General 80-025HC User Manual

SETUP & OPERATION MANUAL
FEATURES
On/off safety switch with lock-out key to prevent unauthorized use.
Helical cutter head for superior finish and qui­eter operation.
Built-in 2 1/2” dust collection outlet.
Powerful 1 HP, 120 V, 10 amp motor.
4” x 19 5/8” adjustable, tilting fence with 45° and 90° stops.
Spring-loaded cutter head guard.
Two safety push blocks included.
Easy to set-up and operate.
Front-mounted infeed table lock.
6″ BENCH-TOP JOINTER
-
WITH HELICAL CUTTER HEAD
SPECIFICATIONS
• Table size 29 7/8” x 6 1/8” (760 x 156 mm)
• Table height 8 1/4” (210 mm)
• Maximum cutting width 6” (152 mm)
• Maximum cutting depth 1/8” (3 mm)
• Fence size 4 1/4” x 19 5/8” (110 x 500 mm)
• Number of insert 12
• Cutter head speed 11,000 rpm
• Dust outlet 2 1/2” (64 mm)
• Base dimensions 19 1/4” x 9 7/16” (490 x 240 mm)
• Motor 1 HP, 120 V, 10A
• Weight (shipping/net) 37,5 lbs (17 kg) / 41 lbs (18,7 kg)
Version #1 - October 2014
© Copyright General International
#
80-025HC
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 80-025HC 6”
bench-top helical head jointer. This jointer 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 jointer 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 not applicable to your machine. Further, as several generations of this model of jointer 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 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.
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
Electrical requirements ...................................................................................................... 6
Identification of main parts and components .................................................................. 7
Unpacking .......................................................................................................................... 8
Basic functions ................................................................................................................... 8
Assembly instructions ................................................................................................... 9-12
Installing the jointer on a table surface ........................................................................................................... 9
Assembling and installing the fence ........................................................................................................... 9-11
Installing the lock-out key ................................................................................................................................ 11
Installing the dust port ................................................................................................................................. 11-12
Connecting to a dust collector ....................................................................................................................... 12
Basic adjustments and controls ................................................................................. 12-16
Connecting to a power source .......................................................................................................................12
On/Off power switch .........................................................................................................................................13
Checking/adjusting the depth of cut indicator zero point .................................................................... 13-14
Setting the 90° and 45° fence stops ........................................................................................................... 14-16
Front to back fence adjustment ..................................................................................................................... 16
Operating Instructions ................................................................................................ 17-18
Basic principles of jointing ............................................................................................................................... 17
Selecting boards suitable for jointing ............................................................................................................ 17
Determine the concave face and edge of your board .............................................................................17
Checklist before starting .................................................................................................................................. 18
Basic jointing operations ............................................................................................ 18-19
Surface planing ................................................................................................................................................. 18
Edge jointing ..................................................................................................................................................... 18
Maintenance ............................................................................................................... 19-22
Inspecting cutter head inserts ......................................................................................................................... 19
Reversing/replacing cutter head inserts ....................................................................................................... 20
Motor brush replacement ............................................................................................................................... 21
Belt replacement .............................................................................................................................................. 21
Periodic maintenance ..................................................................................................................................... 22
Recommended optional accessories ............................................................................. 22
Parts list & diagrams ................................................................................................... 23-26
Contact information ........................................................................................................ 28
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. Do not operate this jointer when tired, distracted, or under the effects of drugs, alcohol or any me­ dication that impairs reflexes or alertness.
2. The work area should be well lit, clean and free of debris.
3. Keep children and visitors at a safe distance when the jointer is in operation; do not permit them to operate the jointer.
4. Childproof and tamper proof your shop and all machinery with locks, master electrical switches and switch keys, to prevent unauthorized or unsu­ pervised 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 jointer is in opera­ tion. Wear protective hair covering to contain long hair and wear non-slip footwear.
®
International disclaims any real or implied warranty and hold itself
12. Do not push or force stock into the cutterhead. The jointer will perform better and more safely when working at the rate for which it was designed.
