General 40-070EK User Manual
SETUP & OPERATION MANUAL
FEATURES
16" x 27" cast-iron router extension table can
be installed on 27”-29” table saws with cast-iron
tables*.
Includes self-adhesive mounting hole drilling
guide/template for easy installation.
Standard 9 1/4" x 11 3/4" router plate opening
with phenolic router plate included.
Two sturdy, flip-up, adjustable-length steel support legs.
Deluxe 27” router fence has 2 1/4” dust collection outlet and adjustable scales.
Kit Includes: 16" x 27" table (#40-070), set of two
adjustable-length steel support legs (#40-068),
deluxe router fence (#40-065) and 9 1/4" x 11
3/4" phenolic router insert plate (#40-114).
* Depending on mounting location, some drilling or
modifications may be required.
SPECIFICATIONS
CAST-IRON ROUTER EXTENSION KIT
FOR TABLE SAWS
• Table size
16" x 27" (902 x 686 mm)
• Router plate size
9 1/4" x 11 3/4"
• 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-slots & 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
3/4” x 3/8” (19 x 10 mm)
3/8” x 1/4” (10 x 7 mm)
• Table opening sizes (diameter)
With insert ring: 1/2" (38 mm)
Without insert ring: 3 3/4" (95 mm)
Version 1 - 29th January 2014
© Copyright General International
MODEL
#
40-070EK
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 40-070EK
router table. This cast-iron table 40-070EK 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 generations
of this model of router table
manual may be in circulation, if you own an earlier or
later version of this unit, this manual may not depict
your unit 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.
and several versions of this
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® 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 1-888-949-1161 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
Identification of main parts and components .................................................................. 6
Basic functions .................................................................................................................. 7
Unpacking ...................................................................................................................... 7-9
List of contents .................................................................................................................................................. 7-9
Cleaning............................................................................................................................. 9
Assembly instructions ................................................................................................... 9-19
Installing the router table support legs ............................................................................................................ 9
Installing the router table ................................................................................................................................. 10
Assembly the router table and support legs ................................................................................................. 12
Installing the router fence ................................................................................................................................ 13
Phenolic insert plate assembly ....................................................................................................................... 15
Leveling and locking the router plate ............................................................................................................ 16
Insert ring removal ............................................................................................................................................ 17
Installing the starting pin .................................................................................................................................. 17
Basic adjustments and controls ...................................................................................... 17
Adjusting the fence along the rails ................................................................................................................ 17
Adjusting the sliding scale on the rails ........................................................................................................... 17
Adjusting the fence faces ................................................................................................................................ 17
Operating Instructions ................................................................................................ 18-19
Using the spacer bars for jointing ................................................................................................................... 18
Jointing ............................................................................................................................................................... 18
Groove cutting .................................................................................................................................................. 19
Profile cutting ..................................................................................................................................................... 19
Recommended optionnal accessories ........................................................................... 20
Parts list & diagrams ................................................................................................... 21-23
Contact information ........................................................................................................ 24
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
harmless for any injury that may result from the improper use of it’s 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. Be sure to read, understand, and follow all instructions, warnings, and safety guidelines supplied
with your table saw and router.
3. Keep the work area well lit, clean, and free of
debris.
4. STAY ALERT! Give your work you undivided attention.
Even a momentary distraction can lead to serious
injury.
5. Do not wear loose clothing, gloves, bracelets, necklaces, or other jewelry. Wear protective hair covering to contain long hair and wear non-slip footwear.
6. 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 chipsand sawdust away with hands; use a brush.
7. 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.
8. Be sure the router bit and/or saw blade has gained
full operating speed before feeding the workpiece.
9. Keep children and visitors at a safe distance when
the table saw is in operation – do not permit them
to operate the table saw.
10. Childproof and tamper-proof your shop and all
machinery with locks, master electrical switches
and switch keys, to prevent unauthorized or unsupervised use.
11. Never stand or lean on your table saw. Serious injury can occur if the table saw is tipped or if unintentional contact is made with the spinning saw blade
or router bit.
®
International disclaims any real or implied warranty and hold itself
12. Keep all guards and safety devices in place and in
good working order. If a guard must be removed
for maintenance or cleaning make sure it is properly re-installed before using the machine again.
13. Hold the workpiece firmly against the table and use
suitable support if the workpiece does not have a
flat surface.
14. Feed the stock into the bit against the rotation direction of the bit. Never run the stock between the
fence and the bit.
15. Do not operate the router with a damaged bit
and/or the table saw with a damaged blade.
16. Always disconnect the router and/or the table
saw from the power source before changing accessories or before performing any maintenance
and adjustments or if the machine will be left unattended.
17. Be sure that all adjustment tools, wrenches, or other clutter are removed from the table surface and
safelystored before sawing or routing.
18. Make sure the router and/or table saw switch(es)
is (are) in the “OFF” position before plugging in to a
power source.
