General International 40-200C Use and Care Manual
Contents
1. co MODEL 40 200 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 desired2. 60100017 INSERT RING 40125 05 60500005 GEAR SHAFT 40125 06 60800021 CARRIAGE PLATE 40125 07 60800004 CLAMP POST 40125 08 60800007A TOP PLATE 40125 08A 60700031 STARTING PIN 40125 08B 906M06025 PHILLIPS HEAD SCREW 40125 09 60500009 CAM GEAR 40125 10 60700010 ELLIPTICAL WHEEL 40125 11 912M14000 NYLON NUT 40125 12 60500012 GEAR SPROCKET 40125 13 60700017 LOCK GUIDE NUT 40125 14 60700002 UPPER GUIDE NUT BASE 40125 15 914M061301 FLAT WASHER 40125 16 9140381902 FLAT WASHER 40125 17 60700009 LIFT CRANK HANDLE 40125 18 40125 19 60800005 60800018 SLEEVE SCALE PLATE 40125 20 908M06006 SET SCREW M X 40125 21 40125 22 60800002 923680570 BUSHING BEARING 680577 40125 23 901 08020 SCREW 8 20 40125 24 903 06018 FLAT 5 HEAD SCREW M6 X 18 40125 25 903 04012 FLAT 5 HEAD SCREW M4X 12 40125 26 40125 27 9180404018 923680470 KEY BEARING M4X4X 12 680477 40125 28 60700009B CRANK HANDLE SLEEVE 40125 29 923690070 BEARING 690077 40125 30 903M06030 FLAT HEX SOCKET HEAD SCREW M6 X 30 40125 31 40125 32 60800020 919501000 CHAIN C RING S10 40125 33 912M06000 NYLON NUT M 40125 34
3. O 111111 0 oPPPPPPPP cc OO 31333130 O UNPACKING CNT D 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 a ROUTER LIFT b ROUTER LIFT CRANK HANDLE INSERT RING WRENCH d STARTER PIN e HEX SOCKET HEAD BOLT f 2 5 MM ALLEN KEY g 3 MM ALLEN KEY h 4 MM ALLEN KEY i 6 ALLEN KEY LIST OF CONTENTS 55555555555 111111111312 40 130 DUST COLLECTION KIT o 1414414 RIGHT SIDE PANEL NK CU UD o il b BOTTOM PANEL d e REAR PANEL e d LEFT SIDE PANEL FRONT PANEL DUST HOSE g DUST PORT h HOSE CLAMP i HEX HEAD BOLT LOCK WASHER Linn FLAT WASHER i VH M PHILLIPS HEAD SCREW SHORT m PHILLIPS HEAD SCREW LONG UNPACKING CNT D 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 a 24 X 32 CASFIRON TABLE CAST IRON TABLE 28 TABLE DE TOUPIE EN 32 X 24 b HEX NUT G
4. use the wood screws supplied with your table to atiach the stand to the table UT 6000 9 1 With the table upside down remove the 4 mounting screws and washers for the stand 2 Attach the stand to the table using the four socket head cap screws and washers B then tighten 3 Turn the stand and table assembly upright and tighten all bolts checking that the table is level with the floor Adjust the leveling feet as needed ENGAGING DISENGAGING THE STAND CASTERS The stand caster system allows you to engage disen gage the stand casters in order to move the router table as needed within the shop Push the pedal down to engage the stand casters Pull the pedal up to disengage the stand casters NEVER MOVE THE ROUTER TABLE WHILE THE ROUTER IS RUNNING AS THIS CAN LEAD TO SERIOUS INJURIES ALWAYS MAKE SURE THAT THE WHEELS OF THE STAND HAVE BEEN DISENGAGED AND THAT THE STAND HAS BEEN COMPLETELY IMMOBILIZED BEFORE TURNING ON THE ROUTER AND STARTING TO CUT Note If you previously threaded all the fasteners into the underside of the cast iron table the leveler screws will 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 ASSEMBLY INSTRUCTIONS 40 080 ROUTER FENCE 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 CON
5. 60100018 INSERT WRENCH 40125 35 40125 36 60800003 901M10070A BACK LASH LOCK CAP SCREW 10 70 40125 37 910 10005 NUT 10 40125 38 901 06060 SCREW 6 60 40125 39 901 10055 SCREW 10 55 40125 40 94300002 O RING 12 42 X 1 78 ro 0 10 40 4100 oo a 1 Dust Collection Kit 440 130 PART NO 40130 01 REF NO 32240001 PARTS LIST 140 130 DESCRIPTION FRONT BOX PANEL SPECIFICATIONS 40130 02 32240002 RIGHT BOX PANEL 40130 03 906 04006 PHILLIPS HEAD SCREW 40130 04 906 04010 PHILLIPS HEAD SCREW 40130 05 32240003 HINGE 40130 06 32240004 LEFT BOX PANEL 40130 07 40130 08 32240005 32240006 REAR BOX PANEL POWER CORD CLAMP 40130 09 32240007 BOTTOM BOX PANEL 40130 10 32240008 VENT BASE 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 M6 X 12 40130 16 915M06000 LOCK WASHER M 40130 17 40130 18 914 061301 32240011 FLAT WASHER MAGNET M 40130 19 32240012 DUST OUTLET 40130 20 952002034 HOSE CLAMP
