SETUP & OPERATION MANUAL
FEATURES
Extra large, heavy cast-iron table with a
smooth, ground surface finish.
Two (2) spindle speeds, with reverse.
Aluminum Independent left and right
fences feature precision micro-adjustment.
Two (2) spindles included: 1/2" (Item #40-
215) & 3/4" (Item #40-220).
T-slot miter gauge for better workpiece
control.
Industrial motor protected against dust by
a totally enclosed cabinet.
Fence system / cutter head guard
includes a cutter guard, spring hold-downs
and a built-in 4” dust collection outlet.
1/4” & 1/2” router bit adapters included.
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 machine.
3/4” WOOD SPINDLE SHAPER
SPECIFICATIONS
TABLE SIZE
27” x 25” (686 x 635 mm)
TABLE HEIGHT
34” (864 mm)
SPINDLE OPENING DIAMETERS
7”, 3 1/2” & 3” (177, 89 & 76 mm)
SPINDLES DIAMETERS
1/2” & 3/4” (13 & 19 mm)
SPINDLE TRAVEL
3” (76 mm)
SPINDLE SPEEDS
8000 & 10 000 RPM
FENCE SIZES (ALUMINUM)
3” x 11”(76 x 279 mm)
DUST CHUTE OUTLET
4” (102 mm)
OVERALL DIMENSIONS (L X W X H)
21 1/4” x 17 1/4” x 42 1/2”
(540 x 438 X 1080 mm)
MOTOR
3 HP, 220 V, 1 PH
MODEL
#40-250 M1
WEIGHT
NET: 326 LBS (148 kg)
SHIPPING: 343 LBS (156 kg)
VERSION 2_RE0VISION 1 - December 14/11
© Copyright General® International 12/2011
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 40-250 M1
3/4" spindle shaper. This shaper 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 shaper 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 shaper 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®& GENERAL®INTERNATIONAL WARRANTY
All component parts of General®, 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® and General®
International agree to repair or replace any part or component which upon examination,
proves to be defective in either workmanship or material to the original purchaser for the life
of the tool. However, the Limited Lifetime Warranty does not cover any product used for profes-
sional or commercial production purposes nor for industrial or educational applications. Such
cases are covered by our Standard 2-year Limited Warranty only. The Limited Lifetime Warranty
is also subject to the “Conditions and Exceptions” as listed below.
Standard 2-Year Limited Warranty
All products not covered by our lifetime warranty including products used in commercial,
industrial and educational applications are warranted for a period of 2 years (24 months) from
the date of purchase. General® and General® International agree to repair or replace any
part or component which upon examination, proves to be defective in either workmanship or
material to the original purchaser during this 2-year warranty period, subject to the“conditions
and exceptions” as listed below.
To file a Claim
To file a claim under our Standard 2-year Limited Warranty or under our Limited Lifetime
Warranty, all 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®
or 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® Internationallwill 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
Placement within the shop /
Establishing a safety zone . . . . . . . . . . . . .
Clean up . . . . . . . . . . . . . . . . . . . . . . . . . .9
Assembly instructions . . . . . . . . . . . . . . .10
Operation instructions . . . . . . . . . . . . .12-13
Changing cutters . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Table insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Operating controls for the fence . . . . . . . . . . . . . .13
Workpiece hold down adjustment . . . . . . . . . . . .13
Protection guard adjustment . . . . . . . . . . . . . . . . .13
Fence adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .13
Tool changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Before operating . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Cutter rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Grain direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
7
Straight edge shaping . . . . . . . . . . . . . . . . . . . . . .15
Depth of cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Edge shaping: long boards . . . . . . . . . . . . . . . . . .15
Edge shaping: short boards . . . . . . . . . . . . . . . . .15
End shaping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Shaping sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Shaping contoured edges with rub collar . . . . .16
Enclosed edge shaping . . . . . . . . . . . . . . . . . . . . .17
Templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
9
Multi-pieces templates . . . . . . . . . . . . . . . . . . . . . .17
Securing a template to the workpiece . . . . . . . .18
Horizontal toggle clamp . . . . . . . . . . . . . . . . . . . . .18
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Special cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Stacked cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Butt joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Basic adjustments & controls . . . . . . . .11-12
Connecting to a power source . . . . . . . . . . . . . . .11
On/off magnetic power switch . . . . . . . . . . . . . . .11
Forward/reverse switch . . . . . . . . . . . . . . . . . . . . . .11
Speed change and belt adjustment . . . . . . . . . .11
Spindle raising and lowering . . . . . . . . . . . . . . . . .12
Changing spindles . . . . . . . . . . . . . . . . . . . . . . . . .12
Tenoning . . . . . . . . . . . . . . . . . . . . . . . . .20
Parts list & diagrams . . . . . . . . . . . . . .21-23
RULES FOR SAFE OPERATION
To help ensure safeoperation, please take a moment tolearn the machine’s applications andlimitations, 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 the shaper 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
shaper is in operation; do not permit them to operate
the shaper.
