General 30-120 M1 User Manual
SETUP & OPERATION MANUAL
FEATURES
Cast-iron table and head for smooth vibration free performance.
Heavy-duty cast-iron dovetailed column,
precision machined for smooth cutter
head height adjustment.
Precision high-speed, sealed,
pre-lubricated bearings.
Independent, variable speed feed motor
provides added control for precision, tearout free performance with hardwoods and
stock with figured grain.
Jackscrew style cutter head adjustment
system.
Triple guide bearing design allows for
curved moldings
Easily adjustable guide fence system; simple lock knob design, to keep stock in-line
through the cut.
In-feed and out-feed table extension
rollers, for added support with longer workpieces.
Magnetic 2-step safety switch to prevent
unwanted or unintentional start-up is
equipped with an extra-large easy access
stop panel and a lock-out key to prevent
unauthorized use of the molder.
Built-in dust hood with 4” dust outlet.
Variable feed speed.
7” MOLDER
SPECIFICATIONS
MAXIMUM PLANING WIDTH
7” (178 MM)
MAXIMUM MOLDING WIDTH
6 3⁄4” (171 mm)
MAXIMUM THICKNESS OF STOCK
8” (203 mm)
MINIMUM THICKNESS OF STOCK
1⁄4” (6 mm)
MINIMUM LENGTH OF STOCK
8” (203 mm)
MAXIMUM DEPTH OF CUT (PLANING)
1⁄8” (3 mm)
MAXIMUM DEPTH OF CUT (MOLDING)
3⁄4” (19 MM)
NUMBER OF KNIVES
2
CUTTER HEAD SPEED
7000 RPM
FEED SPEED (VARIABLE)
3 - 20 FPM (0.9 - 6.1 MPM)
MOTOR
2 HP 220 V, 1 PH, 12 A
OVERALL DIMENSIONS (L X W X H)
32” X 27 1⁄2” X 51” (813 X 699 X 1295 MM)
WEIGHT
242 LBS (110 KG)
MODEL
#30-120 M1
Version 2 _ Revision 1 - November 11, 2013 (s/n 32228713)
© Copyright General® International 11/2013
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 General
®
International model 30-120 M1
7” Molder. This molder 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 molder 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 corres-
ponds 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 generations of this model of molder 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
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.
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
nent 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.
®
International agree to repair or replace any part or compo-
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
designated by General
International, or to a nearby distributor, repair center or other location
®
International. For further details call our service department at
1-888-949-1161 or your local distributor for assistance when filing your claim.
Along with the return of the product being claimed for warranty, a copy of the original proof
of purchase and a “letter of claim” must be included (a warranty claim form can also be used
®
and can be obtained, upon request, from General
International or an authorized distributor)
clearly stating the model and serial number of the unit (if applicable) and including an 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
Electrical requirements . . . . . . . . . . . . . . .6
Grounding instructions . . . . . . . . . . . . . . . . . . . . . . .6
Circuit capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Extension cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Identification of main parts
and components . . . . . . . . . . . . . . . . . . . .
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . .8
List of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Additional requirements for set up . . . . . . . . . . . . .8
Placement within the shop /
Establishing a safety zone . . . . . . . . . . . . .