13. Be sure that the cutterhead has gained full opera­ ting speed before starting to joint.
14. Avoid working from awkward or off balance posi­ tions. Do not overreach and keep both feet on floor.
15. Keep guards in place and in working order. If a guard must be removed for maintenance or clean­ ing be sure it is properly re-attached before using the tool again.
16. Use of parts and accessories NOT recommended by General malfunction or risk of injury.
17. Never stand on machinery. Serious injury could result if the tool is tipped over or if the cutting tool is unintentionally contacted.
18. 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.
19. Make sure that the switch is in the “OFF” position be-­ fore plugging in the power cord.
®
International may result in equipment
8. Be sure that adjusting wrenches, tools, drinks and other clutter are removed from the machine and/or the table surface before operating.
9. Keep hands well away from cutter head 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 cutter head inerts are securely in stalled in the cutter head.
11. Always use clean, properly sharpened inserts. Dirty or dull inserts are unsafe and can lead to accidents.
20. Make sure the tool is properly grounded. If equip­ ped with a 3-prong plug it should be used with a three-pole receptacle. Never remove the third prong.
21. Do not use this jointer for any purpose other than its intended use. If used for other purposes, General International disclaims any real or implied warranty and holds itself harmless for any injury, which may result from that use.
®
5
ELECTRICAL REQUIREMENTS
BEFORE CONNECTING THE MACHINE TO THE POWER SOURCE, VERIFY THAT THE VOLTAGE OF YOUR POWER SUPPLY CORRESPONDS WITH THE VOLTAGE SPECIFIED ON THE MOTOR I.D. NAMEPLATE. A POWER SOURCE WITH GREATER VOLTAGE THAN NEEDED CAN RESULT IN SERIOUS INJURY TO THE USER AS WELL AS DAMAGE TO THE MACHINE. IF IN DOUBT, CONTACT A QUALIFIED ELECTRICIAN BEFORE CONNECTING TO THE POWER SOURCE.
THIS TOOL IS FOR INDOOR USE ONLY. DO NOT EXPOSE TO RAIN OR USE IN WET OR DAMP LOCATIONS.
GROUNDING INSTRUCTIONS
In the event of an electrical malfunction or short circuit, grounding reduces the risk of electric shock. The motor of this machine is wired for 120 V single phase opera­tion and is equipped with a 3-conductor cord and a 3-prong grounding plug A to fit a grounded type receptacle B. Do not remove the 3rd prong (ground­ing pin) to make it fit into an old 2-hole wall socket or extension cord. If an adaptor plug is used C, it must be attached to the metal screw of the receptacle.
Note: The use of an adaptor plug is illegal in some areas. Check your local codes. If you have any doubts or if the supplied plug does not correspond to your electrical outlet, consult a qualified electrician before proceeding.
A
B
C
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.
EXTENSION CORDS
If you find it necessary to use an extension cord with your machine, 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.
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
EXTENSION CORD LENGTH
AMPERES 50 feet 100 feet 200 feet 300 feet
< 5
6 to 10
10 to 12
12 to 16
*NR = Not Recommended
18 16 16 14
18 16 14 12
16 16 14 12
14 12 *NR *NR
6
IDENTIFICATION OF MAIN PARTS AND COMPONENTS
C
B
A
D
G
F
E
I
H
A. DUST OUTLET
B. OUTFEED TABLE
C. FENCE
D. CUTTER HEAD GUARD
E. INFEED TABLE LOCK KNOB
F. DEPTH OF CUT INDICATOR
G. INFEED TABLE
H. INFEED TABLE ADJUSTMENT KNOB
I. SAFETY SWITCH WITH LOCK-OUT KEY
7
UNPACKING
Carefully unpack and remove the unit and its components from the box and check for missing or damaged 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
A. FENCE MOUNT ASSEMBLY ....................................................... 1
B. FENCE BRACKET ...................................................................... 1
C. DUST OUTLET ............................................................................ 1
D. PUSH BLOCKS .......................................................................... 2
E. FENCE FACE ............................................................................. 1
F. LOCK LEVER ............................................................................. 1
G. FLAT WASHER ............................................................................ 1
H. SQUARE NUT ............................................................................ 2
I. RECTANGULAR NUT ................................................................. 1
J. CAP SCREW ............................................................................. 6
K. 4 & 2.5 MM ALLEN KEYS ........................................................ 2
L. TORX™ WRENCH ..................................................................... 1
M. LOCK-OUT KEY ......................................................................... 1
ADDITIONAL REQUIREMENTS FOR SET UP
A. PHILLIPS AND FLAT SCREWDRIVERS B. 10 AND 13 MM WRENCH C. STRAIGHTEDGE
A
B
C
A
E
BASIC FUNCTIONS
B
C
F
G
H
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J
D
K
L
M
This 6” jointer benchtop with helical cutter head is designed for face and edge jointing in solid wood only.
