 LOCK NUT M8 2 40080 08 27160035A H SPACER 388 MM 2 40065 09 27160036 FENCE FACES 388 MM 2 40080 10 32240037 SAFETY GUARD 40065 1 1 32240038 FENCE SPACER 2 40065 12 27160039 SIDE BRACKET BASE 240 MM 2 40065 13 27160040 SIDE BRACKET 280 MM 2 40065 14 27160041 RULE PLATE 205 MM 2 40065 15 12716003 SCALE 205 MM 2 40080 16 9350 14000 SQUARE NUT 1 4 8 40080 17 9140141602 FLAT WASHER M 14 40080 18 901M06012 CAP SCREW M X 12 8 40080 19 904014058 HEX BOLI 1 4 X 5 8 6 40080 20 940M06012 LOCK KNOB M X 12 2 40080 32 32240013A DUST PORT 40080 33 906014034 PHILLIPS HEAD SCREW 1 4 X 3 4 2 40080 34 32240033A T BOLT 2 40080 35 32240060 FLUOROWAY PAD Stand 40 060 16 16 lt 22 Ta 22 PARTS LIST 40 060 PART NO REF NO DESCRIPTION SPECIFICATIONS QTY 40060 02 27160015 LONG TOP BRA
13. CE F amp R 2 40060 03 27160016 SHORT TOP CROSS BRACE L amp R 2 40060 04 27160017 LEG 4 40060 05 27160018 LONG BOTTOM CROSS BRACE FRONT 40060 06 27160018A LONG BOTTOM CROSS BRACE REAR 40060 07 27160019 SHORT BOTTOM CROSS BRACE L amp R 2 40060 08 27160022 SWITCH MOUNTING PLATE 40060 09 93224011 SWITCH BOX 40060 10 27160020 HANDLE BRACKET 40060 11 909M06012 CARRIAGE BOLT M X 12 34 40060 12 L32240001 POWER CORD 14AWG X 3C 40060 14 910M06000 HEX NUT M 48 40060 15 914M061602 FLAT WASHER M 42 40060 16 906M05020 PHILLIPS HEAD SCREW M5 X 20 40060 17 906M04016 PHILLIPS HEAD SCREW M4 X 16 6 40060 18 904M06020 PHILLIPS HEAD SCREW M X 20 4 40060 19 30100016 RUBBER FOOT 4 4 2 27160021 MIDDLE CR BRACE LEFT 40060 22 910M05000 HEX NUT M5 4 40060 23 914M051201 FLAT WASHER M5 2 Router lift 40 125 0 CIL LAS O Ge s f 3 o NN gt 28 36 A HAM J 9 7 OHM Ks PART NO 40125 01 40125 02 40125 03 40125 04 40125 05 40125 06 40125 07 40125 08 40125 08A 40125 08B 40125 09 40125 10 40125 11 40125 12 40125 13 40125 14 40125 15 40125 16 40125 17 40125 18 40125 19 40125 20 40125 21 40125 22 40125 23 40125 24 40125 25 40125 26 40125 27 40125 28 40125 29 40125 30 40125 31 40125 32 40125 33 40125 34 40125 35 40125 36 40125 37 40125 38 40125 39 40125 40 60800001A 60500002 60500003 60100017 60500005 60800021 60800004 60800007A 60700031 906M06025 60500
14. LUXE ROUTER TABLE KIT Bench top model M Model 40 100 IDENTIFICATION OF MAIN PARTS AND COMPONENTS race se um 3 FU ON OFF SWITCH WITH REMOVABLE SAFETY KEY B TABLE C FENCE RAIL WITH SLIDING SCALE D SLIDING ADJUSTABLE FENCE FACE E FENCE LOCKING HANDLE F ROUTER LIFT CRANK HANDLE G DUST SHIELD LOCK KNOB H DUST SHIELD l FENCE BODY J 3 4 X 3 4 MITER T SLOT FOR MITER GAUGE K 3 8 MITER T SLOT FOR SELF MADE JIGS L STAND M DUST ENCLOSURE N RUBBER FEET O DUST VENT P ROUTER LIFT HANDLE HOLDER 2 1 4 BRANCH INLET DUST HOSE 4 DUST PORT Model 40 100C Cast iron table shown DOVETAIL SLOT Carefully unpack and remove the components of the following 5 boxes that make up a complete Excalibur Router Table 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 Bi wa 40 060 STAND 40 100 a CARRIAGE BOLT De HEX NUT u usuyasa pu din c FLAT WASHER d ROUTER LIFT CRANK HANDLE HOLDER e NUT SMALL f RUBBER FOOT g PHILLIPS SCREW h HEX NUI eto da vie teme stet E ew b ra DER j PHILLIPS SCREW SMALL k SWITCH BOX l LONG BO
15. OVEREXERT ARRANGE TO HAVE HELP NEARBY AND READY FOR UNPACK ING AND SET UP 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 INSTALL THE ROUTER TABLE ON A STABLE SURFACE The unit should be installed on a flat sturdy and stable Never install the machine over the edge of a table surface or workbench able to support the weight of or workbench the machine and the workpiece with ease MOUNTING TO A WORK SURFACE If a permanent shop placement is practical consider ORDER OF ASSEMBLY removing the rubber feet on the base and drilling matching through holes in the mounting surface of your A Stand legs workbench or stand to bolt the table in place hard B Hex head bolt ware not included on your workbench C Flat washer D Workbench or stand E Flat washer F Lock washer G Hex nut If a permanent installation is not practical clamps can also be used to secure the table to a bench or work table SAFETY ROUTING MAY PRESENT SERIOUS INJURY HAZARDS TO UNTRAINED USERS BE SURE TO READ UNDERSTAND AND FOL LOW ALL INSTRUCTIONS AND SAFETY GUIDELINES SUPPLIED WITH THE ROUTER YOU WILL INSTALL ON THIS TABLE MAKE SURE THAT ADEQUATE HEARING PROTECTION IS USED AND THAT THE OVERALL SOUND LEVEL WITHIN THE WORK ING ENVIRONMENT IS TAKEN INTO CONSIDERATION DE
