General International 40-250 M1 Use and Care Manual
Contents
1. 6 and components 7 8 ISH OMC Micmile E l 8 Placement within the shop Establishing a safety zone 9 V 3 s s 9 Assembly instructions 10 Basic adjustments amp controls 11 12 Connecting a power source 11 On off magnetic power switch 11 Forward reverse swilch 11 Speed change and belt adjustment 11 Spindle raising and lowering 12 Changing spimdibs 12 Operation instructions 12 13 Changing 12 Table INSE P 12 Operating controls for the fence 13 Workpiece hold down adjustment 13 Protection guard adjustment 13 Fence adjustment 13 ee Ve ale piel ple 24 M exa Een 14 Before operating 14 Cuter rOIallOnh 3 099372 alae aac 14 Grain 14 Straight edge shaping 15 DEON of CUL 43 5d a aca aiat Cara e RU Ee 15 Edge shaping long boards 15 Edge shaping short boards 15 22 te oe eee 16 oshaping sldes rus Re wi 16 Shaping contoured edges with rub collar2. O ROUTER ADAPTER 1 2 amp 1 4 2 GE om ee eee p SPINDLE 1 727 dated e hne ette ee ete s D TENSION SPRING 4 Qe SPINDLE 974 SX Od a eo desired d 1 2 WASHER orones e Toe desee 2 E 4 2 Se PING uu ees 1 G HENGE 2 Te DRAW BAR xenon ae D eee 27 2 7 2 We HANDLE dre Vas ii acd 1 I TABLE SLOT 2 Ve ALLEN KEY 3 NIN u Ss IE Ste Si 4 e 2 W ALLEN 4 E ES 1 2 X WRENCH 12 14 LANES C SSE R eere Y MULTIPLE WRENCH MENSEM TT L n 2 TABLE amp CABINET ALREADY MOUNTED PLACEMENT WITHIN THE SHOP ESTABLISHING A SAFETY ZONE THIS MODEL 40 250 M1 3 4 SPINDLE SHAPER IS HEAVY DO NOT OVER EXERT THE HELP OF AT LEAST ONE ASSISTANT OR A HOIST WILL BE NEEDED FOR THE FOLLOWING STEP TO LIMIT THE RISK OF SERIOUS INJURY OR DAMAGE TO THE MACHINE ANY EQUIPMENT USED TO LIFT THIS MACHINE SHOULD HAVE A RATED CAPACITY IN EXCESS OF 326 LBS 148 KG PLACEMENT WITHIN THE SHOP This
3. 16 Enclosed edge shaping 17 LOMBAO T 17 Multi pieces templates 17 Securing a template to the workpiece 18 Horizontal toggle 18 PIOIOCIIOTI s l ss Quee 18 SPECIALES sounds hara e ARP ans aces 18 Stacked ioa oed p CC RR YES a 19 BUM JOINS ss dob nde a S a 19 Tenoning 20 Parts list amp diagrams 21 23 RULES FOR SAFE OPERATION To help ensure safe operation please take a moment to learn the machine s applications and limitations as well as poten tial hazards Generale International disclaims real implied warranty and holds itself harmless for any injury that may result from improper use of its equipment 10 11 Do not operate the shaper when tired distracted or under the effects of drugs alcohol or any medication that impairs reflexes or alertness The working area should be well lit clean and free of debris Keep children and visitors at a safe distance when the shaper is in operation do not permit them to operate the shaper Childproof and tamper proof your shop and all ma chinery with locks master electrical switches and switch keys to prevent unauthorized or unsupervised use Stay alert Give your work your undivided attention Even momentary distraction can lead to serious injury Fine particulate dus
4. 2 Loosen the screw A and turn set screw D set screw for adjusting the fence to proper position then tighten screw Improper position G 3 Loosen the screw A and adjust set screw E for adjus ting the fence to proper position then tighten screw A Improper position H 4 Loosen the screw A and adjust set screw C for adjus I i ting the fence to proper position then tighten screw A Puls dna 4 Improper position 1 TOOL CHANGING When changing tools the process demands lots of attention and extra precautions keep in mind the following pro cedures 1 Spacers cutters and collars mounted on the spindle shaft must be in a fixed position There must be no move ment space or touching between parts Counter bores and holes of collars cutters or spacers must be in perfect condition with no rust or flaws Before installing the collars cutters and spacers on the spindle they must be cleaned properly The cutter must always be mounted as low as possible on the spindle oP CM Always check before starting the shaper that all parts on the spindle are locked in position BEFORE OPERATING The main drive motor should run for a few seconds to make sure that it is performing in the proper rotation Looking down at the spindle it Should be rotating counter clockwise this is the proper position Machine should stay on for a short period of time to make sure that all moving parts are properly positioned with no