The unit is not designed nor should it be used to surface or prepare, plywood, wood paneling, particleboard, MDF nor any other wood based by-products nor any non-wood based materials.
The unit is equipped with 12 reversible high-speed steel inserts that have two cutting faces each.
Warning! To reduce the risks of accidents leading to injury make sure to always properly secure the jointer to your work surface before operating it.
8
ASSEMBLY INSTRUCTIONS
BEFORE ASSEMBLING, MAKE SURE THAT THE SWITCH IS IN THE “OFF” POSITION AND THAT THE POWER CORD IS UNPLUGGED. DO NOT PLUG IN OR TURN ON THE MACHINE UNTIL YOU HAVE COMPLETED THE ASSEMBLY AND INSTALLATION STEPS DESCRIBED IN THIS SECTION OF THE MANUAL.
INSTALLING THE JOINTER ON A STABLE SURFACE
For your convenience this jointer is shipped from the factory partially assembled and requires only minimal assembly and set up before being put into service.
A
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G
The unit should be immobilized on a flat, level and sta­ble surface, able to support the weight of the machine
and the workpiece with ease. Drill holes in the mount­ing surface corresponding with the holes located in the base of the machine. Immobilize the unit using hardware A (not supplied) in the order shown.
ASSEMBLING AND INSTALLING THE FENCE
B
C
1. Install the fence bracket B by aligning its four mount-
ing holes with the corresponding holes on the ma­chine C.
E
Note: Never install or operate the unit over the edge of a table, workbench or other mounting surface.
D
2. Attach the bracket to the machine using four screws D and a 4 mm Allen key.
H
F
G
3. Insert a screw F into each hole G of the fence hold- er E.
I
4. Loosely thread a square nut H onto each screw I.
9
BEFORE ASSEMBLING, MAKE SURE THAT THE SWITCH IS IN THE “OFF” POSITION AND THAT THE POWER CORD IS UNPLUGGED. DO NOT PLUG IN OR TURN ON THE MACHINE UNTIL YOU HAVE COMPLETED THE ASSEMBLY AND INSTALLATION STEPS DESCRIBED IN THIS SECTION OF THE MANUAL.
ASSEMBLING AND INSTALLING THE FENCE (CONTINUED)
A
B
5. Slide the T-slot on the back of the fence onto the nuts B on the fence holder A.
C
CENTER
CENTER
6. Center the fence on the holder.
7. Secure the fence tightening screws C with a 4 mm
8. Place the assembly on the fence bracket.
Allen key.
9. Slide a flat washer onto the lever. 10. Insert the lever with its flat washer in the hole in the
fence holder.
10
BEFORE ASSEMBLING, MAKE SURE THAT THE SWITCH IS IN THE “OFF” POSITION AND THAT THE POWER CORD IS UNPLUGGED. DO NOT PLUG IN OR TURN ON THE MACHINE UNTIL YOU HAVE COMPLETED THE ASSEMBLY AND INSTALLATION STEPS DESCRIBED IN THIS SECTION OF THE MANUAL.
ASSEMBLING AND INSTALLING THE FENCE (CONTINUED)
A
A
B
11. Screw the lock lever to the rectangular nut A.
Note: Position the nut with the flat side up.