Checking/Setting the knives for planing 13-15
Setting one knife parallel to the table . . . . . . . . .14
Setting the height of the second knife . . . . . . . . .15
Adjusting the feed rollers . . . . . . . . . . .16-17
Adjusting the feed roller height . . . . . . . . . . . . . . .16
Adjusting the feed roller pressure . . . . . . . . . . . . .17
To install molding knives . . . . . . . . . . . . .18
7
Operating instructions . . . . . . . . . . . . .20-24
Basic principles of planing/molding . . . . . . . . . .20
Selecting boards suitable for planing/molding .20
Rated limits of this molder/planer . . . . . . . . . . . . .20
Connecting to a dust collector . . . . . . . . . . . . . . .21
Checklist before starting . . . . . . . . . . . . . . . . . . . . .21
Planing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Repeat/multiple passes (for planing & molding) .23
9
Molding curved pieces using the elliptical jig . .24
Preparation & Clean up . . . . . . . . . . . . . . . .9
Install the cutter head height adjustment
handwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Remove the styrofoam block . . . . . . . . . . . . . . . . . .9
Remove the protctive plastic sheet . . . . . . . . . . . . .9
Clean up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Assembly instructions . . . . . . . . . . . . . . .10
Mount the magnetic safety switch . . . . . . . . . . . .10
Attach the leveling feet to the stand . . . . . . . . . . .10
Install the belt on the drive pulley . . . . . . . . . . . . .10
Basic adjustments & controls . . . . . . . .11-13
Raising/Lowering the cutter head for
depth of cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Connecting to a power source . . . . . . . . . . . . . . .12
On/off power switches . . . . . . . . . . . . . . . . . . . . . .12
On/off magnetic power switch . . . . . . . . . . . . . . .12
Feed motor switch with safety key . . . . . . . . . . . .12
Thermal relay/circuit breaker . . . . . . . . . . . . . . . .13
Changing feed speed . . . . . . . . . . . . . . . . . . . . . .13
Maintenance . . . . . . . . . . . . . . . . . . . .25-19
Periodic maintenance . . . . . . . . . . . . . . . . . . . . . .25
Drive chain/gear lubrication . . . . . . . . . . . . . . . . .26
Inspecting/replacing cutte head knives . . . . . . .26
Recommended optional accessories . . . . .27
Parts list & diagrams . . . . . . . . . . . . . .28-34
RULES FOR SAFE OPERATION
To help ensure safe operation, please take a moment to learnthe machine’s applications and limitations, as well as poten-
ial hazards. General® International disclaims any real or implied warranty and holds itself harmless for any injury that
t
may result from improper use of its equipment.
1. Do not operate this molder when tired, distracted, or
under the effects of drugs, alcohol or any medication
that impairs reflexes or alertness.
2. The working area should be well lit, clean and free of
debris.
3. Keep children and visitors at a safe distance when the
molder is in operation; do not permit them to operate
the molder.
4. Childproof and tamper proof your shop and all ma-
chinery with locks, master electrical switches and
switch keys, to prevent unauthorized or unsupervised
use.
5. Stay alert! Give your work your undivided attention.
Even a momentary distraction can lead to serious
injury.
6. Fine particulate dust is a carcinogen that can be
hazardous to health. Work in a well-ventilated area
and whenever possible use a dust collector. Wear
face, eye, ear, respiratory and body protection
devices.
7. Do not wear loose clothing, gloves, bracelets, neck-
laces or other jewelry while the molder is in operation.
Wear protective hair covering to contain long hair
and wear non-slip footwear.
8. Be sure that adjusting wrenches, tools, drinks and
other clutter are removed from the machine and/or
the table surface before operating.
13. Do not push or force stock into the cutter head. The
molder will perform better and safer when working at
the rate for which it was designed.
14. Kickback is when the workpiece is ejected at high
speeds by the force of the cutter head. To minimize the
risk of injury from kickback, use proper feeding technique and stand to one side, out of the path of a potential kickback.
15. Select appropriate feed speed for the stock being
planed: high speed for softwood and slow for hardwoods.
16. Place stock firmly against the table and use suitable
in-feed and out-feed support if stock is too long.
17. Keep guards in place and in working order. If a guard
must be removed for maintenance or cleaning make
sure it is properly attached before using the machine
again.
18. Use of parts and accessories NOT recommended by
GENERAL®INTERNATIONAL may result in equipment
malfunction or risk of injury.
19. Never stand or lean on machinery. Serious injury could
result if the tool is tipped over or if the cutting tool is unintentionally contacted.
20. Always disconnect the tool from the power source
before servicing or changing accessories such as
knives, or before performing any maintenance or
cleaning, or if the machine will be left unattended.