5. EN a 4 J SK SN oo a A 9 0 mi 9 7 gt 69 y 093 0 eS RJ DJ aum S S ey e A Y N S 0 0 Yq lt D PART NO 40250 01 40250 02N 40250 03 40250 03A 40250 04 40250 04A 40250 04B 40250 05 40250 06 40250 07 40250 08 40250 09 40250 10 40250 1 1 40250 12 40250 12A 40250 13 40250 14 40250 15 40250 16 40250 16A 40250 17N 40250 19 40250 20 40250 21 40250 22 40250 23 40250 24 40250 25 40250 26 40250 27 40250 28 40250 29 40250 30 40250 31 40250 32 40250 33 40250 34 40250 35 40250 36 40250 37 40250 38 40250 39 40250 40 40250 41 40250 42 40250 43 40250 44 40250 45 40250 46 40250 47 40250 48 40250 49 40250 50 40250 51 40250 52 40250 53 40250 54 40250 55 40250 56 40250 57 40250 58 40250 59 40250 60 40250 61 40250 62 40250 63 40250 64 40250 65 PARTS LIST 40 250 DESCRIPTION QTY PARTNO DESCRIPTION QTY STAND ASSEMBLY 1 40250 66 GEAR SWITCH 1 40250 67 COLLAR SCREW 5 32 X 1 L 2 40250 68 1 SCREW 5 32 X 4 L 2 40250 69 GEAR SHAFT FORWARD REVERSE SWITCH 1 40250 70 HEX NUT 5 8 FORWARD REVERSE SWITCH COVER 1 40250 71 HEX NUT 3 4 CONNECTOR 4 40250 72 COLLAR 3 4 X 1 2 NUT HEX 5 32 2 40250 73 COLLAR 3 4 X 3 4 2 BAR 2 40250 74 COLLAR 3 4 X 1 MITER GAUGE 3 40250 75 SPINDLE 3 4 SCREWS SET 5 16 X 5 8 L 1 40250 76 SHAFT INSERT TABLE 1 40250 77 KEY 5MM IN
6. 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 repair or replace any part or component which upon examination proves to be defective in either workmanship or material to the original purchaser during this 2 year warranty period subject to the conditions and exceptions as listed below To file a Claim To file a claim under our Standard 2 year Limited Warranty or under our Limited Lifetime Warranty all defective parts components or machinery must be returned freight or postage prepaid to General 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 retu
7. 2 POINTER 1 40250 127 PLASTIC COVER SCREW SMM X 10MM 1 40250 128 FENCE HOUSING 1 V BELT K 23 40250 129 FRONT GUARD SHAFT GUIDE 1 40250 130 WING SCREW 2 PLATE 1 40250 131 SCREW 4 MOTOR PLATE 1 40250 132 WASHER 2 SCREW 1 2 X 1 1 40250 133 BOLT 2 SCREW 5 16 X 1 4 40250 134 SCALE 2 GEAR SHAFT 1 40250 135 ADJUSTMENT KNOB 2 GEAR SHAFT BASE 1 40250 136 SET SCREW 2 HANDWHEEL 1 40250 137 PUSH STICK 2 KNOB 1 40250 138 T BRACKET 2 WASHER 5 16 2 40250 139 PIN SET SCREW 5 16 X 5 8 1 40250 140 ROUTER 1 4 1 HANDWHEEL 1 40250 141 ROUTER 1 2 SCREW 1 4 X 1 1 40250 142 MULTIPLE WRENCH SHOWN LOCK BAR 1 40250 143 WRENCH 12 14 MM NOT SHOWN LOCK SCREW 1 40250 144 ALLEN KEY 3MM NOT SHOWN GEAR WASHER 1 40250 145 ALLEN KEY 4MM NOT SHOWN MODEL 40 250 M1 ARS AN GENERAL ie INTERNATI NAL y WS 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
8. OR CUTTERHEAD KEEP HANDS AT A DISTANCE OF 12 AWAY FROM ANY CUT TING DEVISES Inside edge work piece are shaped the same way as out side edges When the whole edge needs to be shaped the operator must use a pattern The work piece must be placed on table before starting the motor The operator must shape the whole work piece by feeding into the cutters NEVER ATTEMPT TO PERFORM THIS PROCEDURE WITHOUT A RING GUARD SIMILAR SAFETY DEVICE OVER CUTTERHEAD OPERATION MUST BE AWARE AT ALL TIMES OF THE FEED DIRECTION OPERATION MUST NOT BE LEFT UNATTENDED 1 Use a firm grip to ease the edge into the cutters until stopped by the collar 2 Keep pushing straight while turning and feeding the work piece continue until the cut is finished Turn power switch in the off position and remove the work piece only once the cutters have come to a com plete stop NEVER PERFORM ENCLOSED EDGE SHAPING WHEN THERE IS LESS THAN 12 OF WOOD MATERIAL ALL AROUND THEOPEN ING THE ONLY TIME THIS CAN BE DONE IS IF THE WORK PIECE IS ATTACHED TO A LARGER WOOD BASE NEVER PER FORM ENCLOSED HAPING WHEN WORK PIECE OPENING IS MALLER THAN TWICE THE DIAMETER IN ANY DIRECTION TEMPLATES A template serves as guide for the cutter The template must be made of scrap material thick enough to pro vide a solid bearing edge against a collar recom mended size 3 4 When the work piece requires all around shaping the templ
