Excalibur 40-100 User Manual

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.

Fits all fixed base router motors.*
Smooth above-the-table adjustment mech-

anism for fast tool changes & precision bit
setting.

Available with table in either cast-iron (40­100C), MDF (40-100M) or Phenolic (40-100P).

Sturdy steel stand includes easy access
on/off safety switch with removable lock­out key & non-slip rubber feet.

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.

DELUXE ROUTER TABLE KIT
(Bench top model)

SPECIFICATIONS

OVERALL DIMENSIONS
30 1/2" X 16" X 21” (775 X 406 X 533 MM)

TABLE SIZE
Cast-iron: 16" X 27” (406 X 686 MM)
Phenolic & MDF: 15 3/4" X 25 5/8”(400 X 651 MM)

TABLE HEIGHT
16”(406 MM)

FENCE SIZE (EACH)
3” X 15 1/4" X 3/4” (76 X 387 X 19 MM)

MAXIMUM FENCE TRAVEL
6” (152 MM)

DUST OUTLET
2 1/4” (57 MM)

DISTANCE BETWEEN T-SLOT & SPINDLE CENTER
3/4": 5 1/16” (135 MM)
3/8": 6 9/16" (167 MM)

DISTANCE FROM SPINDLE CENTER TO FRONT
EDGE OF TABLE
8" (205 MM)

T-SLOT DIMENSIONS

/8” (19 X 10 MM) /

3/4” X 3
3/8" X 1/4" (10 X 7 MM)

ROUTER INSERT PLATE
9 1/4” X 11 3/4 (235 X 298 MM)

TABLE OPENING SIZES - DIAMETER
PLATE: 3 3/4” (95 MM)
INSERT RING: 1 1/2” (38 MM)

NET WEIGHT (40-100C MODEL)
119 LBS (54 KG)

MODEL

#40-100

VERSION 2 _ REVISION 3 - APRIL 2015 ©
Copyright General® International

GENERAL® INTERNATIONAL

8360 Champ-d’Eau, Montreal (Quebec) Canada H1P 1Y3

Telephone [phone] • Fax [phone] • 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. 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 com­ponents. 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 printing. Because we are commit­ted 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 corres­ponds with that of the unit with which it was supplied.

However, special orders and “after factory” modifica­tions 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 ear­lier 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 clarifica­tion.

GENERAL® INTERNATIONAL WARRANTY

ll component parts of General® International and Excalibur by General International® prod-

A
ucts are carefully inspected during all stages of production and each unit is thoroughly
inspected upon completion of assembly.

Limited Lifetime Warranty

Because of our commitment to quality and customer satisfaction, General® International
agrees to repair or replace any part or component which upon examination, proves to be
defective in either workmanship or material to the original purchaser for the life of the tool.
However, the Limited Lifetime Warranty does not cover any product used for professional or
commercial production purposes nor for industrial or educational applications. Such cases
are covered by our Standard 2-year Limited Warranty only.The Limited Lifetime Warranty is also
subject to the “Conditions and Exceptions” as listed below.

Standard 2-Year Limited Warranty

All products not covered by our lifetime warranty including products used in commercial,
industrial and educational applications are warranted for a period of 2 years (24 months) from
the date of purchase. General® International agrees to repair or replace any part or compo­nent which upon examination, proves to be defective in either workmanship or material to the
original purchaser 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® International, or to a nearby distributor, repair center or other location
designated by General® International. For further details call our service department at 1-888­949-1161 or your local distributor for assistance when filing your claim.

Along with the return of the product being claimed for warranty, a copy of the original proof
of purchase and a“letter of claim” must be included (a warranty claim form can also be used
and can be obtained, upon request, from General® International or an authorized distributor)
clearly stating the model and serial number of the unit (if applicable) and including an expla­nation of the complaint or presumed defect in material or workmanship.

CONDITIONS AND EXCEPTIONS:

This coverage is extended to the original purchaser only. Prior warranty registration is not
required but documented proof of purchase i.e. a copy of original sales invoice or receipt
showing the date and location of the purchase as well as the purchase price paid, must be
provided at the time of claim.
Warranty does not include failures, breakage or defects deemed after inspection by General®
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 consumable parts or
components.

Repairs made without the written consent of General® International will void all warranty.

TABLE OF CONTENTS

Rules for safe operation . . . . . . . . . . . . . . .5

Installation . . . . . . . . . . . . . . . . . . . . . . . .6

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Identification of main parts

and components . . . . . . . . . . . . . . . . . . . .

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . .8

List of contents - 40-060 Stand . . . . . . . . . . . . . . . . .8

List of contents - 40-065 Router fence . . . . . . . . . . .8

List of contents - 40-125 Router lift . . . . . . . . . . . . . .9

List of contents - 40-130 Dust collection kit . . . . . . .9

List of contents - Table . . . . . . . . . . . . . . . . . . . . . . .10

Additional requirements for set up . . . . . . . . . . . .10

Assembly instructions . . . . . . . . . . . . .11-22

40-060 Router table stand . . . . . . . . . . . . . . . .11

Table 40-070/40-047/40-043 . . . . . . . . . . . . . .13

Cleaning the cast-iron table (for #40-100 only) . .13
Install the table (cast-iron table #40-100C and

phenolic table # 40-100P only) . . . . . . . . . . . . . . .13

Attach the table to the stand (cast-iron #40-100C

and phenolic #40-100P only) . . . . . . . . . . . . . . . .14

40-065 Router fence . . . . . . . . . . . . . . . . . . . .14

Prepare the table for router lift . . . . . . . . . . . .18

40-130 Dust collection kit . . . . . . . . . . . . . . . .19

Mounting a router . . . . . . . . . . . . . . . . . . . . . .20

Leveling and locking the router plate . . . . . . . . .22

Insert ring removal . . . . . . . . . . . . . . . . . . . . . . . . . .22

Installing the starting pin . . . . . . . . . . . . . . . . . . . .22

Operating instructions . . . . . . . . . . . . . . . . .24-26

efore starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

B

Using the spacer bars for jointing . . . . . . . . . . . . .25

Jointing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Groove cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Profile cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Tensioning the drive chain . . . . . . . . . . . . . . . . . . .26