6. 915M06000 LOCK WASHER M 40075 07 901 06016 SCREW M 16 Phenolic table with model 840 200 PART NO 40045 01 REFERENCE NO 3224U014A PARTS LIST 440 045 DESCRIPTION PHENOLIC TABLE 3224 SPECIFICATION 40045 02 903M06030 FLAT HEX SOCKET HEAD SCREW M 30 40045 03 60700030A TSLOT GUIDE RAIL 3224 40045 04 902M05012 ROUND SOCKET HEAD SCREW M5X 12 40045 05 905M06040 FLAT HEAD SCREW M X 40 40045 06 910M06000 HEX NUT 40130 40045 07 901M06016 HEX SOCKET HEAD SCREW 3224 M 16 40045 08 40045 09 914 061302 915 06000 FLAT WASHER 3224 LOCK WASHER 3224 M M MDF table with model 40 200M PARTS LIST 40 049 PART NO REFERENCE NO DESCRIPTION SPECIFICATION 40049 01 3224E014B MDF TABLE 3224 800 X 600 40049 02 903 06030 FLAT HEX SOCKET HEAD SCREW 6 X 30 40049 03 907 06013 WOOD NUT 6 13 40049 04 907007004 WOOD SCREW 7 40 40049 05 60700030 TSLOT GUIDE RAIL 3224 40049 06 905316058 SELF SCREW 3 16 X 5 8 40049 07 907316058 SELF TAPPING SCREW 3224 3 16 X 5 8 Router Fence 840 080 PARTS LIST 40 080 PART NO DESCRIPTION SPECIFICATIONS 40080 01 32240032A FENCE BODY 40080 02 60100001A LOCK HANDLE 40080 03 13224002 SCALE 40080 04 32240052A T BOLT 40080 05 9145162302 FLAT WASHER 40080 06 939M08000
7. blow dry After degreasing reapply some dry lubricant 3 Remove the crank handle and flip the lift over in the table 4 Turn Allan 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 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 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 1 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 3 With the router in position tighten clamping bolt securely using a using a 8 mm Allen key but do not over tighten Important Test that the router is se c
8. ZONE For shops with frequent visitors or multiple opera tors it is advisable to establish a safety zone around shop machinery A clearly defined no go zone on the floor around each machine can help avoid accidents that could cause injury to either the operator or the shop visitor It is advisable to take a few moments to either paint using non slip paint or using tape define on the floor the limits or perimeter of each machines safety zone Take steps to ensure that all operators and shop visitors are aware that these areas are off limits whenever a machine is running for everyone but the individual operating the unit 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 DELUXE ROUTER TABLE KIT Floor model MODEL 840 200 IDENTIFICATION OF MAIN PARTS AND COMPONENTS ON OFF SWITCH WITH REMOVABLE SAFETY KEY DUST ENCLOSURE BOX ACCESS DOOR TABLE FENCE RAIL WITH SLIDING SCALE OUTFEED FENCE FACE FENCE LOCKING HANDLE ROUTER LIFT CRANK HANDLE DUST SHIELD LOCK KNOB DUST SHIELD FENCE BODY INSERT RING WRENCH INFEED FENCE FACE 3 4 X 3 4 MITER TSLOT FOR MITER GAUGE 3 8 MITER T SLOT FOR SELF MADE JIGS I
9. cut on a waste sample before jointing your good workpieces GROOVE CUTTING Beading is commonly defined as cutting a groove or bead in the face of a board If installed remove the spacer bars on the outfeed fence 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 Raise or lower the router bit to the desired height Loosen the knobs and adjust the opening between the fences to allow the bit to clear the edge of bothfences Adjust the main fence until the center of the bit has reached the desired distance A 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 The bearing rides along the uncut edge of the board while the cutter removes the wood Follow steps 1 and 2 from previous section Groove Cutting Adjust the fence back and away from the bit only enough to allow the guide bearing to control the depth of cut or use the starting pin as a support for the work piece as shown in B 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 CHAI