9. excessive vibration If any adjustments are required disconnect machine from the power source before properly adjusting ALL WORK OPERATORS MUST READ AND UNDERSTAND THE MANUAL BEFORE STARTING ANY WORK OPERATIONS ON THE SHAPER ALL SHAPER OPERATIONS MUST BE USED WITH THE PROPER GUARDS AND ANY OTHER SAFETY REQUIREMENTS TO INSURE SAFETY OF THE OPERATOR CUTTER ROTATION COUNTER CLOCKWISE SETUP CLOCKWISE SETUP Cutter must be positioned as work piece must be fed Cutter must be positioned as work piece must be fed from right to left from left to right GRAIN DIRECTION The work piece should always be shaped in the same direction as the grain if possible When cut against the wood grain woods as redwood fir and oak will leave a rough or slightly splintered edge WHEN DEEP CUTS ARE REQUIRED THEY WILL NEED STRONG POWER AND A PUSHING FORCE IN ORDER TO CONTROL THE CUT DEEP CUTS CAN ALSO CAUSE THE WOOD TO SPLIT OR SPLINTER THIS MAY LEAD TO LOSS OF CONTROL OR INJURES TO THE WORK OPERATOR WHEN A FINISHED EDGE IS NOT TO YOUR SATISFACTION CUT A FEW MORE TIMES WITH NO MORE THAN 1 16 DEEP PRE CUT STOCK ON BAND SAW 1 16 WHENEVER POSSIBLE THE TRAILING BOARD EDGE WILL SPLINTER WHEN SHAPING ACROSS THE GRAIN THE BEST SOLUTION WOULD BE TO CUT THE BOARD 1 4 OVERSIZE IN WIDTH SHAPE THE BOARD AND SIMPLY TRIM OFF THE EXCESS STRAIGHT EDGE SHAPING The work piece must always be against the fence to per form straight edge shaping
10. 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 shaper and several versions of this manual may be in circulation if you own an earlier or later version of this unit this manual may not depict your machine exactly If you have any doubts or ques tions contact your retailer or our support line with the model and serial number of your unit for clarification GENERAL amp GENERAL INTERNATIONAL WARRANTY All component parts of General General International and Excalibur by General International products are carefully inspected during all stages of production and each unit is thoroughly inspected upon completion of assembly Limited Lifetime Warranty Because of our commitment to quality and customer satisfaction General and General amp International agree to repair or replace any part or component which upon examination
11. 8 of surface edge ride against the entire edge cannot be shaped C However the use of a pattern or template will permits shaping of the entire edge When work piece needs to be shaped alt around the perimeter hold firmly and press the work straight into the cutter until the collar established depth of cut While holding firmly keep feeding the work so the point of contact on the edge is always 90 to the collar When work piece is not contoured all around start the cut as shown in D Small size materials need a special shaping jig E 16 Using the existing bolts the fence attach a taller shop made fence when the shaper fence does not support firmly support taller stock Note To avoid interference with mounting screw make sure the bolt holes are on your shop made tall fence are countersunk At least 1 8 edge thickness START POSITION Remove entire fence assembly place jig carefully at the desired depth of cut clamp to table securely It is impor tant with arc and circle shapes that the work piece must be roughly cut to desired size and curve of the finished piece before being shaped The curve of the jig must match the work piece exactly The work piece must be firmly attached to the jig This operation should always be in use of a ring guard or a similar safety device over the cutter head NEVER ATTEMPT SHAPE FREEHAND OPERATOR SHOULD NEVER RACE HANDS NEAR THE CUTTERS
12. REMOVE THE LOCK OUT KEY AND STORE IT IN A SAFE PLACE OUT OF THE REACH OF CHILDREN WHENEVER THE SAW IS NOT IN USE SPEED CHANGE AND BELT ADJUSTMENT The 40 250 Shaper has been designed with 2 speed pulley 8000 RPM amp 10000 RPM Follow these procedures to change speed and adjust the proper belt tension 1 Disconnect machine from power source 2 Open the base door 3 Turn lock handle A counter clockwise to release belt tension Move the belt to the other groove B Push handle bar C to get proper belt tension Tighten the lock handle A Close door oS 12 Adjust the main shaft to the up or down position 1 Loosen the front hand wheel A 2 Turn the Hand wheel B to the desired height 3 Tighten the hand wheel A 3 4 and 1 2 spindle assemblies are supplied with your shaper The assemblies are locked in a tapered seat with draw bar and nut To change spindles One wrench must be placed on the flats on top of the spindle and the se cond wrench on the draw bar nut this allows the spindle to loosen Turn the nut two times tap gently upwards with a wooden block this will loosen the spindle from the taper Remove nut and lift out the spindle OPERATION INSTRUCTIONS CHANGING CUTTERS All spindle sizes are equipped with a safety lock nut left hand threads are found above the large spindle nut To ae SPINDLE mount or change culter first remove the safety lock nut Remove the spindle
