General International 40-125 Use and Care Manual
Contents
1. conditions and exceptions as listed below To file a Claim To file a claim under our Standard 2 year Limited Warranty or under our Limited Lifetime Warranty all defective parts components or machinery must be returned freight or postage prepaid to General International or to a nearby 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 International or an authorized distributor clearly stating the model and serial number of the unit if applicable and including an expla nation of the complaint or presumed defect in material or workmanship CONDITIONS AND EXCEPTIONS This coverage is extended to the original purchaser only Prior warranty registration is not required but documented proof of purchase i e a copy of original sales invoice or receipt showing the date and location of the purchase as well as the purchase price paid must be provided at the time of claim Warranty does not include failures breakage or defects deemed after inspection by General or General International to have been directly or indirectly caused by or result2. Note Some motors have pins or 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 mee Close but not touching 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 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 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 E E pa ME 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 LEVELING AND LOCKING THE ROUTER PLATE _ Y a TA 4 The routers collet should now be protruding out from 1 Using a straightedge check that the router plate is the top plate This will facilitate tool router bit level with the main table A changing from above the table eliminating the 2 Adjust the 10 leveling
3. available from you local General Interna 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 AAA AAA A AAA TE ANA p E A 1 Clean packing lubricant from the lift posts screws F Note The factory installed adjusting screw on the Milwau kee motor must be lined up and inserted into the hole D located inod lanp na BrackerE and the chain G Clean it by spraying with a solvant g which will dilute the grease and then wipe clean or use compressed air to blow dry After degreasing reapply some dry lubricant CLOSE UP WIEW Lies F I E il Duras es di ag oe Moris ad 1 Insert the crank handle in the black hole sur 3 Remove the rounded by digits as shown in H the table crank handle and flip the lift over in 2 To raise the lifting carriage on the router lift to the highest or maximum upward position turn the crank handle clockwise i 1 AA A A A E A AAA WT 4 Turn Allan cap screw A 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 as j
4. 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
5. Keep hands and other body paris 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 if Serious injury could occur if the table is tipped or if unintentional contact is made with spin ning router bit Keep all guards and safety devices in place and in good working order lf 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 th
6. LIST OF CONTENTS QTY a ROUTER LFT 050 di ee 1 b ROUTER LIFT CRANK HANDLE 1 c INSERT RING WRENCH 1 dle STARTER PIN ss fines ties eae 1 e HEX SOCKET HEAD BOLT 2 f 25 MM ALLEN KEY 1 g 3 MM ALLEN KEY 1 h 4 MM ALLEN KEY 1 i 6 MM ALLEN KEY 1 ASSEMBLY INSTRUCTIONS PREPARE THE TABLE FOR ROUTER LIFT Y 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 Excalibur Router Tables Note regarding installation on shop made or non Excalibur router tables Before constructing your own table top take note that Excalibur does not use leveler set screws in their router plates or lifts Instead each Excalibur router table includes it s own built in leveling system The reason for this is that on shop made table tops made of wood or MDF metal set screw lev elers in the router plate will eventually sink into the softer material of the table and become ineffective If you are installing this router lift in a shop made router table or on another brand of router table that does not include a built in levelling sytem PLEASE e THE EXCALIBUR 40 092 LEVELER BAR KIT DESIGNED SPECIFICALLY FOR USE WITH SHOP MADE TABLE TOPS
7. Note Model 40 075 for 40 200C Cast iron table shown The following steps apply to all Excalibur router table options j ae prod d a cr A DATO pet 7 gt E i E j i Le i A me 2 Use a straightedge to test the plate for level with the table top GA 3 From the underside of the table adjust the 4 phillips 4 Remove the lift and lock the adjuster screw in place head screws in the corners A up or down until the by turning the lock nut A clockwise tighten plate is flat and level with the table surface Note While tightening the lock nut make sure that the adjuster screw does not turn Confirm by re checking the leveling of the lift and table surface 5 After the four corners are set proceed to set the remaining 6 leveler screws and lock them in place ASSEMBLY INSTRUCTIONS MOUNTING A ROUTER Y 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 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
8. 017 60700002 914M061301 9140381902 60700009 60800005 60800018 908M06006 60800002 9236805Z0 901M08020 903M06018 903M04012 9180404018A 9236804720 60700009B 923690020 903M06030 60800020 919501000 912M06000 60100018 60800003 901M10070A 910M10005 90 1M06060A 901M10055 94300002 PARTS LIST 40 125 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 M6 X 25 M14 M6 M10 M6 X 6 6805ZZ M8 X 20 M6 X 18 M4 X 12 M4 X 4 X 12 680477 6900ZZ M6 X 30 S10 M6 M10 X 70 M10 M6 X 60 M10 X 55 12 42 X 1 78 QTY A rm o A rm rm o on oa rm oo aio oo wlo mn R IR I IR NOTES MODEL 40 125 Excalibur BY GENERAL INTERNATIONAL 8360 Champ d Eau Montreal Quebec Canada HIP 1Y3 Tel 514 326 1161 Fax 514 326 5565 Parts amp Service