4. Childproof and tamper proof your shop and all machinery 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, necklaces 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.
12. Make sure the cutting tool is running at full operating
speed before feeding the work piece.
13. Always use clean, properly sharpened cutters. Dirty,
dull, bent, cracked or otherwise damaged cutters or
bits are unsafe and can lead to accidents.
14. Feed the stock into the cutter or bit against the rotation
direction of the cutter or bit. Never run the stock
between the fence and the cutter.
15. Keep guards in place and in working order. If a guard
must be removed for maintenance or cleaning be
sure it is properly re-attached before using the tool
again.
16. Never leave the machine unattended while it is
running or with the power on.
17. Use of parts and accessories NOT recommended by
GENERAL INTERNATIONAL may result in equipment
malfunction or risk of injury.
18. Never stand on machinery. Serious injury could result
if the tool is tipped over or if the cutting tool is unintentionally contacted.
19. Always disconnect the tool from the power source
before servicing or changing accessories such as
cutters, or before performing any maintenance or
cleaning, or if the machine will be left unattended.
20. Make sure that the switch is in the “OFF” position before
plugging in the power cord.
9. Keep hands well away from knives and all moving
parts. Use a brush, not hands, to clear away chips and
dust.
10. Use recommended speed, cutters or bits, accessories
and work piece material.
11. Be sure the cutters are securely locked in the cutterhead before starting the machine.
21. 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.
22. Do not use this shaper 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
3/4" spindle shaper
0-250 M1
4
IDENTIFICATION OF MAIN PARTS AND COMPONENTS
B
A
K
J
I
C
D
E
F
G
H
A- WORKPIECE HOLD DOWN
B- GUARD
C- GUARD LOCK KNOB
D- GUIDE FENCE
E- FORWARD/REVERSE SWITCH
F- MOTOR ACCESS DOOR
G- MAGNETIC SAFETY SWITCH
H- CABINET
I- SPINDLE HEIGHT HANDWHEEL
J- TABLE EXTENSION
K- MAIN TABLE
7
UNPACKING
arefully unpack and remove the shaper and its components from the box and check for damaged or missing
C
items as per the list of contents below.
NOTE: Please report any damaged or missing items to your General International distributor immediately.
A
D
B C
E
J
H
F
G
K
N
O
I
P
Q
R
M
S
W
L
T
V
U
x
y
HEAD
LIST OF CONTENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . QTY
SAFETY GUARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A-
GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B-
PLATE GUARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C-
TENSION SPRING PLATE . . . . . . . . . . . . . . . . . . . . . . . 4
D-
FENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E-
GUARD LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . 2
F-
FENCE LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . 2
G-
FENCE RETAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
H-
TABLE SLOT RETAINER. . . . . . . . . . . . . . . . . . . . . . . . . 2
I-
PUSH STICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
J-
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
K-
MITER GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
L-
BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
M-
TABLE & CABINET ALREADY MOUNTED
8
LIST OF CONTENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . QTY
KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
N-
ROUTER ADAPTER (1/2” & 1/4) . . . . . . . . . . . . . . . . . 2
O-
SPINDLE 1/2” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
P-
SPINDLE 3/4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Q-
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
R-
PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
S-
DRAW BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
T-
HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
U-
ALLEN KEY 3 MM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
V-
ALLEN KEY 4 MM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
W-
WRENCH 12/14 MM . . . . . . . . . . . . . . . . . . . . . . . . . 1
X-
MULTIPLE WRENCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Y-
PLACEMENT WITHIN THE SHOP / ESTABLISHING A SAFETY ZONE
HIS MODEL 40-250 M1 3/4” SPINDLE SHAPER IS HEAVY. DO NOT OVER-EXERT. THE HELP OF AT LEAST ONE ASSISTANT OR A HOIST
T
WILL BE 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 326 LBS (148 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 vi-sitor. 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.
42½”
21¼”
17¼ ”
CLEAN UP
The protective coating on the table, 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 solvent-soaked
rags according to manfacturer’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.
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.