16. SETUP amp OPERATION MANUAL a DELUXE ROUTER TABLE KIT 11 3 4 aluminum top plate Stable 4 post lift screw design amp chain drive Bench 10 model lifting system controlling all 4 corners simul taneously Fits all fixed base router motors Smooth above the table adjustment mech anism for fast tool changes amp precision bit setting Available with table in either cast iron 40 100C MDF 40 100M or Phenolic 40 100P Sturdy steel stand includes easy access on off safety switch with removable lock out key amp non slip rubber feet 4 Fence has 2 1 4 dust collection outlet and adjustable scales Under table steel dust enclosure with access door adjustable air vent power cord grommet and 4 dust port with 2 1 4 branch inlet to the fence Includes 2 1 4 dust hose and 2 hose clamps Some router models may require reducer collars adaptors SPECIFICATIONS OVERALL DIMENSIONS 30 1 2 X 16 X 21 775 X 406 X 533 MM TABLE SIZE Cast iron 16 X 27 406 X 686 MM Phenolic amp MDF 15 3 4 X 25 5 8 400 X 651 MM TABLE HEIGHT 16 406 MM E Es FENCE SIZE EACH XCalibur 3 15 1 4 X 3 4 76 X 387 X 19 MM mm MAXIMUM FENCE TRAVEL 6 152 MM DUST OUTLET 2 1 4 57 MM DISTANCE BETWEEN FSLOT amp SPINDLE CENTER 3 4 5 1 16 135 MM 3 8 6 9 16 167 MM DISTANCE FROM SPINDLE CENTER TO FRONT EDGE OF TABLE 8 205 MM T SLOT DIMENSIONS 3 4 X 13 32
17. SWITCH 1 Remove the top half of the power cord flange plate from the side panel on the dust containment box A 2 Pass the router s power cord through the opening as shown in B taking just enough cord to reach the inlet on the back of the safety switch box 22 Note Make sure to leave enough of the router s power cord inside the dust containment box fo allow you to remove the lift and the router from the table opening from above 3 Re install the power cord flange plate and plug the router into the inlet on the back of the safety switch BEFORE TURNING ON THE SWITCH ON YOUR ROUTER MAKE SURE THE SWITCH ON THE SWITCH BOX IS IN THE OFF POSITION AND THAT THE SWITCH BOX IS NOT YET CONNECTED TO A POWER SOURCE USING THE SAFETY SWITCH 2 POWER ON POWER OFF SAFETY KEY PREVENTS START UP WHEN REMOVED The safety switch box is equipped with a simple on off switch featuring a removable lock out safety key To prevent unauthorized use or unintentional start up remove the safety key and store it in a safe place whenever the router table is not in use CONNECTING TO A DUST COLLECTOR There is a 4 dust outlet on the rear of the dust enclosure allowing for the connection of a dust collector not included Be sure to use an appropriate size hose and fittings not included and check that all connections are sealed tightly to minimize airborne dust If you do not already own a dust collection sy
18. TS OTY a 16 27 CAST IRON TABLE 40 070 b HEX NUT 10 LEVELER SCREW 10 d FLATWASHER 4 e LOCK WASHER 4 f HEX SOCKET CAP SCREW 4 Model 40 100P LIST OF CONTENTS QTY a 153 4 X 25 5 8 PHENOLIC TABLE 40 043 1 b NUT 10 LEVELER SCREW 10 d FLATWASHER 4 e LOCK WASHER 4 f HEX SOCKET CAP SCREW 4 Model 40 100M LIST OF CONTENTS OTY a 15 3 4 X 25 5 8 MDF TABLE 40 047 1 b WOODSCREW 10 WOODNUT 2 d WOODSCREW 26 ADDITIONAL REQUIREMENTS FOR SET UP 10 Extra person for help with lifting cast iron table Straight edge Phillips screwdriver Socket wrench set Wrench set Allen key set Mounting hardware for 740 070 Cast iron table for model 40 1000 oooocoocoo l ra d 1 0000 o 111 Additional hardware is supplied with the cast iron table to allow for installation on a table saw as part of kit 40 070 Complete mount ing instructions for the 40 070EK can be downloaded at the General International website at www general ca manuals Mounting hardware for 40 043 Phenolic table for model 40 100P ccoscoosos
19. TTOM CROSS BRACE REAR 1 m LONG BOTTOM CROSS BRACE FRONT 1 n MIDDLE CROSS BRACE LEFT o SHORT BOTTOM CROSS BRACE L amp R p SHORTTOP CROSS BRACE L amp R q LONG TOP BRACE FRONT amp REAR Te k LIST OF CONTENTS 40 065 ROUTER FENCE 40 100 da DUSTSHIBLD cosa iia ra als a b 2 1 4 dust collection outlet 1 c FENCE LOCKING HANDLE d FENCE BODY es FENCE FACE Juice edu aie m aputaq en f FENCE SIDE RAIL W SCALE g FENCE MOUNTING BRACKET h SPACER BARS FOR JOINTING WORK i LOCK KNOB corria Pirro bars PETRA TUTTA FM Td AL o j TBOLT LONG i ke CAP SCREW ii ara N TI Liki 1 o l JPLASTE gt SPAGER S tcs tt ee m FLAT WASHER SMALL ont FBOLT SHORT o PHILLIPS HEAD SCREW O y E i k p HEX NUT LARGE q FLAT WASHER LARGE 075 o TTT TT TT 220 UNPACKING CNTD Carefully unpack and remove the components of the following 5 boxes that make up a complete Excalibur Router Table 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 40 125 ROUTER LIFT