13. SERT TABLE 1 40250 78 BEARING 6205LLB INSERT TABLE 1 40250 79 QUILL TABLE 1 40250 80 SPINDLE 1 2 EXTENSION WING 1 40250 81 3 8 1 HEX NUT 3 8 14 40250 82 HEX NUT 1 2 SPRING WASHER 3 8 20 40250 83 COLLAR 1 2 X 3 4 2 WASHER 3 8 17 40250 84 COLLAR 1 2 X 1 2 DUST REMOVABLE DOOR 1 40250 85 COLLAR 1 2 X 1 3 8 X 3 41 SCREW 12 40250 86 BEARING 62057 DOOR LOCK LEVER 1 40250 87 SNAP RING PIN 2 40250 88 SPINDLE PULLEY MOTOR COVER 1 40250 89 LOCK WASHER 1 HANDLE LOCK 1 40250 90 LOCK NUT 1 ELECTRIC CORD 1 40250 91 LOCK BOLT CONNECTOR 1 40250 92 LOCK NUT SPINDLE BASE 1 40250 101 2 HEX NUT 1 2 6 40250 102 TENSION SPRING PLATE 4 SCREW 3 8 X 1 12 40250 103 RETAINER 4 SCREW 3 8 X 1 1 4 1 40250 104 KNOB 2 COLLAR 1 40250 108 UPPER FENCE HOUSING HANDLE 1 40250 109 LOCK LEVER 2 KEY 1 40250 110 CARRIAGE BOLT 2 SET SCREW 5 16 X 3 8 1 40250 111 LEVER 2 MOTOR PULLEY 1 40250 112 WASHER 2 KNOB 1 40250 113 KNOB MOTOR BASE 1 40250 114 2 MOTOR 1 40250 115 SCREW 4 SCREW 5 16 X 5 8 4 40250 116 BOLT 2 SPRING 1 40250 117 FENCE TRAVEL BUSHING 2 SPRING SHAFT 1 40250 118 LOCK HANDLE 2 WASHER 1 2 1 40250 119 WASHER 2 SPRING WASHER 1 4 7 40250 120 2 SCREW 1 4 X 3 4 40250 121 T SCREW 2 WASHER 1 4 7 40250 122 FENCE 2 SCREW 1 2 1 40250 123 BOLT 2 WASHER 5 16 8 40250 124 SET SCREW 8 SPRING WASHER 1 4 9 40250 125 KNOB SCREW 2 HEX NUT 5 16 12 40250 126 THEX NUT 3 8
14. SETUP amp OPERATION MANUAL 2 4 WOOD SPINDLE SHAPER FEATURES amp Extra large heavy cast iron table with a smooth ground surface finish Two 2 spindle speeds with reverse Aluminum Independent left and right fences feature precision micro adjustment Two 2 spindles included 1 2 Item 40 215 amp 3 4 40 220 Tslot miter gauge for better workpiece control Industrial motor protected against dust by a totally enclosed cabinet Fence system cutter head guard includes a cutter guard spring hold downs and a built in 4 dust collection outlet 1 4 amp 1 2 router bit adapters included 7 Magnetic 2 step safety switch to prevent unwanted or unintentional start up is equipped with an extra large easy access stop panel and a lock out key to prevent unauthorized use of the machine SPECIFICATIONS TABLE SIZE 27 x 25 686 x 635 mm TABLE HEIGHT 34 864 mm SPINDLE OPENING DIAMETERS 7 3 1 2 amp 3 177 89 amp 76 mm SPINDLES DIAMETERS 1 2 amp 3 4 13 amp 19 mm SPINDLE TRAVEL 3 76 mm SPINDLE SPEEDS 8000 amp 10 000 RPM FENCE SIZES ALUMINUM 3 x 11 76 x 279 mm DUST CHUTE OUTLET 4 102 mm OVERALL DIMENSIONS L X W X H 21 1 4 x 17 1 4 x 42 1 2 540 x 438 X 1080 mm MOTOR 3 HP 220 V 1 PH WEIGHT NET 326 LBS 148 kg SHIPPING 343 LBS 156 kg 40 250 MI VERSION 2_REOVISION 1 December 14 11 Copyri
15. WET OR DAMP LOCATIONS GROUNDING INSTRUCTIONS In the event of an electrical malfunction or short circuit grounding reduces the risk of electric shock to the ope rator The motor of this machine is wired for 220V single phase operation and is equipped with a 3 conductor cord A and a 3 prong grounded plug B to fit a match ing grounding type receptacle C DO NOT MODIFY THE PLUG PROVIDED If it will not fit your recepta cle have the proper receptacle installed by a quali fied electrician CHECK with a qualified electrician or service person if you do not completely understand these grounding instructions or if you are not sure the tool is properly grounded CIRCUIT CAPACITY Make sure that the wires in your circuit are capable of handling the amperage draw from your machine as well as any other machines that could be operating on the same circuit If you are unsure consult a qualified electrician If the circuit breaker trips or the fuse blows regularly your machine may be operating on a circuit that is close to its amperage draw capacity However if an unusual amperage draw does not exist and power failure still occurs contact a qualified technician or our service department EXTENSION CORDS The use of an extension cord is not generally recom mended for 220V equipment If you find it necessary use only 3 wire extension cords that have 3 prong grounding plug and a matching 3 pole receptacle that accepts the tool s
