General 40-250 M1 User Manual
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-
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