INSTALLING THE SWITCH LOCK-OUT KEY
1. Insert the key into the switch as shown. 2. Make sure the switch is in the OFF position.
INSTALLING THE DUST PORT
12. Place the fence against the table, and lock the fence with the levers B.
C
D
1. Remove screw C using a 4 mm Allen key and the screw D with a Phillips screwdriver.
E
F
2. Slide the dust port notch E onto the screws F.
11
BEFORE ASSEMBLING, MAKE SURE THAT THE SWITCH IS IN THE “OFF” POSITION AND THAT THE POWER CORD IS UNPLUGGED. DO NOT PLUG IN OR TURN ON THE MACHINE UNTIL YOU HAVE COMPLETED THE ASSEMBLY AND INSTALLATION STEPS DESCRIBED IN THIS SECTION OF THE MANUAL.
INSTALLING THE DUST PORT (CONTINUED)
A
3. Retighten screws A. 4. Retighten self-tapping screws in the lower left and
right corners of the jointer.
CONNECTING TO A DUST COLLECTOR
A dust port that fits
2 1/2”
hose is provided to accom-
modate connection to a dust collector (not included). Be sure to use appropriate sized hose and fittings (not
included). Check that all connections are sealed tightly to help
minimize airborne dust. If you do not already own a dust collection system consider contacting your General® International distributor for information on our complete line of dust collection systems and
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accessories or visit our Web Site at www.general.ca.
BASIC ADJUSTMENTS & CONTROLS
TO REDUCE THE RISK OF SHOCK OR FIRE DO NOT OPERATE THE UNIT WITH A DAMAGED POWER CORD OR PLUG. RE­PLACE DAMAGED CORD OR PLUG IMMEDIATELY. TO AVOID UNEXPECTED OR UNINTENTIONAL START-UP, MAKE SURE THE POWER SWITCH IS IN THE OFF POSITION BEFORE CONNECTING TO A POWER SOURCE.
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 Require ments” and make sure all requirements and grounding instructions are followed.
When operations have been completed unplug the machine from the power source.
12
SWITCH OFF
-
TO AVOID UNEXPECTED OR UNINTENTIONAL START-UP, MAKE SURE THAT THE POWER SWITCH IS IN THE OFF POSITION BEFORE CONNECTING TO A POWER SOURCE.
MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORM­ING ANY MAINTENANCE OR ADJUSTMENTS.
ON/OFF POWER SWITCH
The machine is equipped with a rocker type ON/OFF switch that is equipped with a lock-out key.
To prevent unwanted or unauthorized start-up remove the lock-out key A and store it in a safe place.
To start the machine, insert the lock-out key and pull the switch B up.
To stop the machine, push down on the switch C. When the machine comes to a complete stop, remove the lock­out key A by gently pulling it outward.
A
LOCK-OUT KEY
(PREVENTS START-UP WHEN REMOVED)
B
POWER ON
C
POWER OFF
CHECKING / ADJUSTING THE DEPTH OF CUT INDICATOR ZERO POINT
The depth of cut indicator has been factory set to read “0” when the infeed table is at the exact same height as the highest point of the cutter head. However with use and vibration over time, it may eventually become necessary to re-adjust the zero point stop bolt and depth of cut indicator. Proceed as follows, if needed:
1. Loosen the guard screws and remove the guard. 2. Loosen the depth of cut lock knob.
D
3. Set the depth of cut indicator to "0" by turning knob D clockwise.
4. Place a straightedge across the two tables.
13
MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORM­ING ANY MAINTENANCE OR ADJUSTMENTS.
CHECKING / ADJUSTING THE DEPTH OF CUT INDICATOR ZERO POINT (CONTINUED)
A C
B
5. Make sure the two tables are at the same height A.
If the infeed table is higher or lower than the out­feed table, go to the next step.
6. Re-adjust the height of the tables C by turning the depth of cut knob B as needed.
E
D
7. Lock the infeed table in position turning the depth
of cut lock knob, then loosen screw D using a 4 mm Allen key and set the indicator at "0". Retighten screw D and re-install the cutter head guard.
SETTING THE 90° & 45° FENCE STOPS
The fence stops allow you to position the fence at specific pre-set angles in relation to the tables without having to measure each time you return to that angle. Due to wear and vibration, fence stops can over time become misaligned and should be checked periodically and re-set if necessary.
Note: The cutter head guard has been removed for clarity.