10. opened to allow maximum airflow ASSEMBLY INSTRUCTIONS MOUNTING A ROUTER 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 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 kee motor must be lined up and inserted into the hole D located in our clamping bracket E Insert the crank handle in the black hole sur rounded by digits as shown in H To raise the lifting carriage on the router lift to the highest or maximum upward position turn the crank handle clockwise 5 s n m v 2 sh dar n y AMA A Y 1 Nx L 2 y AU 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
11. B LOCK KNOB 40080 07 32240034 LOCK NUT 40080 08 32240035A H SPACER 40080 09 32240036 FENCE FACES 40080 10 32240037 SAFETY GUARD 40080 11 32240038 FENCE 5 40080 12 32240039 SIDE 40080 13 32240040 SIDE BRACKET 40080 14 32240041 RULE PLATE 40080 15 T3224003 SCALE 40080 16 935014000 SQUARE NUT 40080 17 9140141602 FLAT WASHER 40080 18 901M06012 CAP SCREW 40080 19 904014058 HEX BOLT 1 4 X 5 8 40080 20 940M06012 LOCK KNOB M6x 12 40080 32 32240013A DUST PORT 40080 33 906014034 PHILLIPS HEAD SCREW 1 4 X 3 4 40080 34 32240033A TBOLT 40080 35 32240060 FLUOROWAY PAD N N N O CO Stand 440 085 PART N0 40085 01 32240015 PARTS LIST 40 085 DESCRIPTION SPECIFICATIONS LONG TOP BRACE 40085 02 32240016 SHORT TOP CROSS BRACE 40085 03 32240017 LEG 40085 04 32240018 LONG BOTTOM CROSS BRACE F amp R 40085 05 32240019 SHORT BOTTOM CROSS BRACE L amp R 40085 06 27160020 HANDLE STORAGE BRACKET 40085 07 32240029 SQUARE NUT 40085 08 910M 10006 HEX NUT 40085 09 32240030 LEVELING FOOT 40085 10 904M06012 HEX BOLT 40085 11 914M061602 FLAT WASHER 40085 12 910 04000 NUT 40085 13 906
12. M ROUTER INSERT PLATE 9 1 4 X 11 3 4 235 X 298 TABLE OPENING SIZES DIAMETER 4 3 ce PLATE 3 3 4 95 INSERT RING 1 1 2 38 SN NET WEIGHT 40 200 MODEL 179 LBS 81 KG GENERAL GENERADO o GENERAL Y INTERNATIGNAL T Excalibur BY GENERAL INTERNATIONAL SEPTEMBER 20 12 O Copyright General6 International 09 2012 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 40 200 Deluxe Router Table Kit floor 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 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 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 safety of performing a certain operati
13. M04020 PHILLIPS HEAD SCREW 40085 14 32240022 SWITCH MOUNTING PLATE 40085 15 53224011 SWITCH 40085 16 132240001 POWER CORD 14AWG X 3C 40085 17 906M05010 PHILLIPS HEAD SCREW M5 X 10 40085 18 906M05045 PHILLIPS HEAD SCREW M5 X 45 40085 19 914M051201 FLAT WASHER M5 40085 20 40085 21 904M06012 32240023 CAP BOLT M X 12 WHEEL HOUSING 40085 22 32240024 PLASTIC WHEEL 76MM 40085 23 40085 24 914M081915 904M08050 FLAT WASHER HEX BOLT 40085 25 9145161802 FLAT WASHER 40085 26 912M08000 NYLON NUT 40085 27 32240020 WHEEL FRAME BRACKET 40085 28 40085 29 32240031 901M06016 SUPPORT PLATE CAP SCREW 40085 30 910M06000 HEX NUT 40085 31 32240025 WHEEL FRAME 40085 32 32240026 FOOT PEDAL 40085 33 40085 34 904M08090 32240027 HEX BOLT WHEEL BASE 40085 35 32240028 WHEEL 40085 36 9140382503 FLAT WASHER 40085 37 40085 38 915M10000 912M10000 LOCK WASHER NYLON NUT N ANI DO DO BS ON ON 3 4 PART NO 40125 01 REF NO 60800001A PARTS LIST 40 125 DESCRIPTION ALUMINUM CARRIAGE BRACKET SPECIFICATIONS 40125 02 60500002 MAIN GEAR SHAFT 40125 03 60500003 LEAD SCREW 40125 04
14. N Proper tension on the drive chain helps maintain tool bit height in the 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 1 Lower the lift to its lowest position and then remove 3 Push the sprocket assembly B further along its slot it from the table ted opening by hand to add tension to the chain 2 Using a 6 mm allen key loosen the cap screw A 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 fhe fool creep you are experiencing is being cause by fhe router slipping in the reducer collar or in the clamping mechanism on the lift RECOMMENDED OPTIONAL ACCESSORIES We offer some optional accessories available from your local 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 840 175 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 collec
15. NECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCT ED TO DO SO Before opening the fence have a clear work area to prevent the mixing of hardware CAST IRON TABLE 40 200 AND PHENOLIC TABLE 40 200P 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 40 049 MDF table for 40 200M use the wood screws supplied with your table to attach the mounting brackets to the table 1 Attach the two fence side rails with scale A to their 2 Remove the original 8 fence bracket mounting bolts mounting brackets B using 3 hex head bolts with flat A from the table and attach the fence mounting washers and square nuts C in the assembly order brackets to the underside of the table B shown in D 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 3 Attach the second mounting bracket to the oppo site side of the table A down on one short T bolt B then insert the head of Note Adjust the height of the 3 bolts in the slotted holes in the bolt in the front upper slot in the fence body as the rail bracket so that the rail is leveled with the table B shown in C E 5 Slide the 2 bolts and
16. NSERT RING WRENCH STORAGE AIR VENT ROUTER LIFT HANDLE HOLDER STAND STAND CASTER PEDAL LEVELING FEET CASTERS 2 1 4 BRANCH INLET DUST HOSE 4 DUST PORT DOVETAIL SLOT Model 40 200 Cast iron table shown Carefully unpack 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 40 085 STAND 40 200 b LEVELING FOOT W HEX NUT BOTTOM SIDE CROSS BRACE d TOP SIDE CROSS BRACE e FRONT REAR BOTTOM CROSS BRACE f FRONT REAR TOP CROSS BRACE BLACK CROSS BRACE SWITCH BOX CASTER BRACKET CASTER SIDE PEDAL CASTER ASSEMBLY HEXNUT m FLAT WASHER LARGE n HEX HEAD BOLT LONG SOCKET CAP SCREW p FLAT WASHER q ROUTER LIFT CRANK HANDLE HOLDER r HEX HEAD BOLT SHORT 5 FLAT WASHER LIST OF CONTENTS 40 080 ROUTER FENCE 40 200 a DUST SHIELD b 2 1 4 dust collection outlet FENCE LOCKING HANDLE d FENCE BODY e FENCE FACE f FENCE SIDE RAIL W SCALE g FENCE MOUNTING BRACKET h SPACER BARS FOR JOINTING WORK i LOCK KNOB TBOLT LONG k CAP SCREW l PLASTIC SPACER m FLAT WASHER SMALL n T BOLT SHORT o PHILLIPS HEAD SCREW p HEX NUT LARGE q FLAT WASHER LARGE r SQUARE NUT S HEX HEAD 0 Vi o
17. SETUP amp OPERATION MANUAL FEATURES 2 teora mosso cue vns es DELUME ROUTER TABLE KIT 11 3 4 aluminum top plate stable 4 post lift screw design amp chain drive Floor 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 200C MDF 40 200M or Phenolic 40 200P stand made of tubular steel includes mobility kit adjustable leveling feet and easy access on off safety switch with removable lock out key 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 35 1 2 X 24 X 41 902 X 609 X 1041 MM TABLE SIZE HEIGHT 32 X 24 812 X 609 MM 36 1 2 927 MM FENCE SIZE EACH 3 X 17 3 4 X 3 4 76 X 451 X 19 MM MAXIMUM FENCE TRAVEL 9 229 MM DUST OUTLET 4 102 MM DISTANCE BETWEEN T SLOT amp SPINDLE CENTER 3 4 5 5 8 143 MM 3 8 7 3 16 183 MM DISTANCE FROM SPINDLE CENTER TO FRONT EDGE OF TABLE 12 305 MM ESLOT DIMENSIONS 3 4 X 13 32 19 X 10 MM 3 8 X 9 32 10 X 7 M
18. TUP 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 system con sider contacting your General amp International distributor for information on our complete line of dust collection systems or visit our website at www general ca 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 2213 9 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 s
19. ach the 4 inch hose adapter Locate them first You will find additional mounting hardware to attach the 40 130 dust enclosure to the table This additional hardware will not be required with cast iron table for 40 200C because the same fasteners are supplied with the table 1 Attach the dust outlet to the panel with a hole as shown using the 3 longer 3 phillips head screws 3 Turn the assembled router table upside down 4 Remove the 6 hex head bolts from the underside of the table 40 200C and 40 200P only Note For 40 049 MDF table for 40 200M use the wood screws supplied with your table to attach the dust collec tion box to the table im Using the supplied hose clamps secure one end of the dust hose to the 2 1 2 inlet on the dust port A and the other end ot the dust outlet on the fence B 2 Assemble dust enclosure as shown using the 22 short phillips head screws 5 Position and secure the dust enclosure into place A using the 6 hex head bolts with lock washer and flat washer B 6 Turn the assembly back over to its upright and oper ating position 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 The vent on the dust enclosure allows you to adjust 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