9
ASSEMBLY INSTRUCTIONS
For your convenience this shaper is shipped from the factory partially assembled and requires only minimal assembly and set up before being put into service.
B
A
C
Place the guard on the table and tightened by two
lock lever screws, A.
D
Place the plate guard on top of guard and tightened
by two knobs, D. Install the safety guard to front of
plate guard and tightened by two knobs, E. in proper
position.
E
Apart the lock lever, B, and T screw from the hardware
bag, and assemble these two parts to go through the
hole on the bracket, screw it clockwise and leave
some space, then slide the fence, C, through the T
screw till to proper position and tightened by lock
lever.
F
Place two bars on the hole of bracket and tightened
by hex screw, F .
G
Install two bars to the retainer and use the tension
spring plate to go through the retainer and tightened
by knob, G.
10
H
Insert the T screw on retainer, H, to go through the table
t-slot and move to proper position and tightened by
knob. Insert the tension spring plate to go through the
retainer and tighten the bolt, I.
I
S
TO
P
BASIC ADJUSTMENTS & CONTROLS
CONNECTING TO A POWER SOURCE
Once the assembly steps have been completed, plug the
power cord into an appropriate outlet. Refer back to the
section entitled “ELECTRICAL REQUIREMENTS” and make
ure all requirements and grounding instructions are fol-
s
lowed. When cutting operations have been completed
unplug the saw from the power source.
O AVOID UNEXPECTED OR UNINTENTIONAL START-UP,
T
AKE SURE THAT THE POWER SWITCH ON THE SAW IS IN
M
THE OFF POSITION BEFORE CONNECTING TO A POWER
OURCE.
S
O AVOID RISK OF SHOCK OR FIRE DO NOT OPERATE THE
T
UNIT WITH A DAMAGED POWER CORD OR PLUG. REPLACE
DAMAGED CORD OR PLUG IMMEDIATELY.
ON/OFF MAGNETIC POWER SWITCH
This model 40-250 M1 is equipped with a Magnetic 2step safety switch to prevent unwanted or unintentional
start-up and unauthorized use of the saw.
The switch assembly is equipped with a GREEN “START” button A, an extra-large easy access RED stop panel B, and
a lock-out key C.
To start the shaper
the GREEN “START” button A.
To stop the shaper
Once the RED“STOP” panel has been pressed, the saw can
only be started by pressing once again on the RED “STOP”
panel to release the green button, then by pressing on the green button.
: Insert the lock-out key C and press on
: Press on the RED “STOP” panel, B.
SWITCH OFF
A
B
FFOORRWWAARRDD//RREEVVEERRSSEE
SSWWIITTCCHH
C
FORWARD/REVERSE SWITCH
When reverse rotation needs to be used; power must be switched OFF" and press the reverse button.
TO PREVENT UNWANTED OR UNAUTHORIZED START-UP OR USAGE, REMOVE THE LOCK-OUT KEY AND STORE IT IN A SAFE PLACE, OUT
OF THE REACH OF CHILDREN, WHENEVER THE SAW IS NOT IN USE.
SPEED CHANGE AND BELT ADJUSTMENT
The 40-250 Shaper has been designed with 2 speed
pulley 8000 RPM & 10000 RPM.
Follow these procedures to change speed and adjust the
proper belt tension.
1. Disconnect machine from power source.
2. Open the base door.
3. Turn lock handle, A, counter clockwise to release belt
tension.
4. Move the belt to the other groove, B.
5. Push handle bar, C, to get proper belt tension.
6. Tighten the lock handle, A.
7. Close door.
B
A
C
11
SPINDLE RAISING AND LOWERING
Adjust the main shaft to the up or down position.
1. Loosen the front hand wheel, A.
2. Turn the Hand wheel, B, to the desired height.
3. Tighten the hand wheel, A.
B
A
CHANGING SPINDLES
3/4" and 1/2” spindle assemblies are supplied with your
shaper. The assemblies are locked in a tapered seat with
a draw bar and nut. To change spindles One wrench must
be placed on the flats on top of the spindle and the second wrench on the draw bar nut, this allows the spindle
to loosen. Turn the nut two times; tap gently upwards with
a wooden block, this will loosen the spindle from the taper.
Remove nut and lift out the spindle.
OPERATION INSTRUCTIONS
CHANGING CUTTERS
All spindle sizes are equipped with a safety lock nut, lefthand threads are found above the large spindle nut. To
mount or change cutter, first remove the safety lock nut:
Remove the spindle nut by placing one wrench on the
spindle nut and another wrench on the flats on top of the
spindle. Safety lock nut must be replaced before starting
work operations.