7

Recommended optional accessories . . . . .27

Parts list & diagrams . . . . . . . . . . . . . .28-34

Contact information . . . . . . . . . . . . . . . . .35

Basic adjustments & controls . . . . . . . .23-24

Adjusting the fence along the rails . . . . . . . . . . . .23

Adjusting the sliding scale on the rails . . . . . . . . .23

Adjusting the fence faces . . . . . . . . . . . . . . . . . . . .23

Connecting the router to the safety switch . . . . .23

Using the safety switch . . . . . . . . . . . . . . . . . . . . . .24

Connecting to a dust collector . . . . . . . . . . . . . . .24

Rules for Safe Operation

o help ensure safeoperation, please take a momentto learn the machine’s applicationsand limitations, as well as poten-

T
tial hazards. General® International disclaims any real or implied warranty and holds itself harmless for any injury that
may result from improper use of its equipment.

. Make sure that the operator has been properly

1

trained and has read and understands the Owner’s
Manual before operating any machinery.

2. Be sure to read, understand and follow all instructions,
warnings and safety guidelines supplied with your
router.

3. Do not operate this router table when tired, distracted,
or under the effects of drugs, alcohol or any medica­tion that impairs reflexes or alertness.

4. Keep the work area well lit, clean and free of debris.

3. Secure the table to a work surface and never stand or

1

lean on it. Serious injury could occur if the table is
tipped or if unintentional contact is made with spin­ning router bit.

14. 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 re­installed before using the machine again.

15. Hold the workpiece firmly against the table and use
suitable support if the workpiece does not have a flat
surface.

5. Stay Alert! Give your work your undivided attention.
Even a momentary distraction can lead to serious
injury.

6. Do not wear loose clothing, gloves, bracelets, neck­laces, 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.

7. 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.

8. Fine particulate dust is a carcinogen that can be haz­ardous to health.Always work in a well ventilated area
and whenever possible use a dust collector to mini­mize health hazards.

9. Be sure the router is running up to speed before feed­ing the workpiece.

10. Use a suitable support if stock does not have a flat
surface.

11. Keep children and visitors at a safe distance when the
router is in operation – do not permit them to operate
the router and table.

16. Feed the stock into the bit against the rotation direc­tion of the bit. Never run the stock between the fence
and the bit.

17. Do not operate with a damaged bit in the router.

18. 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.

19. Be sure that all adjustment tools, wrenches or other
clutter are removed from the table surface and safely
stored before routing.

20. Make sure the routers switch is in the “OFF” position
before plugging in to a power source.

21. Avoid working from awkward or off balance positions.
Do not overreach and always keep both feet firmly on
the floor.

22. Never leave the router unattended while running or
with the power on.

23. Do not use this router table for any purpose other than
its intended use. If used for other purposes, GENERAL®
INTERNATIONAL disclaims any real or implied warranty
and holds itself harmless for any injury which may
result from such use.

12. Childproof and tamper proof your shop and all
machinery with locks, master electrical switches and
switch keys, to prevent unauthorized or unsupervised
use.

5

INSTALLATION

HE MACHINE IS HEAVY (119 LBS - 54 KG). DO NOT OVEREXERT. ARRANGE TO HAVE HELP NEARBY AND READY FOR UNPACK-

T
ING AND SET UP.

SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COM-

LETED THE INSTALLATION AND ASSEMBLY STEPS. DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED

P

O DO SO.

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INSTALL THE ROUTER TABLE ON A STABLE SURFACE

The unit should be installed on a flat, sturdy and stable
surface or workbench able to support the weight of
the machine and the workpiece with ease.

MOUNTING TO A WORK SURFACE

If a permanent shop placement is practical, consider
removing the rubber feet on the base and drilling
matching through holes in the mounting surface of your
workbench or stand to bolt the table in place (hard­ware not included) on your workbench.

If a permanent installation is not practical, clamps can
also be used to secure the table to a bench or work
table.

SAFETY

Never install the machine over the edge of a table
or workbench.

A

E F

B

C

D

ORDER OF ASSEMBLY

A- Stand legs
B- Hex head bolt
C- Flat washer
D- Workbench or stand
E- Flat washer
F- Lock washer
G- Hex nut

G

ROUTING MAY PRESENT SERIOUS INJURY HAZARDS TO UNTRAINED USERS. BE SURE TO READ, UNDERSTAND, AND FOL­LOW 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 WORK­ING ENVIRONMENT IS TAKEN INTO CONSIDERATION.

6

DELUXE ROUTER TABLE KIT (Bench top model)
Model #40-100

IDENTIFICATION OF MAIN PARTS AND COMPONENTS

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E

D

C

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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- DUST ENCLOSURE

N- RUBBER FEET

O- DUST VENT

P- ROUTER LIFT HANDLE HOLDER

* Model 40-100C Cast-iron table shown.