9. SETUP amp OPERATION MANUAL DS ROUTER LIFT Router lift for Excalibur cast iron tables 40 070 and 40 075 MDF tables 40 047 and 40 049 amp phenolic tables 40 043 OF EXCANIDUr router tables and 40 045 Heavy duty massive router lift with 9 4 x 11 Y aluminum top plate Stable 4 post lift screw design amp chain drive lifting system controlling all 4 corners simul taneously MODEL F 40 125 p 7 AEN GENERAL 3 GENEAN Y Excalibur sims BY GENERAL INTERNATIONAL JANUARY 03 13 ESSA Copyright General International 01 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 THAN K YOU for choosing this Excalibur by General International model 40 125 Router Lift This router liff has been carefully tested and inspected before shipment and if properly used and maintained will provide you with years of reliable service For your safety as well as to ensure optimum performance and trouble free operation and to get the most from your investment please take the time to read this manual before assembling installing and operating the unit The manual s purpose is to familiarize you with the safe operation basic function and features of this router lift as well as the set up maintenance and identification of its parts and compo nents This manual is not intende
10. d as a substitute for formal woodworking instruction nor to offer the user instruction in the craft of woodworking If you are not sure about the safety of performing a certain operation or procedure do not proceed until you can confirm from knowledgeable and qualified sources that it is safe to do 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 lift and several versions of this manual may be in circulation if you own an earlier or later version of this unit this manual may not depict your machine exactly If you have any doubts or ques tions contact your retailer or our support line with the model and ser
11. e 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 IDENTIFICATION OF MAIN PARTS AND COMPONENTS A CLAMPING BOLT E STARTING PIN B CLAMPING BRACKET F CRANK HANDLE C CHAIN G POSTS SCREWS D INSERT RING WRENCH H LOCK NUT dr ir on Carefully unpack and remove the router lift and its components from the box and check for damaged or missing items as per the list of con tents below NOTE Please report any damaged or missing items to your General International distributor immediate ly
12. ial number of your unit for clarification GENERAL amp GENERAL INTERNATIONAL WARRANTY All component parts of General General International and Excalibur by General International 6 products are carefully inspected during all stages of production and each unit is thoroughly inspected upon completion of assembly Limited Lifetime Warranty Because of our commitment to quality and customer satisfaction General and General International agree to repair or replace any part or component which upon examination proves to be defective in either workmanship or material to the original purchaser for the life of the tool However the Limited Lifetime Warranty does not cover any product used for profes sional or commercial production purposes nor for industrial or educational applications Such cases are covered by our Standard 2 year Limited Warranty only The Limited Lifetime Warranty is also subject to the Conditions and Exceptions as listed below Standard 2 Year Limited Warranty All products not covered by our lifetime warranty including products used in commercial industrial and educational applications are warranted for a period of 2 years 24 months from the date of purchase General and General International agree to repair or replace any part or component which upon examination proves to be defective in either workmanship or material to the original purchaser during this 2 year warranty period subject to the
13. ing 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 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 war ranty 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 alertness Keep the work area well lit clean and free of debris Stay Alertl 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
14. ote 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 RECOMMENDED OPTIONAL ACCESSORIES Here are some of the optional accessories available from your local General International dealer For more information about our products please visit our website at www general ca 4 PC ZERO CLEARANCE 4 PC INSERT RING SET INSERT RING SET 40 076 40 074 Va Va 2 Ya amp 1 3 30 mm for 40 099 For Excalibur 9 4 x 11 router plates REDUCER COLLAR FOR REDUCER COLLAR FOR EXCALIBUR MODEL EXCALIBUR 40 125 ROUTER LIFT MODEL 40 125 440 312 ROUTER LIFT 40 314 Fits 3 2 diameter routers Fits 3 4 diameter routers Router lift 40 125 N 28 P EAS mL Ed Qam 36 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 REF NO 60800001A 60500002 60500003 60100017 60500005 60800021 60800004 60800007A 60700031 906M06025 60500009 60700010 912M14000 60500012 60700
15. screws B in the table opening need to remove the router lift system from the table as needed to level the plate on all four sides If to access the collet needed refer back to the instructions on page 6 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 INSTALLING THE STARTING PIN OO OO a Insert the two pins of the wrench in the two holes on Install the starting pin A into the threaded hole on the the insert ring then turn clockwise to unlock the ring router plate as shown The starting pin can be used as A and lift the insert ring up and out of the table inser needed for freehand or template routing only tion B 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 to be tightened If so proceed as follows m D DP HS 1 Lower the lift to its lowest position and then remove 3 Push the sprocket assembly B Fig 2 further along it from the table its slotted opening C Fig 1 by hand to add tension 2 Using a 6 mm allen key loosen the cap screw A to the chain Fig 1 4 While holding the sprocket assembly in position tighten the cap screw to secure it in place N
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