AVAILABLE:
Item #40-225: 1” optional arbor
Item #40-230: 1 1/4” optional arbor
FLAT AT TOP OF SPINDLE
DRAW BAR NUT
SPINDLE ASSEMBLY
SPINDLE
SAFETY LOCK NUT
SPINDLE NUT
SPACER
TABLE INSERT
40-250 spindle shaper has been designed with three
spindle inserts. The 3 table inserts have an opening of 7"
(178 mm), 3 1/2" (89 mm) and 3" (76 mm).
12
PERATING CONTROLS FOR THE FENCE
O
Depending on the type of work you are shaping, either
side of the fence can be moved freely. Fence can be
moved by loosening wing screws, A, proper setting can be
achieved by turning knob, B. The turning knob, B, is with
scale for accurate setting. Wing screws, A, must be then
tightened to fix in position.
Each fence half should be adjusted as close to cutter
head as possible.
o position fence closer to cutter head, loosen handle, C.
T
Fence plate, D, must be moved to correct position. Then
tighten the handle, C.
A
C
B
D
WORKPIECE HOLD DOWN ADJUSTMENT
A
Loosen knob, A, turn tension plate to desired angle,
then tighten the bolt.
FENCE ADJUSTMENT
The fence is fixed the position before shipment, following the instruction for when need to do the minor fence
adjustment.
1. Loosen the screw, A, and turn set screw, B, for adjust
the fence to proper position then tighten screw, A.
(Improper position, F)
2. Loosen the screw, A, and turn set screw, D, set screw for
adjusting the fence to proper position then tighten
screw, A. (Improper position, G)
3. Loosen the screw, A, and adjust set screw, E, for adjus-
ting the fence to proper position then tighten screw, A.
(Improper position, H)
4. Loosen the screw, A, and adjust set screw, C, for adjus-
ting the fence to proper position then tighten screw, A.
(Improper position, I)
PROTECTION GUARD ADJUSTMENT
B
Loosen two knobs to slide protector, B, to desired height.
D
E
C
Bracket
A
Fence
F
Fence
Bracket
G
e
enc
F
Bracket
B
H
Fence
Bracket
I
13
TOOL CHANGING
When changing tools, the process demands lots of attention and extra precautions, keep in mind the following procedures.
1. Spacers, cutters and collars mounted on the spindle shaft must be in a fixed position. There must be no move
ment, space or touching between parts.
2. Counter bores and holes of collars, cutters or spacers must be in perfect condition with no rust or flaws.
3. Before installing the collars, cutters and spacers on the spindle they must be cleaned properly.
4. The cutter must always be mounted as low as possible on the spindle.
5. Always check before starting the shaper that all parts on the spindle are locked in position.
BEFORE OPERATING
The main drive motor should run for a few seconds, to make sure that it is performing in the proper rotation. Looking
down at the spindle, it should be rotating counter-clockwise this is the proper position. Machine should stay on for
a short period of time to make sure that all moving parts are properly positioned with no excessive vibration. If any
adjustments are required disconnect machine from the power source before properly adjusting.
ALL WORK OPERATORS MUST READ AND UNDERSTAND THE MANUAL BEFORE STARTING ANY WORK
OPERATIONS ON THE SHAPER !
ALL SHAPER OPERATIONS MUST BE USED WITH THE PROPER GUARDS, AND ANY OTHER SAFETY REQUIREMENTS
TO INSURE SAFETY OF THE OPERATOR!
CUTTER ROTATION
COUNTER CLOCKWISE SETUP
Cutter must be positioned as work piece must be fed
from right to left.
CLOCKWISE SETUP
Cutter must be positioned as work piece must be fed
from left to right.
GRAIN DIRECTION
The work piece should always be shaped in the same direction as the grain (if possible). When cut against the
wood grain, woods as redwood, fir and oak will leave a rough, or slightly splintered edge.
14
WHEN DEEP CUTS ARE REQUIRED, THEY WILL NEED STRONG POWER AND A PUSHING FORCE IN ORDER TO
CONTROL THE CUT. DEEP CUTS CAN ALSO CAUSE THE WOOD TO SPLIT OR SPLINTER, THIS MAY LEAD TO LOSS
OF CONTROL OR INJURES TO THE WORK OPERATOR. WHEN A FINISHED EDGE IS NOT TO YOUR SATISFACTION,
CUT A FEW MORE TIMES WITH NO MORE THAN 1/16" DEEP. PRE-CUT STOCK ON BAND SAW 1/16" WHENEVER
POSSIBLE. THE TRAILING BOARD EDGE WILL SPLINTER WHEN SHAPING ACROSS THE GRAIN. THE BEST SOLUTION
WOULD BE TO CUT THE BOARD 1 /4" OVERSIZE IN WIDTH SHAPE THE BOARD AND SIMPLY TRIM OFF THE
EXCESS.