O

REAR VIEW

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Q- 2 1⁄4" BRANCH INLET

R- DUST HOSE

S- 4" DUST PORT

T- DOVETAIL SLOT

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7

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 Q

40-060 STAND (40-100)

a- CARRIAGE BOLT . . . . . . . . . . . . . . . . . . . . . .34

b- HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

c- FLAT WASHER . . . . . . . . . . . . . . . . . . . . . . . .34

d- ROUTER LIFT CRANK HANDLE HOLDER . . . . .1

e- HEX NUT (SMALL) . . . . . . . . . . . . . . . . . . . . .4

f- RUBBER FOOT . . . . . . . . . . . . . . . . . . . . . . . .4

g- PHILLIPS SCREW . . . . . . . . . . . . . . . . . . . . . . .4

h- HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

i- HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

j PHILLIPS SCREW (SMALL) . . . . . . . . . . . . . . .2

k- SWITCH BOX . . . . . . . . . . . . . . . . . . . . . . . . .1

l- LONG BOTTOM CROSS BRACE (REAR) . . . .1

m- LONG BOTTOM CROSS BRACE (FRONT) . . .1

n- MIDDLE CROSS BRACE (LEFT) . . . . . . . . . . . .1

o- SHORT BOTTOM CROSS BRACE (L & R) . . . .2

p- SHORT TOP CROSS BRACE (L & R) . . . . . . . .2

q- LONG TOP BRACE (FRONT & REAR) . . . . . . .2

r- LEG

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

TY

0-060 STAND (40-100)

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X 34

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LIST OF CONTENTS QTY

40-065 ROUTER FENCE (40-100)

a DUST SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . .1

b- 2 1⁄4" dust collection outlet. . . . . . . . . . . . .1

c- FENCE LOCKING HANDLE . . . . . . . . . . . . . .2

d- FENCE BODY . . . . . . . . . . . . . . . . . . . . . . . . .1

e- FENCE FACE . . . . . . . . . . . . . . . . . . . . . . . . . . .2

f FENCE SIDE RAIL W/SCALE . . . . . . . . . . . . . . .2

g- FENCE MOUNTING BRACKET . . . . . . . . . . . .2

h- SPACER BARS (FOR JOINTING WORK) . . . . .2

i- LOCK KNOB . . . . . . . . . . . . . . . . . . . . . . . . . .8

j- T-BOLT (LONG) . . . . . . . . . . . . . . . . . . . . . . . .6

k- CAP SCREW . . . . . . . . . . . . . . . . . . . . . . . . . .6

l- PLASTIC SPACER . . . . . . . . . . . . . . . . . . . . . . .2

m- FLAT WASHER (SMALL) . . . . . . . . . . . . . . . . .14

n- T-BOLT (SHORT) . . . . . . . . . . . . . . . . . . . . . . .2

o- PHILLIPS HEAD SCREW . . . . . . . . . . . . . . . . . .2

p- HEX NUT (LARGE) . . . . . . . . . . . . . . . . . . . . .2

q- FLAT WASHER (LARGE) . . . . . . . . . . . . . . . . .2

r- SQUARE NUT . . . . . . . . . . . . . . . . . . . . . . . . .8

s- HEX HEAD BOLT . . . . . . . . . . . . . . . . . . . . . . .6

40-065 ROUTER FENCE (40-100)

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8

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 Q

40-125 ROUTER LIFT

a- ROUTER LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . .1

b- ROUTER LIFT CRANK HANDLE . . . . . . . . . . . . .1

c- INSERT RING WRENCH . . . . . . . . . . . . . . . . . . .1

d- STARTER PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

e- HEX SOCKET HEAD BOLT . . . . . . . . . . . . . . . . . .2

f- 2.5 MM ALLEN KEY . . . . . . . . . . . . . . . . . . . . . .1

g- 3 MM ALLEN KEY . . . . . . . . . . . . . . . . . . . . . . .1

h- 4 MM ALLEN KEY . . . . . . . . . . . . . . . . . . . . . . .1

i- 6 MM ALLEN KEY . . . . . . . . . . . . . . . . . . . . . . .1

TY

0-125 ROUTER LIFT

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LIST OF CONTENTS QTY

40-130 DUST COLLECTION KIT

a- RIGHT SIDE PANEL . . . . . . . . . . . . . . . . . . . . . .1

b- BOTTOM PANEL . . . . . . . . . . . . . . . . . . . . . . . .1

c- REAR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . .1

d- LEFT SIDE PANEL . . . . . . . . . . . . . . . . . . . . . . . .1

e- FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

f- DUST HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

g- DUST PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

h- HOSE CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . .2

i- HEX HEAD BOLT . . . . . . . . . . . . . . . . . . . . . . . .6

j- LOCK WASHER . . . . . . . . . . . . . . . . . . . . . . . . .6

k- FLAT WASHER . . . . . . . . . . . . . . . . . . . . . . . . . .6

l- PHILLIPS HEAD SCREW (SHORT) . . . . . . . . . .22

m- PHILLIPS HEAD SCREW (LONG) . . . . . . . . . . . .3

40-130 DUST COLLECTION KIT

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9

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 QTY

a- 16” X 27” CAST-IRON TABLE (#40-070) . . . . . . 1

b- HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

- LEVELER SCREW . . . . . . . . . . . . . . . . . . . . . . 10

c

- FLAT WASHER. . . . . . . . . . . . . . . . . . . . . . . . . . 4

d

e- LOCK WASHER . . . . . . . . . . . . . . . . . . . . . . . . 4

f- HEX SOCKET CAP SCREW . . . . . . . . . . . . . . . 4

Model 40-100P:

LIST OF CONTENTS QTY

a- 15 3/4” X 25 5/8” PHENOLIC TABLE (#40-043) 1

- HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

b

- LEVELER SCREW . . . . . . . . . . . . . . . . . . . . . . 10

c

d- FLAT WASHER. . . . . . . . . . . . . . . . . . . . . . . . . . 4

e- LOCK WASHER . . . . . . . . . . . . . . . . . . . . . . . . 4

f- HEX SOCKET CAP SCREW . . . . . . . . . . . . . . . 4

Mounting hardware for #40-070 Cast-iron table (for model 40-100C)

b

c

a

Additional hardware is supplied with the cast–iron table to allow for
installation on a table saw as part of kit #40-070EK. Complete mount­ing instructions for the 40-070EK can be downloaded at the General
International website at: www.general.ca/manuals

d

e

f

Mounting hardware for #40-043 - Phenolic table (for model 40-100P)

Model 40-100M:

LIST OF CONTENTS QTY

a- 15 3/4” X 25 5/8” MDF TABLE (#40-047) . . . . 1

b- WOOD SCREW . . . . . . . . . . . . . . . . . . . . . . . 10

c- WOOD NUT. . . . . . . . . . . . . . . . . . . . . . . . . . . 2

d WOOD SCREW . . . . . . . . . . . . . . . . . . . . . . . 26

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

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Mounting hardware for #40-047 - MDF table (for model 40-100M)

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c

d

10

ASSEMBLY INSTRUCTIONS

SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COMPLE-

ED THE INSTALLATION AND ASSEMBLY STEPS. DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED TO DO

T
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.)

EAR

A

B

D

C

E

R

FRONT

1. Attach a rubber foot to each leg using a phillips
screw, flat washer and hex nut A, in the assembly
order shown in B.

F

G

H

3. Using 4 carriage bolts with flat washers and hex nuts,
F, attach one leg to one top brace and one top

cross brace as show in G, in the assembly order
shown in H.

2. Lay the stand braces and legs on the floor as
shown. This will help you to rapidly locate the
braces and know what to attach where.

Note: Bottom brace C goes on the rear of the stand and
bottom brace D goes on the front. Put middle cross brace,
E, aside for now.

I

J

4. Using the same hardware, attach a second leg to

the top cross brace, I, then attach the second top
brace J to this leg, as shown.

N

M

L

K

J

5. Attach a third leg K to the top brace J, then attach
second top cross brace L, then fourth leg M.

O

6. Attach the rear bottom cross brace N and the front
bottom cross brace O as shown.

11

P

S

T

R

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.

W

U

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.

11. Insert a phillips head screw with hex nut through
both holes on the middle cross brace, and from
the other side of the brace, lightly thread a hex
nut to lock the screws in position

X

W.

9. Install the switch box by sliding it’s mounting brack-

et over the right front leg X, and attach with the two
phillips head screws and washers already mount­ed to the bracket.

The insert ring wrench may be stored on one of the
screws as shown above.

10. Stand assembly is now complete.

12

TABLE 40-070/40-047/40-043

There are 3 different table options for Deluxe Router Table Kit, model 40-100:

ast-iron table (#40-070) for 40-100C

C

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. (Dispose of potentially flammable solvent­soaked rags according to manufacturer’s safety recom­mendations.)

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 any after-market surface protec­tant or rust inhibitor.

Phenolic table (#40-043) for 40-100P

Tip: With a screw driver, push a solvent-saturated rag into
the T-slots to remove the grease.

INSTALL THE TABLE (CAST-IRON TABLE #40-100C AND PHENOLIC TABLE#40-100P ONLY)*

* For #40-047 MDF table (for #40-100M), only thread in all leveler screws and nuts as shown below. You will use

the wood screws supplied with your table in the upcoming steps to attach the table and dust collection box
to the stand, and the fence mounting rails to the table.

B

5. As a precaution, thread in all fasteners as shown to
make sure there are no filings in any of the threaded
holes, and leave the fasteners in the underside of the
table. Only remove as assembly is taking place.

C

Note 1: The leveler screws need to be inserted from the
bottom of the table. The nut will sit on the top side of the
flange that the router lift/plate will rest on, A.

Note 2: There are 3 holes on each side of the table open­ing, 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.

A

13

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

1. With the table upside down, remove the 4 mounting
screws and washers, A, for the stand.

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.

B

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 tight-

en all bolts.

40-065 ROUTER FENCE

Before opening the fence, have a clear work area to prevent the mixing of hardware.

CAST-IRON TABLE #40-100C AND PHENOLIC TABLE #40-100P ONLY)*

Note: You will find 6 additional side bracket mounting fasteners in the fence hardware to attach the side brackets to the
cast iron table. These will not be required if you have purchased a complete kit, because the same fasteners have been
supplied with the table top.

For #40-047 MDF table (for #40-100M),use the wood screws supplied with your table to attach the mounting brackets

*

to the table.

Note: The hex head bolts and square nuts supplied with the fence are coarse thread and the hex head bolts supplied to attach
the #40-130 Dust Enclosure are fine thread.

A

B

D

1. Attach the two fence side rails with scale A to their
mounting brackets B, using 3 hex head bolts with flat
washers and square nuts C, in the assembly order
shown in D.

14

C

B

A

2. Remove the original 6 fence bracket mounting bolts
A from the table and attach one fence mounting
brackets to the underside of the table, B, using 3 bolts.

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.

5. Slide the 2 bolts and spacers to the middle of the
fence body (approx.)

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.

A

B

C

D

6. Install the orange dust shield A on the two bolts and
secure in place using two flat washers B and 2 lock
knobs C as shown in D.

7. Secure the dust shield in place by tightening the two
lock knobs.

Note: The dust shield can be adjusted in height along the
T-slots.

B

A

C

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 T­head of the bolts protruding from the fence.

15

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.

A

B

C

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.

A

A

B

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

B

C

B

15. Center the dust outlet with the hole in the fen­ce body A, then tighten the two phillips head
screws B.

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 tighten the locking handle to lock
the fence in position.