16. ate may be built from various sections fixed together 17 SECURING A TEMPLATE TO THE WORK PIECE Various methods are used to secure template to the work piece The operator should select the best method to secure the template to the work piece based on the size shape and constriction of the template and work piece C clamps can be used to securely hold a template The work piece may be placed against the template when the work piece is large enough to surpass the using dowels as anchor points and wooden blocks to front of table while still leaving space for the desired help the operator in guiding the work piece through cut the cut HORIZONTAL TOGGLE CLAMP Horizontal toggle clamp are useful when the regular C a Toggle clamp clamps cannot allow the freedom of movement required c we C in shaping No additional hand pressure is necessary for the operator to control the work piece Anchor points like dowels are necessary with this setup PROTECTION The operators should take precautions to protect themselves and all others around the work area and the machine itself for improper use Never leave machine unattended while it is running the operator needs to be very focused and attentive and not looking elsewhere or carrying on conversation while using the machine Carelessness or inattention will result in seri ous injuries and damages SPECIAL CUTS The illustrations in this section show the profile or section vie
17. follow these procedures to set up Disconnect machine from the power source 2 Fence faces must be parallel properly in line or offset If necessary and securely tightened 3 Cutter must be rotated and inspected for clearance Position the leading face of a cutter head blade at 90 to the infeed fence and adjust the spindle to the desired height of the cut At the same time check the desired depth of cut with the blade in the 90 position DEPTH OF CUT The depth of cut is the distance from the outside circumference edge of the collar which the work rides against to the outside edge of the cutter The depth of the cut is determined by the position of the fence relative to the cutter head or by the use of shaper collars 1 Spindle must be locked 2 Right guard should be installed wherever possible 3 Connect the power source 4 Make a test cut on a piece of scrap with the same thickness as the work piece Note To determine if the cut profile and depth are correct you will only need a short cut 5 Make adjustments if required or proceed shaping using the work piece The work piece must be at least 12 inches long when edge shaping long boards 1 To hold work piece down and against the fence use the hold downs and horizontal clamps If the work piece is too wide for the horizontal clamps clamp a scrap board to the table to keep the work piece against the fence 2 Check the rotation of the cutterhead and be
18. ght General International 12 2011 5275 NN GENN GENERAL NY INTEHNATIC TON ADY 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 General International model 40 250 MI 3 4 spindle shaper This shaper has been carefully tested and inspected before shipment and if properly used and maintained will provide you with years of reliable service For your safe ty 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 shaper as well as the set up maintenance and identification of its parts and compo nents This manual is not intended as a substitute for formal woodworking instruction nor to offer the user instruction in the craft of woodworking If you are not sure about the safety of performing a certain operation or procedure do not proceed until you can confirm from knowledgeable and qualified sources that it is safe to do 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
19. machine should be installed and operated only on a solid flat and stable floor that is able to support the weight of the molder and the operator Using the dimensions shown as a guideline plan for placement within your shop that will allow the operator to work unencumbered and unobsiructed by foot traffic either passing shop visi tors or other shop workers or other tools or machinery ESTABLISHING A SAFETY ZONE For shops with frequent visitors or multiple operators it is advisable to establish a safety zone around shop machi nery A clearly defined no go zone on the floor around each machine can help avoid accidents that could cause injury to either the operator or