20. UNEE mounng Noles 14 Insert the other square nut in the slot on the other 12 Loosely thread a square nut B on both screws as side of the fence B shown in C 15 Center the dust outlet with the hole in the fen 16 Insert a locking handle A with large flat washer B ce body A then tighten the two phillips head in the T slot at one end of the fence then screws B from below loosely thread a large hex nut C as shown in D 17 Slide the hex nut in the fence rail as shown ANT HA Mee 1 i Re 35 Te EN 18 Repeat steps 16 and 17 on the other end of the fence then fully tighten the locking handle to lock the fence in position 16 PREPARE THE TABLE FOR THE ROUTER LIFT Note Model 40 070 for 40 100C Cast iron table shown The following steps apply to all 3 table options 1 Place the router lift into the opening in the table 3 From the underside of the table adjust the 4 phillips head screws in the corners A up or down until the plate is flat and level with the table surface Note While tightening the lock nuf make sure that the adjuster screw does not turn Confirm by re checking the leveling of the lift and table surface 2 Use a straightedge to test the plate for level with the table top 4 Remove the lift and lock the adjuster screw in place by turning the lock nut A clockwise tighten 5 After the four corners are set proceed to set the remaining 6 leveler sc
21. alertness Keep the work area well lit clean and free of debris Stay Alert Give your work your undivided attention Even a momentary distraction can lead to serious injury Do not wear loose clothing gloves bracelets neck laces or other jewelry Wear face eye ear respiratory and body protection devices Wear protective hair covering to contain long hair and wear non slip footwear Keep hands and other body parts well away from bits or cutting tools When working close to the cutting tool always use a feather board or push stick to hold or guide the workpiece Do not clear chips and sawdust away with hands Use a brush Fine particulate dust is a carcinogen that can be haz ardous to health Always work in a well ventilated area and whenever possible use a dust collector to mini mize health hazards Be sure the router is running up to speed before feed ing the workpiece Use a suitable support if stock does not have a flat surface Keep children and visitors at a safe distance when the router is in operation do not permit them to operate the router and table Childproof and tamper proof your shop and all machinery with locks master electrical switches and switch keys to prevent unauthorized or unsupervised use 13 14 15 16 17 18 19 20 21 22 23 Secure the table to a work surface and never stand or lean on it Serious injury could occur if the table is tipped or
22. all the fence airflow and maximize dust collection efficiency based on the size of your dust collector The smaller the dust collector the wider the vents should be opened to allow maximum airflow 8 Using the remaining hose clamp secure the other end of the dust hose to the dust outlet on the fence E 18 ASSEMBLY INSTRUCTIONS MOUNTING A ROUTER PLETED THE INSTALLATION AND ASSEMBLY STEPS DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED T SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COM TO DO SO This model 40 125 fixed base router lift A is designed to accommodate the largest diameter router motor body currently available Note Based on our research this is the Porter Cable model 7518 and 7519 router motors which measure 4 200 in diam eter All other motors smaller diameters will require a shim C item 40 626 available from you local General Intera tional dealer or a reducer collar such as our model 40 312 for 3 1 2 motors or 40 314 for 3 1 4 motors B to center the router as well as prevent from overtightening the clamping system Note The factory installed adjusting screw on the Milwau kee motor must be lined up and inserted into the hole D located in our clamping bracket E 1 Insert the crank handle in the black hole sur rounded by digits as shown in H 2 To raise the lifting carriage on the