9. Keep hands well away from knives and all moving
parts. Use a push stick to feed stock, and a brush, not
hands, to clear away chips and dust.
10. Be sure that the knives are securely installed in the
cutter head.
11. Always use clean, properly sharpened knives. Dirty or
dull knives are unsafe and can lead to accidents.
12. Inspect stock and remove all foreign objects before
planing. Make sure that any stock you plane is clean
and free of any dirt,nails, staples, tiny rocks or any other
foreign objects that may damage the molder knives.
Only process natural solid wood boards. Never plane
MDF, particle board, plywood, laminates or other synthetic materials.
21. Make sure that the switch is in the “OFF” position before
plugging in the power cord.
22. Make sure the tool is properly grounded. If equipped
with a 3-prong plug it should be used with a three-pole
receptacle. Never remove the third prong.
23. Do not use this molder for other than its intended use.
If used for other purposes, GENERAL INTERNATIONAL
disclaims any real implied warranty and holds itself
harmless for any injury, which may result from that use.
5
ELECTRICAL REQUIREMENTS
EFORE CONNECTING THE MACHINE TO THE POWER SOURCE, VERIFY THAT THE VOLTAGE OF YOUR POWER SUPPLY CORRESPONDS
B
WITH THE VOLTAGE SPECIFIED ON THE MOTOR I.D. NAMEPLATE. A POWER SOURCE WITH GREATER VOLTAGE THAN NEEDED CAN
ESULT IN SERIOUS INJURY TO THE USER AS WELL AS DAMAGE TO THE MACHINE. IF IN DOUBT, CONTACT A QUALIFIED ELECTRICIAN
R
BEFORE CONNECTING TO THE POWER SOURCE.
HIS TOOL IS FOR INDOOR USE ONLY. DO NOT EXPOSE TO RAIN OR USE IN WET OR DAMP LOCATIONS.
T
A
B
GROUNDING INSTRUCTIONS
In the event of an electrical malfunction or short circuit,
grounding reduces the risk of electric shock to the operator. The motor of this machine is wired for 220V single
phase operation and is equipped with a 3-conductor
cord A and a 3-prong grounded plug B to fit a matching grounding type receptacle C.
DO NOT MODIFY THE PLUG PROVIDED ! If it will not fit your recepta-
cle, have the proper receptacle installed by a qualified electrician.
CHECK with a qualified electrician or service person if
you do not completely understand these grounding
instructions, or if you are not sure the tool is properly
grounded.
C
EXTENSION CORDS
The use of an extension cord is not generally recommended for 220V equipment. If you find it necessary,
use only 3-wire extension cords that have 3-prong
grounding plug and a matching 3-pole receptacle that
accepts the tool’s plug. Repair or replace a damaged
extension cord or plug immediately.
If you find it necessary to use an extension cord with
your machine make sure the cord rating is suitable for
the amperage listed on the motor I.D. plate. An undersized cord will cause a drop in line voltage resulting in
loss of power and overheating. The accompanying
chart shows the correct size extension cord to be used
based on cord length and motor I.D. plate amp rating.
If in doubt, use the next heavier gauge. The smaller the
number, the heavier the gauge.
TABLE - MINIMUM GAUGE FOR CORD
AMPERE
RATING
< 5
6 TO 10
10 TO 12
12 TO 16
* NR = Not Recommended
220 VOLTS 25 FEET 50 FEET 100 FEET 150 FEET
------->
------->
------->
------->
TOTAL LENGTH OF CORD IN FEET
AWG
18 16 16 14
18 16 14 12
16 16 14 12
14 12 * NR * NR
CIRCUIT CAPACITY
Make sure that the wires in your circuit are capable of
handling the amperage draw from your machine, as
well as any other machines that could be operating on
the same circuit. If you are unsure, consult a qualified
electrician. If the circuit breaker trips or the fuse blows
regularly, your machine may be operating on a circuit
that is close to its amperage draw capacity. However, if
an unusual amperage draw does not exist and a
power failure still occurs, contact a qualified technician
or our service department.