the shop vi sitor It is advisable to take a few momenis to either paint using non slip paint or using tape define on the floor the limits or perimeter of each machines safety zone Take steps to ensure that all operators and shop visitors are aware that these areas are off limits whenever a machine is running for everyone but the individual operating the unit CLEAN UP The protective coating on the table prevents rust from forming during shipping and storage Remove it by rub bing with a rag dipped in kerosene mineral spirits or paint thinner Important Dispose of potentially flammable solvent soaked rags according to manfacturer s safety recommendations A putty knife held flat to avoid scratching the surface may also be used to scrape off the coa
20. nded while it is running or with the power on Use of parts and accessories NOT recommended by GENERAL amp INTERNATIONAL may result in equipment malfunction or risk of injury Never stand on machinery Serious injury could result if the tool is tipped over or if the cutting tool is uninten tionally contacted Always disconnect the tool from the power source before servicing or changing accessories such as cutters or before performing any maintenance or cleaning or if the machine will be leff unattended Make sure that the switch is in the OFF position before plugging in the power cord Make sure the tool is properly grounded If equipped with a 3 prong plug it should be used with a three pole receptacle Never remove the third prong Do not use this shaper for other than its intended use If used for other purposes GENERAL INTERNATIONAL disclaims any real implied warranty and holds itself harmless for any injury which may result from that use AAN ELECTRICAL REQUIREMENTS N BEFORE CONNECTING THE MACHINE THE POWER SOURCE VERIFY THAT THE VOLTAGE YOUR POWER SUPPLY CORRESPONDS WITH THE VOLTAGE SPECIFIED ON THE MOTOR I D NAMEPLATE A POWER SOURCE WITH GREATER VOLTAGE THAN NEEDED CAN RESULT IN SERIOUS INJURY TO THE USER AS WELL AS DAMAGE TO THE MACHINE IF IN DOUBT CONTACT A QUALIFIED ELECTRICIAN BEFORE CONNECTING TO THE POWER SOURCE THIS TOOL IS FOR INDOOR USE ONLY DO NOT EXPOSE TO RAIN OR USE IN
21. nut by placing one wrench on the 4 carey LOCK NUT spindle nut and another wrench on the flats on top of the spindle Safety lock nut must be replaced before starting work operations AVAILABLE Item 40 225 1 optional arbor 440 230 1 1 4 optional arbor SPINDLE NUT AN gt SPACER TABLE INSERT 40 250 spindle shaper has been designed with three spindle inserts The 3 table inserts have an opening of 7 178 mm 3 1 2 89 mm and 3 76 mm OPERATING CONTROLS FOR THE FENCE Depending on the type of work you are shaping either side of the fence can be moved freely Fence can be moved by loosening wing screws proper setting can be achieved by turning knob B The turning knob B is with scale for accurate setting Wing screws A must be then tightened to fix in position Each fence half should be adjusted as close to cutter head as possible To position fence closer to cutter head loosen handle C Fence plate D must be moved to correct position Then tighten the handle C WORKPIECE HOLD DOWN ADJUSTMENT PROTECTION GUARD ADJUSTMENT Loosen knob A turn tension plate to desired angle then tighten the bolt FENCE ADJUSTMENT The fence is fixed the position before shipment follo wing the instruction for when need to do the minor fence adjustment 1 Loosen the screw A and turn set screw B for adjust the fence to proper position then tighten screw Improper position F
22. pleted plug the power cord into an appropriate outlet Refer back to the seclion entitled ELECTRICAL REQUIREMENTS and make sure all requirements and grounding instructions are fol lowed When cutting operations have been completed SWITCH OFF unplug the saw from the power source TO AVOID UNEXPECTED OR UNINTENTIONAL START UP MAKE SURE THAT THE POWER SWITCH ON THE SAW IS IN THE OFF POSITION BEFORE CONNECTING TO A POWER SOURCE TO AVOID RISK OF SHOCK OR FIRE DO NOT OPERATE THE UNIT WITH A DAMAGED POWER CORD OR PLUG REPLACE DAMAGED CORD OR PLUG IMMEDIATELY ON OFF MAGNETIC POWER SWITCH This model 40 250 MI is equipped with a Magnetic 2 step safety switch to prevent unwanted or unintentional start up and unauthorized use of the saw The switch assembly is equipped with a GREEN START but ton A an extra large easy access RED stop panel B and a lock out key C To start the shaper Insert the lock out key C and press on the GREEN START button A To stop the shaper Press on the RED STOP panel B Once the RED STOP panel has been pressed the saw can only be started by pressing once again on the RED STOP panel to release the green button then by pressing on the green button FORWARD REVERSE SWITCH When reverse rotation needs to be used power must be switched OFF and press the reverse button TO PREVENT UNWANTED OR UNAUTHORIZED START UP OR USAGE