20. al 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 amp and General amp International agree to repair or replace any part or component which upon examination proves to be defective in either workmanship or material to the original purchaser for the life of the tool However the Limited Lifetime Warranty does not cover any product used for profes sional or commercial production purposes nor for industrial or educational applications Such cases are covered by our Standard 2 year Limited Warranty only The Limited Lifetime Warranty is also subject to the Conditions and Exceptions as listed below Standard 2 Year Limited Warranty All products not covered by our lifetime warranty including products used in commercial industrial and educational applications are warranted for a period of 2 years 24 months from the date of purchase General amp and General amp International agree to 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 defecti
21. along the rails A Loosen locking handles B slide fence then lock in position by re tightening the locking handle Repeat on the other extremity of the fence ADJUSTING THE SLIDING SCALE ON THE RAILS The scale on the rails can be adjusted along the rails A Loosen lock knob B 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 ADJUSTING THE FENCE FACES 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 head as shown in C CONNECTING THE ROUTER TO THE SAFETY SWITCH Remove the top half of the power cord flange plate from the side panel on the dust containment box A 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 Note Make sure to leave enough of the router s power cord inside the dust containment box to allow you to remove the lift and the router from the table opening from above USING THE SAFETY SWITCH POWER ON POWER OFF SAFETY KEY PREVENTS STAR
22. dous 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 lean on it 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 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
23. en the locking handle to lock the fence in position ASSEMBLY INSTRUCTIONS PREPARE THE TABLE FOR ROUTER LIFT PLETED THE INSTALLATION AND ASSEMBLY STEPS DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED TO DO SO T SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COM Note Model 40 075 for 40 200 Cast iron table shown The following steps apply to all 3 table options 1 Place the router lift into the opening in the table 2 Use a straightedge to test the plate for level with the table top 3 From the underside of the table adjust the 4 phillips 4 Remove the lif and lock the adjuster screw in place head screws in the corners A up 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 5 After the four corners are set proceed to set the adjuster screw does not turn Confirm by re checking the ini i leveling of the lift and table surface remaining leveler screws and lock them in place ASSEMBLY INSTRUCTIONS 40 130 DUST COLLECTION KIT 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 Note There are three longer screws in the hardware kit that are required to att