To adjust the 90° stop:
Note: the threaded rod E on the lock knob serves as the zero point stop. To avoid damaging the threaded rod, do not force the depth of cut adjustment above zero.
90°
1. Place a machinists square on the table and
against the fence. if the fence is not square to the table, go to the next step.
14
A
2. Loosen the lever A.
MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORM­ING ANY MAINTENANCE OR ADJUSTMENTS.
SETTING THE 90° & 45° FENCE STOPS (CONTINUED)
B
C
3. Set the fence to 90°, then turn the set screw B until it touches the fence bracket C.
4. Retighten the lock lever once the adjustment is
complete.
To adjust the 45° stop:
D
1. Loosen the lever D. 2. Raise the fence as shown.
3. Tilt the fence back as shown 4. Sit the fence on the table as shown.
15
MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORM­ING ANY MAINTENANCE OR ADJUSTMENTS.
SETTING THE 90° & 45° FENCE STOPS (CONTINUED)
To adjust the 45° stop (continued):
45°
A
B
5. Place a square on the table and against the fence
as shown.
6. Turn the set screw A until it touches the fence brack­et B.
MOVING THE FENCE FRONT TO BACK
C
1. Loosen the lever C as shown . 2. Loosen the lever D as shown.
D
3. Raise the fence as shown.
16
4. Move the fence front as shown untill the desired po­sition, then retighten the levers.
MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORM­ING ANY MAINTENANCE OR ADJUSTMENTS.
OPERATING INSTRUCTIONS
BASIC PRINCIPLES OF JOINTING
This jointer is designed to remove material from one face of a board in order to make it (or a series of boards) per­fectly flat A.
This perfectly flat face is then placed against the fence, set at 90º to the tables, to obtain a perfectly perpendicular 90º flat edge B.
A
SELECTING BOARDS SUITABLE FOR JOINTING
ALWAYS JOINT IN THE GENERAL DIRECTION OF THE GRAIN. JOINTING AGAINST THE GRAIN OR JOINTING END GRAIN IS DANGEROUS AND MAY CAUSE THE WORKPIECE TO SHATTER.
This jointer is not intended (and should not be used) to joint any material other than solid wood.
1. Jointing safety begins with the stock used with the machine. Inspect the work piece carefully before jointing it. Never joint a board that has loose knots, staples, nails or other embedded foreign objects. If you have the slightest doubt about the structural integrity or stability of a board:
2. Only boards with the grain running more or less length-wise are suitable for jointing C.
Do Not Joint It
.
B
C
GRAIN DIRECTION
GRAIN DIRECTION
DETERMINE THE CONCAVE FACE AND EDGE OF YOUR BOARD
Place your board on a flat surface to identify its con concave face and edge against the jointer table.
cave face D and edge E. The boards must be jointed with the
D
E
17
CHECKLIST BEFORE STARTING
VERIFY ALL CHECK POINTS BEFORE STARTING. FAILURE TO COMPLY CAN RESULT IN SERIOUS INJURIES.
Make sure you and any assistants are wearing safe appropriate workshop attire. Roll up long sleeves, secure long hair and remove any jewelry: watches, rings, bracelets or anything that could become caught in the moving parts, potentially causing serious injury.
• Make sure the board has been inspected and is suitable for jointing as explained in the previous section “Selecting boards suitable for jointing”.
Verify that the cutter head guard is functioning properly (snaps back against the fence and covers the knives).
Make sure that the fence is properly set and locked in place.
Make sure to have on safety glasses as well as hearing and respiratory protection at all times when using the jointer.
BASIC JOINTING OPERATIONS
FAILURE TO USE PUSH BLOCKS WHEN SURFACE PLANING MAY RESULT IN SERIOUS PERSONAL INJURY. ALWAYS USE PUSH BLOCKS TO HELP KEEP YOUR HANDS AT A SAFE DISTANCE FROM THE KNIVES WHEN SURFACE PLANING.
SURFACE PLANING
1. Inspect the stock before starting & remove any for-
eign objects or debris.
2. Set the depth of cut as required (1/32” is recom-
mended for face planing - Less for hard wood or wider stock.)
3. Set & lock the fence at 90°.
4. If your workpiece is cupped, place the cupped
side face down on the infeed (right) table.