16

16. Insert a locking handle A with large flat washer B
in the T-slot at one end of the fence, then
from below, loosely thread a large hex nut C as
shown in D.

CLOSE UP VIEW

PREPARE THE TABLE FOR THE ROUTER LIFT

Note: Model #40-070 for 40-100C Cast-iron table shown. The following steps apply to all 3 table options.

1. Place the router lift into the opening in the table.

3. From the underside of the table, adjust the 4 phillips

head screws in the corners A - up or down until the
plate is flat and level with the table surface.

2. Use a straightedge to test the plate for level with the
table top.

A

4. Remove the lift and lock the adjuster screw in place
by turning the lock nut A clockwise (tighten).

Note: While tightening the lock nut, make sure that the
adjuster screw does not turn. Confirm by re-checking the
leveling of the lift and table surface.

5. After the four corners are set, proceed to set the
remaining 6 leveler screws and lock them in place.

17

40-130 DUST COLLECTION KIT

Note: There are three longer screws in the hardware kit that are required to attach the 4 inch hose adapter. Locate them
first. You will find additional mounting hardware to attach the 40-130 dust enclosure 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.

R

OTTOM

B

EAR

IGHT SIDE

R

RONT

F

EFT SIDE

L

1. Assemble dust enclosure as shown, using the 22
short phillips head screws.

2. Remove the fence then

turn the assembled router

table upside down.

3. Remove the 6 hex head bolts from the underside of
the table. (40-100C and 40-100P only)

Note: For #40-047 MDF table (for #40-100M), use the wood
screws supplied with your table to attach the dust collec­tion box to the table.

B

A

4. Position and secure the dust enclosure into place
using the 6 hex head bolts with lock washer and flat
washer A.

E

7. Turn the assembly back over to its upright and oper­ating position, then re-install the fence.

8. Using the remaining hose clamp, secure the other

end of the dust hose to the dust outlet on the
fence, E.

18

C

D

5. Using the supplied hose clamps, secure one end
of the dust hose to the 2 1/2” inlet on the dust port B.

6. Attach the dust port to the hole on the rear panel C,

using the 3 longer 3 phillips head screws D.

Note: To prevent overheating the router motor inside the
confined space of the enclosure, always use a dust col­lector or vacuum to allow for air to flow.

9. 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
opened to allow maximum airflow.

ASSEMBLY INSTRUCTIONS -

SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COM-

LETED THE INSTALLATION AND ASSEMBLY STEPS. DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED

P
TO DO SO.

MOUNTING A ROUTER

This model 40-125 “fixed base” router lift, A is designed to

ccommodate the largest diameter router motor body

a
currently available.

Note: Based on our research this is the Porter Cable model
7518 and 7519 router motors which measure 4.200” in diam­eter.

All other motors (smaller diameters) will require a shim C
(item # 40-626, available from you local General Intera­tional dealer), or a reducer collar such as our model 40­312 (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.

E

D

B

C

A

G

F

Note: The factory installed adjusting screw on the Milwau­kee motor must be lined up and inserted into the hole D
located in our clamping bracket E.

H

CLOSE UP VIEW

I

1. Insert the crank handle in the black hole sur­rounded by digits as shown in H.

2. To raise the lifting carriage on the router lift to the
highest or maximum upward position, turn the
crank handle clockwise.

Clean packing lubricant from the lift posts/screws F
and the chain G. Clean it by spraying with a solvant
which will dilute the grease, and then wipe clean or
use compressed air to “blow dry”. After degreasing,
reapply some dry lubricant.

3. Remove the crank handle, and flip the lift over in
the table.

19

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.

E

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.

E

E

Note: When mounting the Milwaukee model 5625/5626
motor, please ensure that a shim D is between the router
and the clamping surface of the lift.

5. Slide the router motor into the clamping area as
shown above using shim or reducers if necessary.

F

G

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.

H

Close but not touching

2. Adjust the height of the router in the collar H to
ensure that the router is as close as possible to the
underside of the plate without touching I.

20

tighten

J

I

3. With the router in position, tighten clamping bolt J
securely, using a using a 8 mm Allen key, but do not
over tighten. Important

: Test that the router is se­curely clamped in the reducer collar by trying to
twist the router in the collar by hand.

LEVELING AND LOCKING THE ROUTER PLATE

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.

A

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. (If
needed, refer back to the instructions on page 17.)

D

B

E

C

3. With the router plate leveled tothe 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

A

B

For #40-049 MDF table (for #40-200M) only: From the
underside of the table,thread the 2 supplied wood nuts
D onto the screws, as shown in E.

INSTALLING THE STARTING PIN

A

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 inser­tion, B.

Install the starting pin A into the threaded hole on the
router plate as shown. The starting pin can be used as
needed for freehand or template routing only.

21

BASIC ADJUSTMENTS & CONTROLS

ADJUSTING THE FENCE ALONG THE RAILS

B

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.

ADJUSTING THE FENCE FACES

A

ADJUSTING THE SLIDING SCALE ON THE RAILS

C

D

The scale on the rails can be adjusted along the rails
C. Loosen lock knob D,slide the fence up to where you
need it to be, then lock in position by re-tightening the
lock knob.Repeat for the sliding scale on the other rail.

C

B

Depending on the size of the workpiece and the bit being used, the white fence faces can be adjusted along the
fence body A. Loosen the 3 lock knobs, B on one side of the fence and then slide the fence face up to where you
need it to be. Then lock in position by re-tightening the lock knobs. Repeat with the second fence face on the other
side of the fence body.

Note: Do not slide the fence faces too far and off the first T-bolt head, as shown in C.