24. ered con sumable parts or components Repairs made without the written consent of General International will void all warranty TABLE OF CONTENTS Placement within the shop Establishing a safety zone Identification of main parts and components Unpacking List of contents 40 085 Stand List of contents 40 080 Router fence List of contents 40 125 Router lift List of contents 40 130 Dust collection kit List of contents Table Additional requirements for set up Assembly instructions 40 085 Router table stand Table 40 0708 40 049 40 045 Cleaning the cast iron table for 40 200 only 13 Install the table cast iron table 40 200C and phenolic table 40 200P only Attach the stand to the table Engaging disengaging the stand casters 40 080 Router fence Prepare the table for router lift 40 130 Dust collection kit Mounting a router Leveling and locking the router plate Insert ring removal Installing the starting pin Basic adjustments amp controls Adjusting the fence along the rails Adjusting the sliding scale on the rails Adjusting the fence faces Connecting the router to the safety switch Using the safety switch Connecting to a dust collector Operating instructions Before starting Using the spacer bars for jointing Jointing Groove cutting Profile cutting Tensioning the drive chain Recommended optional accessories Parts list amp diagrams Contact information Rules for Sa
25. fe Operation To help ensure safe operation please take a moment to learn the machine s applications and limita tions as well as potential hazards GENERALO INTERNATIONAL disclaims any real or implied war ranty and holds itself harmless for any injury that may result from improper use of its equipment Make sure that the operator has been properly 13 Secure the table to a work surface and never stand or 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 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 carcinogen that can be haz ar
26. on 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 GENERAL amp GENERAL INTERNATIONAL WARRANTY All component parts of General amp General amp International and Excalibur by Gener
27. p screw and flat washer attach the adjustment handle holder A to one stand leg asshowm above as shown in B The router lift crank handle may be stored on the holder 12 Insert a phillips head screw with hex nut through h one of the holes on the left top cross brace and Hd es Ul Wronchondy Restored ion the screw from the other side of the brace lightly thread a second hex nut to lock the screw in position ASSEMBLY INSTRUCTIONS TABLE 40 075 40 049 40 045 SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COMPLE AN TED THE INSTALLATION AND ASSEMBLY STEPS DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED TO DO 50 There are 3 different table options for Deluxe Router Table Kit model 40 200 Castiron table 40 075 for 40 200C MDF table 40 049 for 40 200M Phenolic table 2440 045 for 40 200P CLEANING THE CAST IRON TABLE FOR 40 200 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 solvent 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 prevent rust apply a light coating of paste wax or use regular applications of an
28. rews with wash ers A attach a caster bracket to the front and rear right side legs as shown in B 5 Using the supplied long hex head bolts with 2 flat washers and 1 hex nut C attach a caster to each bracket D Do not over tighten The casters must turn freely 1 Insert an adjustable leveling foot into each leg as shown in A Note The four legs need to be positioned with the mount ing holes on bofh faces on the corners B 3 Attach the swivel caster assembly to a bottom side brace as shown in A using the 2 supplied socket head screws with washers B RIGHT SIDE STAND SUB ASSEMBLY LEFT SIDE STAND SUB ASSEMBLY 6 Using the supplied short hex head bolts with wash ers attach the bottom side brace with black swivel caster assembly to the 2 legs without casters as shown in A Then attach a top side brace to the top of the legs B Attach the other bottom side brace to the bottom of the two remaining legs C and the other top side bra ce to the top of the legs D 8 Using short hex head bolts with washers assemble Install the switch box by sliding it s mounting brack the two sub assemblies using the front rear bot et over the left front leg A and attach with the two tom A and top B braces phiilips head screws and washers already mount Do not tighten the stand bolts until affer you have ed to the bracket B fastened the stand to the router table top See 10 Lightly tighten step 3 on page 14 11 Using a short ca