6
7” MOLDER
0-120 M1
3
IDENTIFICATION OF MAIN PARTS AND COMPONENTS
A
C
D
E
H
J
K
F
I
L
B
G
E
A- CUTTER HEAD HEIGHT
ADJUSTMENT HANDWHEEL
B- BELT COVER
C- DUST HOOD
D- FEED MOTOR
E- TABLE EXTENSION ROLLERS
F- FENCES
G- FENCE LOCK KNOBS
M
H- FEED SPEED CONTROL KNOB
I- FEED MOTOR SWITH WITH SAFETY KEY
J- THERMAL RELAY
K- PANEL
L- MAGNETIC SWITCH WITH LOCK-OUT KEY
M- STAND
7
UNPACKING
Carefully unpack and remove the molder and its components from the box and check for damaged or missing items as per the list of contents below.
NOTE: Please report any damaged or missing items to
your General International distributor immediately.
LIST OF CONTENTS QTY
MOLDER.........................................................................1
A-
HANDWHEEL ..................................................................1
B-
A
EVELING FOOT & HARDWARE
L
C - HEX NUT .........................................................................4
D - FLAT WASHER .................................................................4
E - LEVELING FOOT .............................................................4
ELLIPTICAL JIG & HARDWARE
F - ELLIPTICAL JIG................................................................1
G - IDLER BEARING ..............................................................1
H - CAP SCREW M8 X 1.25 - 110L .....................................2
I - WASHER..........................................................................2
J - BUTTON HEAD SCREW M6 X 1.0 - 16L. ........................2
TOOLS
SCREWDRIVER ...............................................................1
K -
22-24 MM OPEN END WRENCH ..................................1
L -
17-19 MM OPEN END WRENCH ..................................1
M -
12-14 MM OPEN END WRENCH ..................................1
N -
7-8 MM OPEN END WRENCH ......................................1
O -
6 MM ALLEN KEY ..........................................................1
P -
4 MM ALLEN KEY ..........................................................1
Q -
2 MM ALLEN KEY ...........................................................1
R-
4 MM T-HANDLE WRENCH.............................................1
S -
:
:
B
F
G
H
D
ADDITIONAL REQUIREMENTS FOR SET UP
• Extra person for help with lifting
• Feeler gauge set (0.030”)
• 3 mm Allen key
• Gauge block
8
C
E
I
J
K
L
M
T
N
O
P
Q
R
PLACEMENT WITHIN THE SHOP / ESTABLISHING A SAFETY ZONE
HIS MODEL 30-120 M1 7” MOLDER IS HEAVY. DO NOT OVER-EXERT. THE HELP OF AT LEAST ONE ASSISTANT OR A HOIST WILL BE
T
NEEDED FOR THE FOLLOWING STEP.
TO LIMIT THE RISK OF SERIOUS INJURY OR DAMAGE TO THE MACHINE, ANY EQUIPMENT USED TO LIFT THIS MACHINE SHOULD HAVE
RATED CAPACITY IN EXCESS OF 242 LBS (110 KG).
A
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 molder and the operator. Using the dimensions shown as a guideline, plan for placement within
your shop that will allow the operator to work unencumbered and unobstructed by foot traffic (either passing
shop visitors or other shop workers) or other tools or
machinery.
ESTABLISHING A SAFETY ZONE
For shops with frequent visitors or multiple operators, it is
advisable to establish a safety zone around shop
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.
51”
32”
27½”
PREPARATION & CLEAN UP
INSTALL THE CUTTER HEAD HEIGHT ADJUSTMENT HANDWHEEL
B
A
C
1. Using a 3 mm Allen key, loosen the set screw A on
the handwheel.
2. Fit the handwheel shaft onto the shaft, B.
3. Tighten the set screw C to secure the handwheel in
place.