CONNECTING THE ROUTER TO THE SAFETY SWITCH

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.

A

B

1. Remove the top half of the power cord flange plate
from the side panel on the dust containment box A.

2. Pass the router’s power cord through the opening as
shown in B, taking just enough cord to reach the
inlet on the back of the safety switch box.

22

3. Re-install the power cord flange plate and plug the
router into the inlet on the back of the safety switch.

BEFORE TURNING ON THE SWITCH ON YOUR ROUTER,
MAKE SURE THE SWITCH ON THE SWITCH BOX IS IN
THE OFF POSITION AND THAT THE SWITCH BOX IS NOT
YET CONNECTED TO A POWER SOURCE.

USING THE SAFETY SWITCH

A

POWER ON

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.

POWER OFF

SAFETY KEY

PREVENTS START-UP

(

WHEN REMOVED)

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,con­sider contacting your General® International distributor
for information on our complete line of dust collection
systems or visit our website at: www.general.ca

B

With the safety switch on the stand in the “off” position
A, turn or flip the switch on your router to the “on” posi­tion 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 un­der the table to access the switch on the router.

ALWAYS TURN ON THE DUST COLLECTOR BEFORE STAR-

ING THE ROUTER AND ALWAYS STOP THE ROUTER

T
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 WORK­PIECE.

WHEN JOINTING, GROOVE CUTTING, AND/OR PROFILE CUTTING BE SURE TO ATTACH THE SUPPLIED DUST SHIELD.

BEFORE STARTING:

• 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.

23

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.

1.5 mm

0.7 mm

Note: both spacer bars should be used in the top and bot­tom t-slots in the fence body as shown. Take care to install
them in matching offset positions; both at 0.7mm or both
at 1.5mm.

Each spacer bar has two sides which allow you to off­set the outfeed fence by either 0.7 mm or 1.5 mm stag­gering.

JOINTING

A

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.

Note: when not in use, the spacer bars can be stored on
the t-track on the back of the fence body as shown.

B

1. Loosen but do not remove the outfeed fence face and install the spacer bars between the outfeed fence and
the fence body.

2. With the router unplugged and the safety switch in the off position, follow the instructions supplied with your router
and install a straight cutting bit in the router.

3. Adjust the height of the lift to raise or lower the bit as need until the bit is slightly higher than the workpiece.

4. Loosen the fence locking knobs, and using a straightedge, position the outfeed fence aligned flush with the bit.
A. Rotate the bit by hand to validate alignment with the “highest”point of the cutting edge on the bit, then tight-

en the knobs to lock the fence in position.

5. Adjust the height of the safety shield to make sure it clears the bit and the workpiece slightly.

6. If needed, loosen the lock knobs on the back of the fence and adjust the faces to adjust the gap between the
fence faces and the bit leaving a clearance of roughly 1/4” between the bit and each fence face, B.

7. Plug in and turn on the router and make a test cut on a waste sample before jointing your “good” workpieces.

24

GROOVE CUTTING

Beading is commonly defined as cutting a groove or
bead in the face of a board.

1. If installed, remove the spacer bars on the outfeed
ence.

f

2. With the router unplugged and the safety switch in the

off position, follow the instructions supplied with your
router and install a cutting bit in the router.

3. Raise or lower the router bit to the desired height.

4. Loosen the knobs and adjust the opening between

the fences to allow the bit to clear the edge of bothfences.

5. Adjust the main fence until the center of the bit has reached the desired distance, A.

6. Align the infeed and outfeed fences parallel to each other using a machinist square or a straightedge..

A

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.

1. Follow steps 1 and 2 from previous section “Groove

Cutting”.

2. Adjust the fence back and away from the bit only

enough to allow the guide bearing to control the depth of cut or use the starting pin as a support for the work
piece, as shown in B.

3. Adjust the fence as close as possible to the bearing. The fence will serve as a backup support, reducing the

chance of an accident.

B

A

TENSIONING THE DRIVE CHAIN

Proper tension on the drive chain helps maintain tool bit height in the lift without the need for a locking mechanism.
If you experience problems with tool creep it may be a sign that tension on the chain needs to be tightened. If so
proceed as follows:

Fig. 1 Fig. 2

CLOSE UP VIEW

CLOSE UP VIEW

A

1. Lower the lift to its lowest position and then remove

it from the table.

2. Using a 6 mm allen key loosen the cap screw A

(Fig.1).

C

3. Push the sprocket assembly B (Fig.2) further along
its slotted opening C (Fig.1) by hand to add tension
to the chain.

4. While holding the sprocket assembly in position,
tighten the cap screw to secure it in place.

Note: To avoid unnecessary adjustments, make sure that
the tool creep you are experiencing is not being cause by
the router slipping in the reducer collar or in the clamping
mechanism on the lift.

B

25

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.

or more information about our products, please visit our website at www.general.ca

F

Horizontal
featherboard

#40-175

For Excalibur router table.

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.

Reducer collar
(fits 3 1/2" motor)

#40-312

For Excalibur router lift
#40-125.

Shim

#40-626

Shim for Milwaukee router,
model 5625/5626.

Reducer collar
(fits 3 1/4" motor)

#40-314

For Excalibur router lift
#40-125.

Vertical featherboard

#40-160

For Excalibur router table.

Flip stop

#40-090

For Excalibur router fence
#40-065 (bench top model)
& #40-080 (floor model).

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

9 1/4" x 11 3/4"
Aluminum insert plate

#40-115

For Excalibur router tables.

4 pc insert ring set
1⁄4", 1⁄2", 2 1⁄2" & 1
3/8"" (30 mm for #40-

099)

#40-076

9 pcs brass precision tem­plate 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) & #40-080
(floor model).