29. s both at 0 7mm or both at 1 5mm Two spacer bars A are supplied with the fence system to facilitate jointing by offsetting the outfeed fence B to the infeed fence and providing a straight path for the workpiece to follow as it is machined fully support ed at its start and end Note when in use the spacer bars can be stored on the t track on the back of the fence body as shown JOINTING Loosen but do not remove the outfeed fence face and install the spacer bars between the outfeed fence and the fence body 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 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 alignment with the highest point of the cutting edge on the bit then tight en the knobs to lock the fence in position Adjust the height of the safety shield to make sure it clears the bit and the workpiece slightly 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 Plug in and turn on the router and make a test
30. spacers to the middle of the fence body approx 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 9 Slide the slot of one fence face onto the 3 elongat ed bolt heads then tighten the lock knobs on the other side of the fence 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 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 10 Repeat with the second fence face on the other side of the fence body 11 Insert a Phillips head screw A through both dust 13 Insert the square nut in the fence body slot A outlet mounting holes 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 18 Repeat steps 16 and 17 on the other end of the fence then fully tight
31. 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 GENERALO INTERNATIONAL disclaims any real or implied warranty and holds itself harmless for any injury which may result from such use PLACEMENT WITHIN THE SHOP ESTABLISHING A SAFETY ZONE THE MACHINE IS HEAVY 179 LBS 81 KG DO NOT OVEREXERT ARRANGE 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 PLACEMENT WITHIN THE SHOP This machine should be installed and operated only on a solid flat and stable floor that is able to support the weight of the router table 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 unobstruct ed by foot traffic either passing shop visitors or other shop workers or other tools or machinery ESTABLISHING A SAFETY
32. tors contribute to a cleaner more healthful workshop environment Reducer collar fits 3 1 2 motor 40 312 For Excalibur router lift 40 125 9 1 4 x 11 3 4 Aluminum insert plate Shim 1140 626 Shim for Milwaukee router model 5625 5626 N Reducer collar fits 3 1 4 motor 1440 314 For Excalibur router lift 340 125 Vertical featherboard 840 160 For Excalibur router table S n Flip stop 140 090 For Excalibur router fence 840 065 bench top model amp 1440 080 floor model 9 pcs brass precision 340 115 For Excalibur router tables 4 pc insert ring set 1 4 1 2 2 1 2 8 1 3 8 30 mm for 40 099 40 076 plate guide set 40 099 Designed for most routers Included accessories 1 locking nut 8 guides 1 1 19 64 5 8 27 32 17 32 17 64 9 32 11 32 13 32 Stock pusher 40 120 For Excalibur router fence 40 065 bench top model amp 40 080 floor model 29 Cast iron table with model 40 200C PART NO 40075 01 REFERENCE NO 3224U014 PARTS LIST 40 075 DESCRIPTION CAST IRON TABLE SPECIFICATION 32 X 24 40075 02 903M06030 FLAT HEAD CAP SCREW M 30 MM 40075 03 910M06000 HEX NUT M 40075 04 905M06020 FLAT HEAD SCREW 6 X 20 40075 05 914M061602 FLAT WASHER M 40075 06