23. by General International prod ucts 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 satisfaction General amp International agrees 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 professional 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 International agrees to repair or replace any part or compo nent 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 excep tions 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
24. e cross braces P and 9 Using a carriage bolt flat washer and nut S attach the router lift crank handle holder T to the middle cross brace as shown in U in R The router lift crank handle may be stored on the holder as ii shown in V when not being used 8 Turn the stand in the upright position and attach the middle cross brace on the left side as shown 11 Insert a phillips head screw with hex nut through the other side of the brace lightly thread dd nut to lock the screws in position W 9 Install the switch box by sliding it s mounting brack 10 Stand assembly is now complete et over the right front leg X and attach with the two phillips head screws and washers already mount ed to the bracket 12 TABLE 40 070 40 047 40 043 There are 3 different table options for Deluxe Router Table Kit model 40 100 Cast iron table 40 070 for 40 100C MDF table 40 047 for 40 100M Phenolic table 40 043 for 40 100 CLEANING THE CAST IRON TABLE FOR 40 100C ONLY The protective coating on the cast iron table prevents rust from forming during shipping and storage Remove it by rubbing with a rag dipped in kerosene mineral spirits or paint thinner Dispose of potentially flammable solveni soaked rags according to manufacturer 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 To
25. ents Repairs made without the written consent of General International will void all warranty TABLE OF CONTENTS Rules for safe operation 5 Installation 6 Safety 6 identification of main parts and components 7 Unpacking 8 List of contents 40 060 Stand 8 List of contents 40 065 Router fence 8 List of contents 40 125 Router lift 9 List of contents 40 130 Dust collection kit 9 List of contents Table 10 Additional requirements for setup 10 Assembly Instructions 11 22 40 060 Router table stand 11 Table 40 070 40 047 40 043 13 Cleaning the cast iron table for 40 100 only 13 Install the table cast iron table 40 100C and phenolic table 40 100P only 13 Attach the table to the stand cast iron 40 100C and phenolic 40 100P only 14 40 065 Router fence 14 Prepare the table for router liff 18 40 130 Dust collection kit 19 Mounting a router 20 Leveling and locking the router plate 22 Insert ring removql 22 Installing the starting pin 22 Basic adjustments 8 controls 23 24 Adjusting the fence along t
26. er back to the instructions on page 17 For 440 049 MDF table for 40 200M only From the underside of the table thread the 2 supplied wood nuts D onto the screws as shown in E INSTALLING THE STARTING PIN Install the starting pin A into the threaded hole on the router plate as shown The starting pin can be used as needed for freehand or template routing only 21 BASIC ADJUSTMENTS 8 CONTROLS ADJUSTING THE FENCE ALONG THE RAILS The fence can be slid along the rails A Loosen locking handles B slide fence then lock in position by re tight ening the locking handle Repeat on the other extrem ity of the fence ADJUSTING THE FENCE FACES ADJUSTING THE SLIDING SCALE ON THE RAILS la The scale on the rails can be adjusted along the rails C Loosen lock knob D slide the fence up to where you need it to be then lock in position by re tightening the lock knob Repeat for the sliding scale on the other rail Depending on the size of the workpiece and the bit being used the white fence faces can be adjusted along the fence body A Loosen the 3 lock knobs B on one side of the fence and then slide the fence face up to where you need it to be Then lock in position by re tightening the lock knobs Repeat with the second fence face on the other side of the fence body Note Do not slide the fence faces too far and off the first T bolt head as shown in C CONNECTING THE ROUTER TO THE SAFETY
