SETUP & OPERATION MANUAL FEATURES Heavy-duty massive router lift with 9 1/4" x 11 3/4" aluminum top plate. Stable 4 post/lift screw design & chain drive lifting system controlling all 4 corners simultaneously. DELUXE ROUTER TABLE KIT (Bench top model) Fits all fixed base router motors.* Smooth above-the-table adjustment mechanism for fast tool changes & precision bit setting. Available with table in either cast-iron (40100C), MDF (40-100M) or Phenolic (40-100P).
GENERAL® INTERNATIONAL 8360 Champ-d’Eau, Montreal (Quebec) Canada H1P 1Y3 Telephone (514) 326-1161 • Fax (514) 326-5555 • www.general.ca THANK YOU for choosing this Excalibur by General® International model 40-100 Deluxe Router Table Kit (bench top model). This router table has been carefully tested and inspected before shipment and if properly used and maintained, will provide you with years of reliable service.
GENERAL® INTERNATIONAL WARRANTY All component parts of 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.
TABLE OF CONTENTS Rules for safe operation . . . . . . . . . . . . . . .5 Installation . . . . . . . . . . . . . . . . . . . . . . . .6 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Identification of main parts and components . . . . . . . . . . . . . . . . . . . .7 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . .8 List of contents - 40-060 Stand . . . . . . . . . . . . . . . . .8 List of contents - 40-065 Router fence . . . . . . . . . . .
Rules for Safe Operation To help ensure safe operation, please take a moment to learn the machine’s applications and limitations, as well as potential hazards. General® International disclaims any real or implied warranty and holds itself harmless for any injury that may result from improper use of its equipment. 1. Make sure that the operator has been properly trained and has read and understands the Owner’s Manual before operating any machinery. 2.
INSTALLATION THE MACHINE IS HEAVY (119 LBS - 54 KG). DO NOT OVEREXERT. ARRANGE TO HAVE HELP NEARBY AND READY FOR UNPACKING AND SET UP. SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COMPLETED THE INSTALLATION AND ASSEMBLY STEPS. DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED TO DO SO.
DELUXE ROUTER TABLE KIT (Bench top model) Model #40-100 IDENTIFICATION OF MAIN PARTS AND COMPONENTS G E H G I E F D C J C B K P A L M O N REAR VIEW A- ON/OFF SWITCH WITH REMOVABLE SAFETY KEY B- TABLE* C- FENCE RAIL WITH SLIDING SCALE D- SLIDING ADJUSTABLE FENCE FACE E- FENCE LOCKING HANDLE F- ROUTER LIFT CRANK HANDLE G- DUST SHIELD LOCK KNOB H- DUST SHIELD I- FENCE BODY J- 3/4” X 3/4” MITER T-SLOT (FOR MITER GAUGE) K- 3/8” MITER T-SLOT (FOR SELF MADE JIGS) L- STAND M- D
UNPACKING 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 QTY 40-060 STAND (40-100) f 40-060 STAND (40-100) a- CARRIAGE BOLT . . . . . . . . . . . . . . . . . . . . . .34 b- HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 QTY 40-125 ROUTER LIFT a 40-125 ROUTER LIFT a- ROUTER LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . .1 b- ROUTER LIFT CRANK HANDLE . . . . . . . . . . . . .
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. Model 40-100C: LIST OF CONTENTS abcdef- QTY Mounting hardware for #40-070 Cast-iron table (for model 40-100C) 16” X 27” CAST-IRON TABLE (#40-070) . . . . . . 1 HEX NUT . . . . . . . . . . . . .
ASSEMBLY INSTRUCTIONS SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COMPLETED THE INSTALLATION AND ASSEMBLY STEPS. DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED TO DO SO. 40-060 ROUTER TABLE STAND Note: Do not tighten the stand bolts until after you have fastened the stand to the router table top. (See step 3 on page 14.) REAR B A C D E FRONT 1.
S P T R U Q 7. Attach the two bottom side cross braces, P and Q. 8. Turn the stand in the upright position and attach the middle cross brace on the left side, as shown in R. V 9. Using a carriage bolt, flat washer and nut, S, attach the router lift crank handle holder T to the middle cross brace as shown in U. The router lift crank handle may be stored on the holder as shown in V when not being used. W 11.
TABLE 40-070/40-047/40-043 There are 3 different table options for Deluxe Router Table Kit, model 40-100: Cast-iron table (#40-070) for 40-100C Phenolic table (#40-043) for 40-100P MDF table (#40-047) for 40-100M CLEANING THE CAST-IRON TABLE FOR #40-100C ONLY) The protective coating on the cast-iron table, prevents rust from forming during shipping and storage. Remove it by rubbing with a rag dipped in kerosene, mineral spirits or paint thinner.
ATTACH THE TABLE TO THE STAND (CAST-IRON TABLE #40-100C AND PHENOLIC TABLE #40-100P ONLY)* * For #40-047 MDF table (for #40-100M), use the wood screws supplied with your table to attach the stand to the table. A B 1. With the table upside down, remove the 4 mounting screws and washers, A, for the stand. 2. Attach the stand to the table using the four socket head cap screws and washers, B, then tighten.
A B C A B 3. Attach the second mounting bracket to the opposite side of the table, A. Note: Adjust the height of the 3 bolts in the slotted holes in the rail bracket so that the rail is leveled with the table, B. 4. Insert an orange plastic spacer A with the short end down on one short T- bolt B, then insert the head of the bolt in the front upper slot in the fence body as shown in C. D A C B 5. Slide the 2 bolts and spacers to the middle of the fence body (approx.) 6.