23. plug Repair or replace a damaged extension cord or plug immediately If you find it necessary to use an extension cord with your machine make sure the cord rating is suitable for the amperage listed on the motor I D plate An under sized cord will cause a drop in line voltage resulting in loss of power and overheating The accompanying chart shows the correct size extension cord to be used based on cord length and motor I D plate amp rating If in doubt use the next heavier gauge The smaller the number the heavier the gauge TABLE MINIMUM GAUGE FOR CORD TOTAL LENGTH OF CORD IN FEET 220 VOLTS 25 FEET 50 FEET 100 FEET 150 FEET RATING NR Not Recommended 3 4 spindle shaper 40 250 M1 A WORKPIECE HOLD DOWN E FORWARD REVERSE SWITCH 1 SPINDLE HEIGHT HANDWHEEL B GUARD MOTOR ACCESS DOOR J TABLE EXTENSION C GUARD LOCK KNOB G MAGNETIC SAFETY SWITCH K MAIN TABLE D GUIDE FENCE H CABINET Carefully unpack and remove the shaper 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 HEAD LIST OF CONTENTS QTY LIST OF CONTENTS QTY SAFER CUBRES P me euet dichas ERES 2 BR CAM DET
24. rn 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 the 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 operation 5 Electrical requirements 6 Grounding instructions 6 B 6
25. sure to feed the work piece against the ration of cutterhead 3 To make a smooth cut the work piece should be fed slowly and steadily with firm even pressure Note The rate feed depends on depth of cut and experience of operator EDGE SHAPING SHORT BOARDS When edge shaping short boards never attempt to hand guide any stock less than 12 inches long or narrower than 3 inches without the use of a special guide Special Guide When end shaping narrow stock at least one half of the work piece end must be in contact with either the outfeed or infeed fence NEVER ATTEMPT SHAPE NARROW PIECE WITHOUT SPECIAL GUIDE THE WORK PIECE MAY STAR ROCKING INTO THE CUTTER HEAD CAUSING MINOR OR MAJOR INJURY TO THE WORK OPERATOR When shaping across the grain some woods are more likely to chip out or splinter It is recommended to shape cross grain sides first Any chipping that does occur will be removed by the subsequent cut with the grain SHAPING CONTOURED EDGES WITH RUB COLLARS To shape contoured edges the fence assembly should be removed In order to control the work piece and limit the depth of cut an anti friction collar must be used A The purpose of the collar is to ride against the work piece at the same time the collar establishes the depth of cut B The collar can be positioned above or below the cutters The ring guard should be used whenever possible Note The collar requires at least 1
26. t is a carcinogen that can be hazardous to health Work in a well ventilated area and whenever possible use a dust collector Wear face eye ear respiratory and body protection devices Do not wear loose clothing gloves bracelets neck laces or other jewelry while the molder is in operation Wear protective hair covering to contain long hair and wear non slip footwear Be sure that adjusting wrenches tools drinks and other clutter are removed from the machine and or the table surface before operating Keep hands well away from knives and all moving parts Use a brush not hands to clear away chips and dust Use recommended speed cutters or bits accessories and work piece material Be sure the cutters are securely locked in the cuftter head before starting the machine 12 13 14 15 16 17 18 19 20 21 22 Make sure the cutting tool is running at full operating speed before feeding the work piece Always use clean properly sharpened cutters Dirty dull bent cracked or otherwise damaged cultters or bits are unsafe and can lead to accidents Feed the stock into the cutter or bit against the rotation direction of the cutter or bit Never run the stock between the fence and the cutter Keep guards in place and in working order If a guard must be removed for maintenance or cleaning be sure it is properly re attached before using the tool again Never leave the machine unatte