33. u C LEVELER SCREW 4 FLAT WASHER e LOCK WASHER es ars ITEM 40 075 mounting hardware for 40 075 cast iron F HEX SOCKET CAP SCREW GREA and 40 045 phenolic table Note Supplied hardware is the same for 40 200C or 40 200P with cast iron or phenolic table o 0000000000 with MDF table the following hardware is Model 440 075 for 40 200C Cast iron o 1 1 1 1 1 111 1 1 table shown WOOD SCREW b WOOD NUT 0000 ol SELF TAPPING SCREW mounting hardware for 40 049 MDF table Oss 91111111 114414411 ADDITIONAL REQUIREMENTS FOR SET UP Extra person for help with lifting cast iron table Straight edge Phillips screwdriver Socket wrench set Wrench set Allen key set ASSEMBLY INSTRUCTIONS 40 085 ROUTER TABLE STAND 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 TOP SIDE FRONT REAR FRONT REAR BOTTOM SIDE BOTTOM CROSS TOP CROSS BRACE BRACE You will find two different brace lengths and styles the 4 shorter ones are for the sides All the narrow braces are for the top of the stand and the wider ones are for the bottom Attach the pedal caster assembly A to the black brace B using the 4 supplied socket head screws with washers C as shown in D 4 Using the supplied socket head sc
34. urely 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 Adjustthe 10 leveling screws B in the table opening as needed to level the plate on all four sides needed refer back to the instructions on page 19 For 440 049 MDF table for 40 200M only From th 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 BASIC ADJUSTMENTS amp CONTROLS ADJUSTING THE FENCE ALONG THE RAILS eh m ow 4 The fence can be slid
35. ve parts components or machinery must be returned freight or postage prepaid to General amp International or to a nearby distributor repair center or other location designated by General International For further details call our service department at 1 888 949 1161 or your local distributor for assistance when filing your claim Along with the return of the product being claimed for warranty a copy of the original proof of purchase and a letter of claim must be included a warranty claim form can also be used and 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 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 GeneralO or General6 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 consid
36. witch on the router ALWAYS TURN ON THE DUST COLLECTOR BEFORE STAR TING THE ROUTER AND ALWAYS STOP THE ROUTER BEFORE TURNING OFF THE DUST COLLECTOR OPERATING INSTRUCTIONS 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 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 on a scrap piece of wood before cutting your final piece WHEN JOINTING GROOVE CUTTING AND OR PROFILE CUTTING BE SURE TO ATTACH THE SUPPLIED DUST SHIELD USING THE SPACER BARS FOR JOINTING Jointing the edge of a board involves using a straight cutting router bit to remove material from the edge face of a board The result is a perfectly flat and square edge Each spacer bar has two sides which allow you to off set the outfeed fence by either 0 7 mm or 1 5 mm stag gering Note both spacer bars should be used in the top and bot fom t slots in the fence body as shown Take care to install them in matching offset position
37. y aftermarket surface protec Tip With a screw driver push a solvent saturated rag into tant or rust inhibitor the T slots to remove the grease INSTALL THE TABLE CAST IRON TABLE 7740 2000 AND PHENOLIC TABLE 40 200P ONLY For 40 049 MDF table for 40 200M 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 Note 1 The leveler screws need fo be inserted from the make sure there are no filings in any of the threaded bottom of the table The nut will sit on the top side of the holes and leave the fasteners in the underside of the men sd piate Ki ad 2 i table Only remove as assembly is taking place Ole 2 Ierecare 2 NOLES edem side oi Tie opens x y y gp 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 ASSEMBLY INSTRUCTIONS ATTACH THE STAND TO THE TABLE 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 CAST IRON TABLE 40 200 AND PHENOLIC TABLE 40 200P ONLY For 40 049 MDF table for 40 200M
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