27. he rails 23 Adjusting the sliding scale on the rails 23 Adjusting the fence faces 23 Connecting the router to the safety switch 23 Using the safety switch 24 Connecting to a dust collector 24 Operating instructions 24 26 Before starting 17 E 24 Using the spacer bars for jointing 25 Jointing S qM S 25 Groove cutting 3 1 03 03 3 F 26 Profile cutting 2 4 1 9691 A 26 Tensioning the drive chain 26 Recommended optional accessories 27 Parts list amp diagrams 28 34 Contact information 35 Rules for Safe Operation To help ensure safe operation please take a moment to learn the machine s applications and limitations as well as poten tial hazards 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 11 12 Make sure that the operator has been properly trained and has read and understands the Owner s Manual before operating any machinery Be sure to read understand and follow all instructions warnings and safety guidelines supplied with your router Do not operate this router table when tired distracted or under the effects of drugs alcohol or any medica tion that impairs reflexes or
28. k pusher 40 120 For Excalibur router fence 40 065 bench top model amp 40 080 floor model Cast iron table with models 40 100C amp 40 070EK gt PART NO REFERENCE NO DESCRIPTION 40070 01 40075 02 40075 03 40075 04 40075 05 40075 06 40075 07 40070 08 40070 09 40070 10 40070 11 40070 12 2716U014 903M06030 910M06000 905M06020 914M061602 915M06000 901M06016 12716020 904M10035 9014382503 915M10000 910M10008 CAST IRON TABLE FLAT HEAD CAP SCREW HEX NUT FLAT HEAD SCREW FLAT WASHER LOCK WASHER CAP SCREW DRILLING TEMPLATE HEX BOLT FLAT WASHER LOCK WASHER HEX NUT 16 X 27 M X 30 MM M M X 20 MM M M X 1 MM M10 X 35 MM M10 M10 M10 40070 13 953M11000A DRILL BIT Phenolic table with model 40 100P PARTS LIST 40 043 PART NO REFERENCE NO DESCRIPTION SPECIFICATION QTY 40043 01 2716U014A PHENOLIC TABLE 400 X 600 MM 40045 02 903M06030 FLAT HEX SOCKET HEAD SCREW M X 30 2 40043 03 60700030A TSLOT GUIDE RAIL 40045 04 902M05012 ROUND SOCKET HEAD SCREW M5 X 12 8 40045 05 905M06040 FLAT HEAD SCREW M X 40 10 40045 06 910M06000 HEX NUT 40130 10 40045 07 901M06016 HEX SOCKET HEAD SCREW M X 16 32 40045 08 914M061302 FLAT WASHER M 24 40045 09 915M06000 LOCK WASHER MDF table with model 40 100M PARTS LIST 40 047 PART NO REFERENCE NO DESCRIPTION SPECIFICATION QTY 40047 01 2716E014
29. l General International dealer for increased con venience productivity accuracy and safety when using your router table For more information about our products please visit our website at www general ca Horizontal featherboard 40 175 For Excalibur router table 9 1 4 x 11 3 4 Phenolic insert plate 40 114 For Excalibur router tables 4 pc zero clearance insert ring set 40 074 For Excalibur 9 1 4 x 11 3 4 router plates Dust collector We offer a wide selection of top quality dust collec tors to suit all your shop needs Dust collectors contribute to a cleaner more healthful workshop environment Reducer collar fits 3 1 2 motor 40 31 2 For Excalibur router lift 40 125 9 1 4 x 11 3 4 Aluminum insert plate 140 115 For Excalibur router tables 4 pc insert ring set 1 4 1 2 2 12 amp 1 3 8 30 mm for 40 099 40 076 shim 40 626 Shim for Milwaukee router model 5625 5626 Vertical featherboard 40 160 For Excalibur router table Ad o Reducer collar fits 3 1 4 motor 40 314 For Excalibur router lift 40 125 Flip stop 40 090 For Excalibur router fence 40 065 bench top model amp 40 080 floor model 9 pcs brass precision tem plate guide set 40 099 Designed for most routers Included accessories e 1 locking nut 8 guides 1 1 19 64 5 8 27 32 17 32 17 64 9 32 11 32 13 32 Stoc
30. 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 amp International For further details call our service department at 1 888 949 1161 or your local distributor for assistance when filing your claim Along with the return of the product being claimed for warranty a copy of the original proof of purchase and a letter of claim must be included a warranty claim form can also be used and can be obtained upon request from General International or an authorized distributor clearly stating the model and serial number of the unit if applicable and including an expla nation of the complaint or presumed defect in material or workmanship CONDITIONS AND EXCEPTIONS This coverage is extended to the original purchaser only Prior warranty registration is not required but documented proof of purchase i e a copy of original sales invoice or receipt showing the date and location of the purchase as well as the purchase price paid must be provided at the time of claim Warranty does not include failures breakage or defects deemed after inspection by General6O 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 han dling or transport or normal wear and tear of any generally considered consumable parts or compon