26

4

4

3

1

7

7

7

7

7

7

7

7

5

6

5

6

9

8

2

2

CAST-IRON TABLE 27”X 16”

# 40-070

1

2

5
6

7

4

3

8

10 9

10

12

11

13

Cast-iron table

(with models #40-100C
& #40-070EK )

PARTS LIST – #40-070

PART NO. REFERENCE NO. DESCRIPTION SPECIFICATION QTY

40070-01 2716U014 CAST-IRON TABLE 16” X 27” 1
40075-02 903M06030 FLAT HEAD CAP SCREW M6 X 30 MM 2
40075-03 910M06000 HEX NUT M6 10
40075-04 905M06020 FLAT HEAD SCREW M6 X 20 MM 10
40075-05 914M061602 FLAT WASHER M6 6
40075-06 915M06000 LOCK WASHER M6 6
40075-07 901M06016 CAP SCREW M6 X 16 MM 6
40070-08 T2716020 DRILLING TEMPLATE 1
40070-09 904M10035 HEX BOLT M10 X 35 MM 3
40070-10 9014382503 FLAT WASHER M10 6
40070-11 915M10000 LOCK WASHER M10 3
40070-12 910M10008 HEX NUT M10 3
40070-13 953M11000A DRILL BIT Ø11 1

Phenolic table

(with model #40-100P)

PART NO. REFERENCE NO. DESCRIPTION SPECIFICATION QTY

40043-01 2716U014A PHENOLIC TABLE 400 X 600 MM 1
40045-02 903M06030 FLAT HEX SOCKET HEAD SCREW M6 X 30 2
40043-03 60700030A T-SLOT GUIDE RAIL 1
40045-04 902M05012 ROUND SOCKET HEAD SCREW M5 X 12 8
40045-05 905M06040 FLAT HEAD SCREW M6 X 40 10
40045-06 910M06000 HEX NUT 40130 10
40045-07 901M06016 HEX SOCKET HEAD SCREW M6 X 16 32
40045-08 914M061302 FLAT WASHER M6 24
40045-09 915M06000 LOCK WASHER M6 24

PARTS LIST – #40-043

27

2

2

6

6

6

6

5

34

1

7

MDF table

with model #40-100M)

(

PARTS LIST – #40-047

PART NO. REFERENCE NO. DESCRIPTION SPECIFICATION QTY

40047-01 2716E014B MDF TABLE 400 X 600 MM 1
40049-02 903M06030 FLAT HEX SOCKET HEAD SCREW M6 X 30 2
40049-03 907M06013 WOOD NUT M6 X 13 2
40049-04 907007004 WOOD SCREW 7 X 40 10
40047-05 60700030A T-SLOT GUIDE RAIL 1
40049-06 905316058A SELF TAPPING SCREW 3/16 X 5/8 8
40049-07 907316058 SELF TAPPING SCREW 3/16 X 5/8 32

NOTES:

28

2

3

4

4

7

4

16

33

33

32

1

6

6

1

7

3

5

35

3

5

11

17

6

6

17

10

4

7

8

15

9

13

12

18

16

17

19

20

35

35

1

14

5

2

1

5

13

14

9

16

17

19

18

12

8

Router Fence

(#40-065)

PARTS LIST – #40-065

PART NO. REF. N0. DESCRIPTION SPECIFICATIONS QTY

4006501 27160032A FENCE BODY 780 MM 1
40080-02 60100001A LOCK HANDLE 5/16” 2
40065-03 T2716002 SCALE 780 MM 1
40080-04 32240052A T-BOLT 6
40080-05 9145162302 FLAT WASHER M8 2
40080-06 939M08000B LOCK KNOB M8 8
40080-07 32240034 LOCK NUT M8 2
40080-08 27160035A H SPACER 388 MM 2
40065-09 27160036 FENCE FACES 388 MM 2
40080-10 32240037 SAFETY GUARD 1
40065-11 32240038 FENCE SPACER 2
40065-12 27160039 SIDE BRACKET BASE 240 MM 2
40065-13 27160040 SIDE BRACKET 280 MM 2
40065-14 27160041 RULE PLATE 205 MM 2
40065-15 T2716003 SCALE 205 MM 2
40080-16 935014000 SQUARE NUT 1/4” 8
40080-17 9140141602 FLAT WASHER M6 14
40080-18 901M06012 CAP SCREW M6 X 12 8
40080-19 904014058 HEX BOLT 1/4” X 5/8” 6
40080-20 940M06012 LOCK KNOB M6 X 12 2
40080-32 32240013A DUST PORT 1
40080-33 906014034 PHILLIPS HEAD SCREW 1/4” X 3/4” 2
40080-34 32240033A T-BOLT 2
40080-35 32240060 FLUOROWAY PAD 1

29

16

17

2

15

14

15

14

15

14

18

19

12

17

9

11

8

7

3

11

11

6

3

2

11

5

22

20

22

16

11

10

4

7

15

15

14

4

14

14

15

4

23

Stand

(#40-060)