STRAIGHT EDGE SHAPING
90°
The work piece must always be against the fence to per-
orm straight edge shaping, follow these procedures to set
f
up:
1. Disconnect machine from the power source.
2. Fence faces must be parallel, properly in line or offset
If necessary, and securely tightened.
3. Cutter must be rotated and inspected for clearance.
4. Position the leading face of a cutter head blade at 90°
to the infeed fence and adjust the spindle to the
desired height of the cut. At the same time check the
esired depth of cut with the blade in the 90° position.
d
DEPTH OF CUT
The depth of cut is the distance from the outside circumference edge of the collar which the work rides against to
the outside edge of the cutter. The depth of the cut is determined by the position of the fence relative to the cutter
head or by the use of shaper collars.
1. Spindle must be locked.
2. Right guard should be installed wherever possible.
3. Connect to the power source.
4. Make a test cut on a piece of scrap with the same thickness as the work piece.
Note: To determine if the cut, profile and depth are correct you will only need a short cut.
5. Make adjustments if required, or proceed shaping using the work piece.
EDGE SHAPING: LONG BOARDS
The work piece must be at least 12 inches long when
edge shaping long boards.
1. To hold work piece down and against the fence use
the hold-downs and horizontal clamps. If the work
piece is too wide for the horizontal clamps, clamp a
scrap board to the table to keep the work piece
against the fence.
2. Check the rotation of the cutterhead, and be sure to
feed the work piece against the ration of cutterhead.
3. To make a smooth cut the work piece should be fed
slowly and steadily with firm, even pressure.
Note: The rate feed depends on depth of cut and experience of operator.
EDGE SHAPING: SHORT BOARDS
When edge shaping short boards, never attempt to hand
guide any stock less than 12 inches long, or narrower than
3 inches without the use of a special guide.
STOCK
Special Guide
15
END SHAPING
hen end shaping narrow stock at least one half of the
W
work piece end must be in contact with either the outfeed
or infeed fence.
EVER ATTEMPT TO SHAPE A NARROW PIECE WITHOUT A
N
SPECIAL GUIDE, THE WORK PIECE MAY STAR ROCKING
NTO THE CUTTER HEAD CAUSING MINOR OR MAJOR
I
INJURY TO THE WORK OPERATOR.
Scrap
Workpiece
SHAPING SIDES
4thCUT
t
t
s
2
CUT
d
r
3
CUT
When shaping across the grain, some woods are more
likely to chip out or splinter. It is recommended to
shape cross grain sides first. Any chipping that does
occur will be removed by the subsequent cut with the
grain.
SHAPING CONTOURED EDGES WITH RUB COLLARS
To shape contoured edges the fence assembly should
be removed. In order to control the work piece and limit
the depth of cut an anti-friction collar must be used, A.
The purpose of the collar is to ride against the work
piece, at the same time the collar establishes the depth
of cut, B. The collar can be positioned above or below
the cutters. The ring guard should be used whenever
possible.
Note: The collar requires at least 1/8" of surface
edge to ride against, the entire edge cannot be
shaped, C. However the use of a pattern or template
will permits the shaping of the entire edge.
When work piece needs to be shaped alt around the
perimeter, hold firmly and press the work straight into
the cutter until the collar established depth of cut. While
holding firmly, keep feeding the work so the point of
contact on the edge is always 90° to the collar.
When work piece is not contoured all around, start the
cut as shown in D. Small size materials need a special
shaping jig, E.
1
s
CUT
ON-EDGE SHAPING
Wide stock
High fence
Using the existing bolts in the fence, attach a taller
shop-made fence when the shaper fence does not
support firmly support taller stock.
Note: To avoid interference with mounting screw,
make sure the bolt holes are on your shop-made tall
fence are countersunk.
A
Collar
B
Depth
of cut
Cutter
Cutter
Anti-friction collar
C
D
At least
1/8” edge
Collar
thickness
Workpiece
edge
Collar
Feed
90°
Workpiece
16
Cutter
START POSITION
emove entire fence assembly; place jig carefully at the
R
desired depth of cut, clamp to table securely. It is important with arc and circle shapes that the work piece must
be roughly cut to desired size and curve of the finished
piece, before being shaped. The curve of the jig must
match the work piece exactly. The work piece must be
firmly attached to the jig. This operation should always be
in use of a ring guard or a similar safety device over the
cutter head.