19. Avoid working from awkward or off-balance positions. Do not overreach and always keep both feet
firmly on the floor.
20. Never leave the table saw and/or router unattended while running or with the power “ON”.
21. Do not use this router extension wing/router fence
for any purposes other than its intended use.
22. 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.
5
IDENTIFICATION OF MAIN PARTS AND COMPONENTS
FRONT VIEW
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A. CAST-IRON ROUTER TABLE
B. FENCE RAIL WITH SLIDING SCALE
C. SLIDING ADJUSTABLE FENCE FACE
D. FENCE LOCKING HANDLE
E. DUST SHIELD LOCK KNOB
F. DUST SHIELD
G. FENCE BODY
K
H. 3/4” X 3/4” MITER T-SLOT (FOR MITER GAUGE)
I. 3/8” MITER T-SLOT (FOR SHOP MADE JIGS)
J. SUPPORT LEG
K. LEG ADJUSTMENT LOCK KNOB
L. LEG SWIVEL LOCK KNOB
M. PHENOLIC ROUTER INSERT PLATE
6
BASIC FUNCTIONS
The Excalibur by General International model 40-070EK Cast-Iron Router Extension Kit for Table Saws is designed
to provide you with the full features and functionality of a stand-alone shop router table along with space-saving
convenience and easy bolt-on installation directly to the end of your existing table saw.
The 40-070EK is designed to either be fit onto the end of, or to replace one of the existing cast-iron extension wings
on your table saw. Though 40-070 cast-iron table measures 27” the unit can also be installed centered on table
saws with 28” or 29” tables with only a slight protrusion of the saw table beyond each end. To facilitate such installations, a self adhesive center-marked drilling template is included to allow you to locate and mark the mounting
holes that may need to be drilled into your saw table or extension wing.
Deciding whether to install the wing to the left or right of the saw is entirely a matter of personal preference, and
will be determined by your own shop space considerations as well as the configuration, type, and model of saw
you are installing it on. Whichever side you choose, here are a few factors to consider before installing:
1. Some cabinet saws have motor cover doors that extend underneath beyond the main table, this may prevent
the router from being hung from that side of the saw, or may require lifting the router out of the table to allow
opening the motor cover door.
2. The distance between the 40-070EK support legs and the cabinet door should also be verified to ensure adequate clearance for the door.
3. Table saw rip fence rails that go beyond the width of the table saw may cause obstructions at one or both
ends, preventing installation of the router fence rails. Depending on your specific saw, the fence rails may need
to be repositioned or shortened, or you may be obliged to install the 40-070EK on one specific end of the saw.
4. At least 3 of the pre-drilled mounting holes in the 40-070 should be used to secure it to the saw table. One near
the front, middle, and rear. If mounting to the main table of your saw, drilling mounting holes into the lip of your
saw table may not be required. However if mounting to the end of the saw’s extension wing, mounting holes
will be required and an appropriate sized drill bit and mounting hardware are included.
UNPACKING
Carefully unpack and remove the components of the following 4 packages - that make up a complete Excalibur
40-070EK Router Table and check for damaged or missing items as per the list of contents below.
TIP: PLEASE REPORT ANY DAMAGED OR MISSING ITEMS TO YOUR GENERAL® INTERNATIONAL DISTRIBUTOR IMMEDIATELY.
INSERT PLATE (#40-114)
LIST OF CONTENTS QTY
A. ROUTER INSERT PLATE ................................................... 1
B. INSERT WRENCH ........................................................... 1
C. FLAT HEX SOCKET HEAD SCREW .................................. 2
D. INSERT RING .................................................................. 1
E. STARTING PIN ................................................................ 1
SUPPORT LEGS (#40-068)
LIST OF CONTENTS QTY
SWIVEL LOCK KNOB ................................................................ 2
A.
B. LEG ADJUSTMENT LOCK KNOB .............................................. 2
C. SUPPORT LEG ........................................................................... 2
D. LEG MOUNTING BRACKET....................................................... 2
E. EXTENSION LEG ....................................................................... 2
F. HARDWARE BAG/END CAPS ................................................... 1
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ROUTER FENCE (#40-065)
LIST OF CONTENTS QTY
A. DUST SHIELD .................................................................. 1
B. 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
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CAST-IRON ROUTER TABLE (#40-070)
LIST OF CONTENTS QTY
CAST-IRON TABLE 16” X 27” ..................................................... 1
A.
B. FLAT HEAD CAP SCREW ........................................................ 10
C. HEX NUT ................................................................................. 10
D. FLAT WASHER ............................................................................ 4
E. LOCK WASHER ......................................................................... 4
F. CAP SCREW ............................................................................ 4
G. HEX BOLT .................................................................................. 3
H. FLAT WASHER ............................................................................ 6
I. LOCK WASHER ......................................................................... 3
J. HEX NUT ................................................................................... 3
K. DRILL TEMPLATE AND DRILL BIT ............................................... 1
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