REMOVE THE PROTECTIVE PLASTIC SHEET
1. Loosen the fence lock knobs F and remove the
fences G and H.
2. Remove the protective plastic sheet I from the
table.
REMOVE THE STYROFOAM BLOCK
D
E
To limit the potential for damage in transport, this molder is shipped from the factory with the molder’s head sitting on a styrofoam block for support.
1. Loosen the cutter head lock lever D by turning it
counterclockwise.
height of the cutter head with it’s lock lever tightened
will cause premature wear of the locking mechanism.
2. Rotate the handwheel counterclockwise to raise
the cutter head enough to remove the styrofoam
block E.
Important! Attempting to adjust the
H
G
F
I
9
CLEAN UP
The protective coating on the table, K, prevents rust
from forming during shipping and storage. Remove it
by rubbing with a rag dipped in kerosene, mineral
spirits or paint thinner.
Important: Dispose of potentially flammable solventsoaked rags according to manfacturer’s safety recommendations.
K
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.
Note: Avoid rubbing the molder’s painted surfaces, as many
solvent-based products will remove paint.
Tip: To prevent rust, apply a light coating of paste wax
or use regular applications of any after-market surface
protectant or rust inhibitor.
ASSEMBLY INSTRUCTIONS
For your convenience this molder is shipped from the factory partially assembled and requires only minimal assembly and set up before being put into service.
MOUNT THE MAGNETIC SAFETY SWITCH
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.
A
B
Attach the magnetic safety swith to the right side of the
molder using the 2 button head screws already
mouned to the stand A as shown in B.
ATTACH THE LEVELING FEET TO THE STAND
B
C
A
Attach the 4 leveling feet A to the stand using 2 nuts B
and 1 washer C.
Note: After the stand is placed in its final location, level
the feet by loosening the top nut, adjusting lower nut up or
down on the screw stem as needed, then tightening down
the top nut.
10
INSTALL THE BELT ON THE DRIVE PULLEY
CLOSE UP
D
D
Note: To limit the potential for damage in transport, this
molder is shipped from the factory with the motor mounting plate secured to the stand with a cap screw D.
1. Using the supplied 6 mm allen key, loosen and
remove the cap screw and flat washer D that secures the motor mounting plate to the stand.
H
F
F
G
I
I
F
2. Using the supplied 4 mm T-handle wrench, loosen
and remove the 3 Allen screws F, then remove the
pper pulley cover G.
u
Note: The dr ive belt is already installed on the upper
pulley H.
J
4. Remove the motor cover panel to access the
motor J.
I
3. Using the supplied 4 mm T-handle wrench, unscrew and remove the 4 button head screws I
that secure the motor cover panel to the stand.
I
K
5. With the help of an assistant, lift the motor up and
install the other end of the belt in the slot on the
lower pulley K.
6. Re-install the motor cover panel and upper pul-
ley cover.
BASIC ADJUSTMENTS & CONTROLS
RAISING/LOWERING THE CUTTER HEAD FOR DEPTH OF CUT
The depth of cut is set by raising or lowering the cutter head.
DOWN
UP
1. Loosen the cutter head lock lever A by turning it
counterclockwise.
Important! Attempting to adjust the height of the cutter
head with it’s lock lever tightened will cause premature
wear of the locking mechanism.
2. Use handwheel B to adjust the cutter head height to
the desired depth of cut, turning:
- Clockwise to raise the cutter head.
- Counterclockwise to lower the cutter head.
B
A
1/3 x = 1/32”
C
A
Note: the depth gauge, C, on the front of the machine can
be used as a reference but it is not intended for high precision measurements
3. Re-tighten lock lever A to secure the cutter head in
position.
NOTE: 1/3 of a clockwise rotation of the crank handle
will raise the cutter head by 1/32”. 1/3 of a counterclockwise rotation will lower the cutter head by 1/32”.
11
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