NEVER ATTEMPT TO SHAPE FREEHAND. OPERATOR SHOULD
EVER RACE HANDS NEAR THE CUTTERS OR CUTTERHEAD !
N
KEEP HANDS AT A DISTANCE OF 12" AWAY FROM ANY CUT-
ING DEVISES.
T
ENCLOSED EDGE SHAPING
Inside edge work piece are shaped the same way as outside edges. When the whole edge needs to be shaped,
the operator must use a pattern.
The work piece must be placed on table before starting
the motor. The operator must shape the whole work piece
by feeding into the cutters.
EVER ATTEMPT TO PERFORM THIS PROCEDURE WITHOUT A
N
RING GUARD OR A SIMILAR SAFETY DEVICE OVER
UTTERHEAD ! OPERATION MUST BE AWARE AT ALL TIMES
C
OF THE FEED DIRECTION ! OPERATION MUST NOT BE LEFT
UNATTENDED!
E
F
Use the guard!
eed
Clamp
Feed
Hand hold
1. Use a firm grip to ease the edge into the cutters untilstopped by the collar.
2. Keep pushing straight while turning and feeding the
work piece, continue until the cut is finished. Turn
power switch in the off position and remove the work
piece only once the cutters have come to a complete stop.
NEVER PERFORM ENCLOSED EDGE SHAPING WHEN THERE IS
LESS THAN 12" OF WOOD MATERIAL ALL AROUND THEOPENING ! THE ONLY TIME THIS CAN BE DONE IS IF THE WORK
PIECE IS ATTACHED TO A LARGER WOOD BASE! NEVER PERFORM ENCLOSED HAPING WHEN WORK PIECE OPENING IS
MALLER THAN TWICE THE DIAMETER IN ANY DIRECTION.
TEMPLATES
Guide pin
Feed
MULTI-PIECED TEMPLATES
Workpiece
Template
A template serves as guide for the cutter. The template
must be made of scrap material thick enough to provide a solid bearing edge against a collar, recommended size 3/4".
When the work piece requires all-around shaping, the
template, may be built from various sections fixed
together.
17
SECURING A TEMPLATE TO THE WORK PIECE
Various methods are used to secure template to the work piece. The operator should select the best method to
ecure the template to the work piece based on the size, shape, and constriction of the template and work piece.
s
andles
H
andles
H
Workpiece
“C” Clamps
"C" clamps can be used to securely hold a template
when the work piece is large enough to surpass the
front of table, while still leaving space for the desired
cut.
The work piece may be placed against the template
using dowels as anchor points and wooden blocks to
help the operator in guiding the work piece through
the cut.
Dowels
HORIZONTAL TOGGLE CLAMP
Horizontal toggle clamp are useful when the regular "C"
clamps cannot allow the freedom of movement required
in shaping. No additional hand pressure is necessary for
the operator to control the work piece. Anchor points like
dowels are necessary with this setup.
Toggle clamp
Workpiece
PROTECTION
The operators should take precautions to protect themselves, and all others around the work area and the machine
itself for improper use.
Never leave machine unattended while it is running, the operator needs to be very focused and attentive, and not
looking elsewhere or carrying on conversation while using the machine. Carelessness or inattention will result in serious injuries and damages.
SPECIAL CUTS
The illustrations in this section show the profile or section
views made by the cutters. The most efficient cutters are
carbide tipped to ensure cleaner cuts and longer cutter
life. Small cutters may be solid carbide, some use inserts.
Since there is such various choices, the operator is limited
only by his experience and imagination.
18
STOCK
Cutter collar
STACKED CUTTERS
A variety of timesaving and interesting cuts can be made in a single setup by stacking the cutters, A. When stacking cutters extra care should be taken. Check that cutters have no flaw nicks, or just. Cutters must cleaned and perfectly balanced before placing in the stacked poisiton.
A
Cutter
Collar
Stock
Collar
Groove cutter
Door shaping requires two
operations, demonstrates
sash cut for the first operation.
When the stock is flipped
over and the sash cutter
with a 1/4" groove cutter to
complete the cut.
Sash
cutter
Collar
Groove cutter
First shaping out, for a window sash stile using a sash
cutter, collar, and a 1/2" groove cutter.
Stock
Sash
cutter
Flip over cut
First shaping cut with the
sash cutter for the matching door stile sash.
Same cut with the stock
flipped over.