31. rews and lock them in place 17 40 130 DUST COLLECTION KIT Note There are three longer screws in the hardware kit that are required to attach the 4 inch hose adapter Locate them first You will find additional mounting hardware to attach the 40 130 dust enclosure fo the table This additional hardware will not be required with cast iron table for 40 100C because the same fasteners are supplied with the table RIGHT SIDE LEFT SIDE 1 Assemble dust enclosure as shown using the 22 3 Remove the 6 hex head bolts from the underside of short phillips head screws the table 40 100C and 40 100P only 2 Remove the fence then turn the assembled router Note For 40 047 MDF table for 40 100M use the wood screws supplied with your table to attach the dust collec table upside down tion box to the table 4 Position and secure the dust enclosure into place 5 Using the supplied hose clamps secure one end using the 6 hex head bolts with lock washer and flat of the dust hose to the 2 1 2 inlet on the dust port B washer A 6 Attach the dust port to the hole on the rear panel C using the 3 longer 3 phillips head screws D Note To prevent overheating the router motor inside the confined space of the enclosure always use a dust col lector or vacuum to allow for air to flow 7 Turn the assembly back over to its upright and oper 9 The vent on the dust enclosure allows you to adjust ating position then re inst
32. safety of performing a certain operation or procedure do not proceed until you can confirm from knowledgeable and qualified sources that it is safe to do 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 International reserves the right to make changes to components 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 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 factory modifica tions may render some or all information in this manual inapplicable to your machine Further as several gene rations of this model of router table and several versions of this manual may be in circulation if you own an ear lier or later version of this unit this manual may not depict your machine exactly If you have any doubts or questions contact your retailer or our support line with the model and serial number of your unit for clarifica tion GENERALO INTERNATIONAL WARRANTY All component parts of General International and Excalibur
33. stem con sider contacting your General International distributor for information on our complete line of dust collection systems or visit our website at www general ca OPERATING INSTRUCTIONS With the safety switch on the stand in the off position A turn or flip the switch on your router to the on posi tion and then plug the cord on the safety switch box B into an appropriate wall outlet You will now be able to turn the router on or off using the safety switch box rather than having to reach un der the table to access the switch on the router ALWAYS TURN ON THE DUST COLLECTOR BEFORE STAR TING THE ROUTER AND ALWAYS STOP THE ROUTER MAKE SURE TO READ UNDERSTAND AND FOLLOW ALL OPERATING INSTRUCTIONS AND SAFETY GUIDELINES THAT CAME WITH YOUR ROUTER FAILURE TO DO SO MAY LEAD TO SERIOUS INJURY AND OR DAMAGE TO THE ROUTER ROUTER TABLE OR WORK PIECE WHEN JOINTING GROOVE CUTTING AND OR PROFILE CUTTING BE SURE TO ATTACH THE SUPPLIED DUST SHIELD BEFORE STARTING e Install the required bit in your router according to the instructions supplied with your router Make sure that the router is securely installed in the lift and that the plate is properly fitted and level in the table opening The router table should be installed on a flat sturdy and stable surface When jointing groove cutting and or profile cutting always perform a test cut a scrap piece of wood before 23 cutting