9. Slide the slot of one fence face onto the 3 elongated bolt heads, then tighten the lock knobs on the other side of the fence. 10. Repeat with the second fence face on the other side of the fence body. C A A B B 11. Insert a Phillips head screw A through both dust outlet mounting holes. 12. Loosely thread a square nut B on both screws as shown in C. 13. Insert the square nut in the fence body slot, A. 14. Insert the other square nut in the slot on the other side of the fence, B. A A B C B 15.
PREPARE THE TABLE FOR THE ROUTER LIFT Note: Model #40-070 for 40-100C Cast-iron table shown. The following steps apply to all 3 table options. 1. Place the router lift into the opening in the table. 2. Use a straightedge to test the plate for level with the table top. A 3. From the underside of the table, adjust the 4 phillips head screws in the corners A - up or down until the plate is flat and level with the table surface. 4.
40-130 DUST COLLECTION KIT Note: There are three longer screws in the hardware kit that are required to attach the 4 inch hose adapter. Locate them first. You will find additional mounting hardware to attach the 40-130 dust enclosure to the table. This additional hardware will not be required with cast-iron table for 40-100C because the same fasteners are supplied with the table. RIGHT SIDE FRONT REAR LEFT SIDE BOTTOM 1. Assemble dust enclosure as shown, using the 22 short phillips head screws. 3.
ASSEMBLY INSTRUCTIONS - MOUNTING A ROUTER SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COMPLETED 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. B Note: Based on our research this is the Porter Cable model 7518 and 7519 router motors which measure 4.
D B C D A 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. 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.
LEVELING AND LOCKING THE ROUTER PLATE A 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. B 1. Using a straightedge check that the router plate is level with the main table, A. 2. Adjust the 10 leveling screws B in the table opening as needed to level the plate on all four sides.
BASIC ADJUSTMENTS & CONTROLS ADJUSTING THE FENCE ALONG THE RAILS ADJUSTING THE SLIDING SCALE ON THE RAILS B C D A The fence can be slid 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. The scale on the rails can be adjusted along the rails C. Loosen lock knob D, slide the fence up to where you need it to be, then lock in position by re-tightening the lock knob.
USING THE SAFETY SWITCH A POWER ON POWER OFF SAFETY KEY B (PREVENTS START-UP WHEN REMOVED) The safety switch box is equipped with a simple “on/ off” switch featuring a removable lock out safety key. To prevent unauthorized use or unintentional start-up, remove the safety key and store it in a safe place whenever the router table is not in use. CONNECTING TO A DUST COLLECTOR There is a 4” dust outlet on the rear of the dust enclosure allowing for the connection of a dust collector (not included).
USING THE SPACER BARS FOR JOINTING A B 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. 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 supported at its start and end. 1.5 mm 0.
GROOVE CUTTING Beading is commonly defined as cutting a groove or bead in the face of a board. 1. If installed, remove the spacer bars on the outfeed fence. A 2. With the router unplugged and the safety switch in the off position, follow the instructions supplied with your router and install a cutting bit in the router. 3. Raise or lower the router bit to the desired height. 4. Loosen the knobs and adjust the opening between the fences to allow the bit to clear the edge of bothfences. 5.
RECOMMENDED OPTIONAL ACCESSORIES We offer some optional accessories available from your local General International dealer for increased convenience, productivity, accuracy and safety when using your router table. For more information about our products, please visit our website at www.general.ca Dust collector We offer a wide selection of top quality dust collectors to suit all your shop needs. Dust collectors contribute to a cleaner more healthful workshop environment.
Cast-iron table 1 (with models #40-100C & #40-070EK ) 8 3 2 10 9 4 5 6 13 7 11 10 12 PARTS LIST – #40-070 PART NO. REFERENCE NO.
2 MDF table (with model #40-100M) 6 6 2 6 6 5 1 3 4 7 PARTS LIST – #40-047 PART NO. REFERENCE NO.
Router Fence 2 (#40-065) 5 9 8 3 16 32 33 7 4 4 12 17 33 16 2 16 11 19 6 35 35 14 13 15 17 17 6 18 5 34 4 8 10 6 17 1 7 35 35 9 12 13 15 14 18 16 17 20 19 PARTS LIST – #40-065 PART NO. REF. N0.
Stand (#40-060) 3 16 11 16 20 2 22 22 4 10 14 6 15 14 11 15 15 14 4 11 2 7 3 17 23 4 7 14 15 14 15 5 11 15 19 14 8 11 17 18 9 12 PARTS LIST – #40-060 PART NO. 40060-02 40060-03 40060-04 40060-05 40060-06 40060-07 40060-08 40060-09 40060-10 40060-11 40060-12 40060-14 40060-15 40060-16 40060-17 40060-18 40060-19 40060-20 40060-22 40060-23 30 REF. NO.
Router lift (#40-125) 19 25 25 24 8B 8A 17 4 30 40 13 8 29 34 14 2 3 32 5 5 22 22 28 5 23 22 1 27 26 20 12 11 20 27 27 26 27 12 26 10 29 12 26 12 33 15 6 9 29 32 20 33 15 20 37 35 18 7 31 18 21 39 15 15 38 16 36 38 16 36 31
PARTS LIST – #40-125 PART NO. REF. N0.
Dust Collection Kit 20 (#40-130) 13 20 19 6 12 17 16 15 12 11 4 7 10 3 3 8 3 5 3 4 2 1 14 18 4 3 3 9 PARTS LIST – #40-130 PART NO. REF. NO.
MODEL 40-100 8360 Champ-d’Eau, Montreal (Quebec) Canada H1P 1Y3 Fax: (514) 326-5565 - Tel.: (514) 326-1161 Fax: (514) 326-5555 - Parts & Service / 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.