Rabbet cut
Stub spindle
Both cuts needed for a window sash rail end. The first
operation at top is a rabbet cut made with a groove
cutter. The second operation is performed with a stub
spindle and button head screw.
BUTT JOINTS
GLUE BUTT JOINT: To perform a glue butt joint, both fences
must be kept inline and adjusted for a depth of cut, A. Both
cuts on the work pieces are part-edge cuts that do not
reduce the width of material during cutting procedures.
When shaping the work pieces, one must be ted top-side
up, and the other is fed bottom-side up.
TONGUED JOINT:
kept in-line for the tongued joint and must be adjusted for
1/4" depth of cut with no reduction in stock width. With this
joints, both work pieces are fed with the same side up, B.
DROP LEAF JOINT:
using a Drop Leaf Bead cutter, the table work piece is
shaped with d Drop Leaf Cove cutter. This joint type, the
whole edge of both work pieces are shaped the same
side up and allows 1/16" reduction in width. Adjust the
infeed fence to reduce the work piece width by 1/16" and
adjust the outfeed-fence to compensate for stock
removed, C.
similar to the glue joint, both fences are
A drop leaf joint work piece is shaped
A
B
C
19
TENONING
igure A demonstrates the tenoning fixture which shows a
F
miter gauge equipped with a hold-down for shaping the
ends of narrow work piece. A Miter gauge can also be
adapted to cut square and centered tenons at the ends
of leg for table, chairs etc. Secure leg to the jig and position for cut, B.
First cuts must be made with the same jig setting and spindle height. When the first several cuts have been made,
reposition the leg on the jig for each succeeding cut.
Note: If legs are tapered. Use a wedge to set the side
acing the cutter to 90 degrees vertical, C.
f
A
Miter
gauge
Hold
down
B
Miter
gauge
NOTE:
Clamp
Leg
Cutter
C
Taper leg
Wedge
20
CABINET
54
66
63
67
68
69
24
49
.
25
25
65
64
46
42
62
40
45
46
55
54
46
47
48
61
14
26
26
13
28
29
14
15
59
56
54
60
57
58
53
25
50
13
15
51
15
13
52
41
40
42
46
45
44
40
41
25
43
42
25
25
39
38
37
36
35
33
34
31
30
32
27
79
QUILL
21
SPINDLE
116
118
119
120
121
122
125
126
129
135
1
33
136
113
114
115
117
123
124
128
103
120
118
119
116
117
135
133
136
111
112
126
125
114
26
102
101
104
103
108
109
110
111
103
121
132
109
26
1
34
131
112
130
127
FENCE
22
PARTS LIST 40-250
PART N0. DESCRIPTION QTY
40250-01 STAND ASSEMBLY 1
40250-02N SWITCH 1
40250-03 SCREW 5/32" X 1"L 2
40250-03A SCREW 5/32" X 4"L 2
40250-04 FORWARD-REVERSE SWITCH 1
40250-04A FORWARD-REVERSE SWITCH COVER 1
40250-04B CONNECTOR 4
40250-05 NUT. HEX 5/32" 2
40250-06 BAR 2
40250-07 MITER GAUGE 3
40250-08 SCREWS SET 5/16" X 5/8" L 1
40250-09 INSERT TABLE 1
40250-10 INSERT TABLE 1
40250-11 INSERT TABLE 1
40250-12 TABLE 1
40250-12A EXTENSION WING 1
40250-13 HEX NUT 3/8" 14
40250-14 SPRING WASHER 3/8" 20
40250-15 WASHER 3/8" 17
40250-16 DUST REMOVABLE DOOR 1
40250-16A 3/8" X 3/4"L SCREW 12
40250-17N DOOR LOCK LEVER 1
40250-19 PIN 2
40250-20 MOTOR COVER 1
40250-21 HANDLE LOCK 1
40250-22 ELECTRIC CORD 1
40250-23 CONNECTOR 1