34. t with the highest point of the cutting edge on the bit then tight en the knobs to lock the fence in position 5 Adjust the height of the safety shield to make sure it clears the bit and the workpiece slightly 6 If needed loosen the lock knobs on the back of the fence and adjust the faces to adjust the gap between the fence faces and the bit leaving a clearance of roughly 1 4 between the bit and each fence face B 7 Plug in and turn on the router and make a test cut on a waste sample before jointing your good workpieces 24 GROOVE CUTTING Beading is commonly defined as cutting a groove or bead in the face of a board 1 If installed remove the spacer bars on the outfeed fence 2 With the router unplugged and the safety switch in the off position follow the instructions supplied with your router and install a cutting bit in the router 3 Raise or lower the router bit to the desired height 4 Loosen the knobs and adjust the opening between the fences to allow the bit to clear the edge of bothfences 5 Adjust the main fence until the center of the bit has reached the desired distance A 6 Align the infeed and outfeed fences parallel to each other using a machinist square or a straightedge PROFILE CUTTING Profile cutting is usually performed using a bit with a guide bearing The guide bearing controls the depth of cut into the edge face of a board A good example would be a chamfer bit A
35. to the table using the four socket screws and washers A for the stand head cap screws and washers B then tighten Note If you previously threaded all the fasteners into the 3 Turn the stand and table assembly upright and tight underside of the cast iron table the leveler screws will en all bolts already be in place If you didn t thread them in now The nut will sit on the top side of the flange that the router lift plate will rest on 40 065 ROUTER FENCE Before opening the fence have a clear work area to prevent the mixing of hardware CAST IRON TABLE 40 100C AND PHENOLIC TABLE 40 100P ONLY Note You will find 6 additional side bracket mounting fasteners in the fence hardware to attach the side brackets to the cast iron table These will not be required if you have purchased a complete kit because the same fasteners have been supplied with the table top For 40 047 MDF table for 40 100M use the wood screws supplied with your table to attach the mounting brackets to the table Note The hex head bolts and square nuts supplied with the fence are coarse thread and the hex head bolts supplied to attach the 40 130 Dust Enclosure are fine thread 1 Attach the two fence side rails with scale A to their 2 Remove the original 6 fence bracket mounting bolts mounting brackets B using 3 hex head bolts with flat A from the table and attach one fence mounting washers and square nuts C in the assembly order bracke
36. ts to the underside of the table B using 3 bolts shown in D 14 3 Attach the second mounting bracket to the oppo site side of the table A Note Adjust the height of the 3 bolts in the slotted holes in the rail bracket so that the rail is leveled with the table B h m um 4 eer O 7 eL M 5 Slide the 2 bolts and spacers to the middle of the fence body approx EM a 4 Insert an orange plastic spacer A with the short end down on one short T bolt B then insert the head of the bolt in the front upper slot in the fence body as shown in C 6 Install the orange dust shield A on the two bolts and secure in place using two flat washers B and 2 lock knobs C as shown in D 7 Secure the dust shield in place by tightening the two lock knobs Note The dust shield can be adjusted in height along the T slots 8 Insert a long T bolt A through all 6 holes in the fence body B and from the other side of the fence loosely attach a flat washer C and lockknob D Note Do not tighten down the lock knobs leave the T head of the bolts protruding from the fence 15 9 Slide the slot of one fence face onto the 3 elongat 10 Repeat with the second fence face on the other ed bolt heads then tighten the lock knobs on the side of the fence body other side of the fence 11 Insert a Phillips head screw A through both dust 13 Insert the square nut in the fence body slot A G
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