27. ting followed by clean up with solvent Note Avoid rubbing the molder s painted surfaces as many sol vent based products will remove paint Tip To prevent rust apply a light coating of paste wax or use regular applications of any aftermarket surface protectant or rust inhibitor ASSEMBLY INSTRUCTIONS For your convenience this shaper is shipped from the factory partially assembled and requires only minimal assem bly and set up before being put into service rA Apart the lock lever B and T screw from the hardware lock lever screws A bag and assemble these two parts to go through the hole on the bracket screw it clockwise and leave some space then slide the fence C through the T screw till to proper position and tightened by lock lever Place the plate guard on top of guard and tightened Place two bars on the hole of bracket and tightened by two knobs D Install the safety guard to front of by hex screw F plate guard and tightened by two knobs E in proper position Install two bars to the retainer and use the tension Insert the T screw on retainer H to go through the table spring plate to go through the retainer and tightened t slot and move to proper position and tightened by by knob G knob Insert the tension spring plate to go through the retainer and tighten the bolt I 10 BASIC ADJUSTMENTS amp CONTROLS CONNECTING TO A POWER SOURCE Once the assembly steps have been com
28. utting procedures When shaping the work pieces one must be ted top side up and the other is fed bottom side up TONGUED JOINT similar to the glue joint both fences are kept in line for the tongued joint and must be adjusted for 1 4 depth of cut with no reduction in stock width With this joints both work pieces are fed with the same side up B DROP LEAF JOINT A drop leaf joint work piece is shaped using Drop Leaf Bead cutter the table work piece is shaped with d Drop Leaf Cove cutter This joint type the whole edge of both work pieces are shaped the same side up and allows 1 16 reduction in width Adjust the infeed fence to reduce the work piece width by 1 16 and adjust the outfeed fence to compensate for stock removed C TENONING Figure A demonstrates the tenoning fixture which shows a miter gauge equipped with a hold down for shaping the ends of narrow work piece A Miter gauge can also be adapted to cut square and centered tenons at the ends of leg for table chairs etc Secure leg to the jig and posi tion for cut B First cuts must be made with the same jig setting and spin dle height When the first several cuts have been made 4 reposition the leg on the jig for each succeeding cut Miter gauge Note If legs are tapered Use a wedge set the side facing the cutter to 90 degrees vertical C Taper leg REDE Z Es 20 S P D 9
29. ws made by the cutters The most efficient cutters are carbide tipped to ensure cleaner cuts and longer cutter life Small cutters may be solid carbide some use inserts Since there is such various choices the operator is limited only by his experience and imagination 18 STACKED CUTTERS A variety of timesaving and interesting cuts can be made in a single setup by stacking the cutters A When stack ing cutters extra care should be taken Check that cutters have no flaw nicks or just Cutters must cleaned and per fectly balanced before placing in the stacked poisiton Groove cutter Flip ov r cut Door shaping requires wo When the stock is flipped First shaping cut with the Same cut with the stock operations demonstrates over and the sash cutter sash cutter for the match flipped over sash cut for the first opera witha 1 4 groove cutterto ing door stile sash tion complete the cut Rabbet cut Groove cutter First shaping out for a window sash stile using a sash Both cuts needed for a window sash rail end The first cutter collar and a 1 2 groove cutter operation at top is a rabbet cut made with a groove cutter The second operation is performed with a stub spindle and button head screw BUTT JOINTS GLUE BUTT JOINT To perform a glue butt joint both fences must be kept inline and adjusted for a depth of cut A Both cuts on the work pieces are part edge cuts that do not reduce the width of material during c
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