40250-24 SPINDLE BASE 1
40250-25 HEX NUT 1/2" 6
40250-26 SCREW 3/8" X 1" 12
40250-27 SCREW 3/8" X 1-1/4" 1
40250-28 COLLAR 1
40250-29 HANDLE 1
40250-30 KEY 1
40250-31 SET SCREW 5/16" X 3/8" 1
40250-32 MOTOR PULLEY 1
40250-33 KNOB 1
40250-34 MOTOR BASE 1
40250-35 MOTOR 1
40250-36 SCREW 5/16" X 5/8" 4
40250-37 SPRING 1
40250-38 SPRING SHAFT 1
40250-39 WASHER 1/2" 1
40250-40 SPRING WASHER 1/4" 7
40250-41 SCREW 1/4" X 3/4" 6
40250-42 WASHER 1/4" 7
40250-43 SCREW 1/2" 1
40250-44 WASHER 5/16" 8
40250-45 SPRING WASHER 1/4" 9
40250-46 HEX NUT 5/16" 12
40250-47 POINTER 1
40250-48 SCREW 5MM X 10MM 1
40250-49 V-BELT K-23 1
40250-50 SHAFT GUIDE 1
40250-51 PLATE 1
40250-52 MOTOR PLATE 1
40250-53 SCREW 1/2" X 1" 1
40250-54 SCREW 5/16" X 1" 4
40250-55 GEAR SHAFT 1
40250-56 GEAR SHAFT BASE 1
40250-57 HANDWHEEL 1
40250-58 KNOB 1
40250-59 WASHER 5/16" 2
40250-60 SET SCREW 5/16" X 5/8" 1
40250-61 HANDWHEEL 1
40250-62 SCREW 1/4" X 1" 1
40250-63 LOCK BAR 1
40250-64 LOCK SCREW 1
40250-65 GEAR WASHER 1
PART N0. DESCRIPTION QTY
40250-66 GEAR 1
40250-67 COLLAR 1
40250-68 KEY 1
40250-69 GEAR SHAFT 1
40250-70 HEX NUT 5/8" 1
40250-71 HEX NUT 3/4" 1
40250-72 COLLAR 3/4" X 1/2" 1
40250-73 COLLAR 3/4" X 3/4" 2
40250-74 COLLAR 3/4" X 1" 1
40250-75 SPINDLE 3/4" 1
40250-76 SHAFT 1
40250-77 KEY 5MM 1
40250-78 BEARING 6205LLB 1
40250-79 QUILL 1
40250-80 SPINDLE 1/2" 1
40250-81 HEX NUT 3/8" 1
40250-82 HEX NUT 1/2" 1
40250-83 COLLAR 1/2" X 3/4" 2
40250-84 COLLAR 1/2" X 1" 2
40250-85 COLLAR 1/2" X 1" 1
40250-86 BEARING 6205Z 1
40250-87 SNAP RING 1
40250-88 SPINDLE PULLEY 1
40250-89 LOCK WASHER 1
40250-90 LOCK NUT 1
40250-91 LOCK BOLT 1
40250-92 LOCK NUT 1
40250-101 BAR 2
40250-102 TENSION SPRING PLATE 4
40250-103 RETAINER 4
40250-104 KNOB 2
40250-108 UPPER FENCE HOUSING 1
40250-109 LOCK LEVER 2
40250-110 CARRIAGE BOLT 2
40250-111 LOCK LEVER 2
40250-112 WASHER 2
40250-113 KNOB 1
40250-114 KNOB 2
40250-115 SCREW 4
40250-116 BOLT 2
40250-117 FENCE TRAVEL BUSHING 2
40250-118 LOCK HANDLE 2
40250-119 WASHER 2
40250-120 BRACKET 2
40250-121 T- SCREW 2
40250-122 FENCE 2
40250-123 BOLT 2
40250-124 SET SCREW 8
40250-125 KNOB SCREW 2
40250-126 T-HEX NUT 3/8" 2
40250-127 PLASTIC COVER 1
40250-128 FENCE HOUSING 1
40250-129 FRONT GUARD 1
40250-130 WING SCREW 2
40250-131 SCREW 4
40250-132 WASHER 2
40250-133 BOLT 2
40250-134 SCALE 2
40250-135 ADJUSTMENT KNOB 2
40250-136 SET SCREW 2
40250-137 PUSH STICK 2
40250-138 T-BRACKET 2
40250-139 PIN 1
40250-140 ROUTER 1/4" 1
40250-141 ROUTER 1/2" 1
40250-142 MULTIPLE WRENCH (NOT SHOWN) 1
40250-143 WRENCH 12/14 MM (NOT SHOWN) 1
40250-144 ALLEN KEY 3MM (NOT SHOWN) 1
40250-145 ALLEN KEY 4MM (NOT SHOWN) 1
23
MODEL 40-250 M1
8360 Champ-d’Eau, Montreal (Quebec) Canada H1P 1Y3
Tel.: (514) 326-1161
Fax: (514) 326-5565 -
Parts & Service / Fax: (514) 326-5555 - Order Desk
orderdesk@general.ca
www.general.ca
IMPORTANT
When ordering replacement parts, always give the model number, serial number of the machine and
part number. Also a brief description of each item and quantity desired.
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