30

PART NO. REF. NO. DESCRIPTION SPECIFICATIONS QTY

40060-02 27160015 LONG TOP BRACE (F&R) 2
40060-03 27160016 SHORT TOP CROSS BRACE (L&R) 2
40060-04 27160017 LEG 4
40060-05 27160018 LONG BOTTOM CROSS BRACE (FRONT) 1
40060-06 27160018A LONG BOTTOM CROSS BRACE (REAR) 1
40060-07 27160019 SHORT BOTTOM CROSS BRACE (L&R) 2
40060-08 27160022 SWITCH MOUNTING PLATE 1
40060-09 S3224011 SWITCH BOX 1
40060-10 27160020 HANDLE BRACKET 1
40060-11 909M06012 CARRIAGE BOLT M6 X 12 34
40060-12 L32240001 POWER CORD 14AWG X 3C 1
40060-14 910M06000 HEX NUT M6 48
40060-15 914M061602 FLAT WASHER M6 42
40060-16 906M05020 PHILLIPS HEAD SCREW M5 X 20 1
40060-17 906M04016 PHILLIPS HEAD SCREW M4 X 16 6
40060-18 904M06020 PHILLIPS HEAD SCREW M6 X 20 4
40060-19 30100016 RUBBER FOOT 4
40060-20 27160021 MIDDLE CROSS BRACE (LEFT) 1
40060-22 910M05000 HEX NUT M5 4
40060-23 914M051201 FLAT WASHER M5 2

PARTS LIST – #40-060

19

8

30

8A

24

8B

25

25

29

13

40

14

1

22

3

5

22

5

22

5

2

32

27

20

12

29

12

27

26

12

10

9

29

32

20

12

26

20

11

20

26

27

36

36

16

38

16

38

15

15

35

18

21

18

15

33

15

33

6

39

7

31

37

34

4

28

17

23

26

27

Router lift

(#40-125)

31

PARTS LIST – #40-125

PART NO. REF. N0. DESCRIPTION SPECIFICATIONS QTY

40125-01 60800001A ALUMINUM CARRIAGE BRACKET 1

40125-02 60500002 MAIN GEAR SHAFT 1
40125-03 60500003 LEAD SCREW 4
40125-04 60100017 INSERT RING 1-1/2” 1
40125-05 60500005 GEAR SHAFT 4
40125-06 60800021 CARRIAGE PLATE 4
40125-07 60800004 CLAMP POST 1
40125-08 60800007A TOP PLATE 1
40125-08A 60700031 STARTING PIN 1
40125-08B 906M06025 PHILLIPS HEAD SCREW M6 X 25 1
40125-09 60500009 CAM GEAR 1
40125-10 60700010 ELLIPTICAL WHEEL 1
40125-11 912M14000 NYLON NUT M14 1
40125-12 60500012 GEAR SPROCKET 5
40125-13 60700017 LOCK GUIDE NUT 1
40125-14 60700002 UPPER GUIDE NUT BASE 1
40125-15 914M061301 FLAT WASHER M6 8
40125-16 9140381902 FLAT WASHER M10 3
40125-17 60700009 LIFT CRANK HANDLE 1
40125-18 60800005 SLEEVE 3
40125-19 60800018 SCALE PLATE 1
40125-20 908M06006 SET SCREW M6 X 69
40125-21 60800002 BUSHING 4
40125-22 9236805Z0 BEARING 6805ZZ 5
40125-23 901M08020 CAP SCREW M8 X 20 1
40125-24 903M06018 FLAT HEX SOCKET HEAD SCREW M6 X 18 8
40125-25 903M04012 FLAT HEX SOCKET HEAD SCREW M4 X 12 2
40125-26 9180404018A KEY M4 X 4 X 12 5
40125-27 9236804Z0 BEARING 6804ZZ 5
40125-28 60700009B CRANK HANDLE SLEEVE 1
40125-29 9236900Z0 BEARING 6900ZZ 3
40125-30 903M06030 FLAT HEX SOCKET HEAD SCREW M6 X 30 2
40125-31 60800020 CHAIN 1
40125-32 919S01000 C-RING S10 2
40125-33 912M06000 NYLON NUT M6 4
40125-34 60100018 INSERT WRENCH 1
40125-35 60800003 BACK LASH LOCK 1
40125-36 901M10070A CAP SCREW M10 X 70 3
40125-37 910M10005 HEX NUT M10 2
40125-38 901M06060A CAP SCREW M6 X 60 4
40125-39 901M10055 CAP SCREW M10 X 55 1
40125-40 94300002 O-RING 12.42 X 1.78 1

NOTES:

32

20

20

4

19

13

8

7

3

4

4

2

17

6

12

3

10

11

12

15

16

14

18

5

3

3

1

3

3

9

Dust Collection Kit

#40-130)

(

PARTS LIST – #40-130

PART NO. REF. NO. DESCRIPTION SPECIFICATIONS QTY

40130-01 32240001 FRONT BOX PANEL 1
40130-02 32240002 RIGHT BOX PANEL 1
40130-03 906M04006A PHILLIPS HEAD SCREW M4
40130-04 906M04010A PHILLIPS HEAD SCREW M4
40130-05 32240003 HINGE 1
40130-06 32240004 LEFT BOX PANEL 1
40130-07 32240005 REAR BOX PANEL 1
40130-08 32240006 POWER CORD CLAMP 2
40130-09 32240007 BOTTOM BOX PANEL 1
40130-10 32240008 VENT BASE 1
40130-11 32240009 VENT ADJUSTMENT PLATE 1
40130-12 920040100 RIVET M3.2 5
40130-13 94800006B AIR HOSE (FENCE SIZE 35”) M63
40130-14 32240010 DOOR PANEL 1
40130-15 904M06012 HEX BOLT M6
40130-16 915M06000 LOCK WASHER M6 6
40130-17 914M061301 FLAT WASHER M6 6
40130-18 32240011 MAGNET 1
40130-19 32240012 DUST OUTLET 1
40130-20 952002034 HOSE CLAMP M63 2

X 6 28
X 10 7

X 90CM 1

X 12 6

33

MODEL 40-100

8360 Champ-d’Eau, Montreal (Quebec) Canada H1P 1Y3

Tel.: [phone]

Fax: [phone] - Parts & Service / Fax: [phone] - Order Desk

[e-mail]

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.