5. Set the position of the fence so that the length of
blade remaining exposed is roughly 1/4” longer than the width of the board to be jointed.
6. Turn on the machine & using push blocks press the
stock against the table and tight to the fence, feed­ing the stock over the cutter head.
7. Inspect the board & repeat the steps if needed until the surface is flat.
EDGE JOINTING
1. Inspect the stock before starting & remove any for-
eign objects or debris.
2. Set the depth of cut as required (1/16” - 1/8” is rec-
ommended for edge jointing - Less for hard wood or wider stock.)
3. Set & lock the fence at 90°.
4. If your workpiece is cupped, place the cupped
side face down on the infeed (right) table.
5. Set the position of the fence so that the length of
blade remaining exposed is roughly 1/4” longer than the width of the board to be jointed.
6. Turn on the machine, press the stock against the
table and tight to the fence, feeding the stock over the cutter head.
7. Inspect the board & repeat the steps if needed until the surface is flat.
18
MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORM­ING ANY MAINTENANCE OR ADJUSTMENTS.
MAINTENANCE
INSPECTING CUTTER HEAD INSERTS
There are 12 high-speed steel inserts installed in the cutter head A at the factory. With use and normal wear over time, it will eventually become necessary to reverse and/or replace the inserts.
To maintain even insert wear always reverse or replace all 12 inserts each time replacement is required. When needed, replacement inserts B can be ordered through your local General International distributor under part #30-007.
A
B
C
*EACH INSERT A HAS TWO CUTTING EDGES C. WHEN ONE OF THEM IS BLUNTED OR DAMAGED, SIMPLY ROTATE THE INSER­TION TO USE THE OTHER EDGE.
Observing jointed workpieces as they come off of the machine and looking for signs of knife damage or wear is the best method to help you to determine when knives are due to be changed.
Signs to look for include:
1. A raised ridgeline in the workpiece that runs a
straight line from beginning to end of the board D. This is generally an indication that one or more knives has been nicked or damaged E by a foreign object such as a nail, staple or other hard object hidden or embedded in the workpiece.
2. A slight washboard or chatter effect F which can
be an indication of uneven knife wear causing one knife to cut slightly deeper than the others.
3. Rough, irregular, torn or fuzzy grain on a freshly
jointed surface may be a sign of worn or dull blades causing the wood to tear out. Sharp blades cut crisply and leave a relatively smooth finish.
D
E
Note: Fuzzy grain can also be a sign of high moisture content in the workpiece. If knives have recently been changed or if you suspect that moisture con­tent and not dull inserts is the cause, set the work­piece aside and test by jointing other boards with known or acceptable moisture content.
If the jointed results using a different workpiece are smooth, then moisture content in your wood is the problem - no adjustments can be made to the ma­chine for this. Set the “wet” stock aside and simply work with drier wood.
F
19
MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORM­ING ANY MAINTENANCE OR ADJUSTMENTS.
REVERSING/REPLACING CUTTER HEAD INSERTS
Note: The cutter head guard has been removed for clarity,
1. Unplug the machine from the power source and
remove the lock-out key from the switch.
B
A
3. Immobilize the cutter head using a 4 mm Allen key A, and remove the 12 inserts using the supplied
Torx™ key B. Thoroughly clean the housing and cavity before turning/replacing an insert.
2. Loosen the cutter head guard screws, and remove
the guard.
C
D
E
4. Thoroughly clean the inserts C and screws D using
a lacquer thinner and small brush then apply a light coating of machine oil on the screws, taking­care to remove any excess.
Note: When turning the inserts in the cutter head, re­fer to the etched mark E on the inserts to keep track of the rotations.
5. Place each insert in the housing and firmly secure it
in place with a screw.
Note: To avoid stripped screws and cracked inserts, do not overtighten the screws
20
6. Re-install the cutter head guard before starting the
machine.
MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORM­ING ANY MAINTENANCE OR ADJUSTMENTS.
MOTOR BRUSH REPLACEMENT (AFTER ABOUT 150 HOURS OF SERVICE)
Note: Replace the brush when its length is less than 6 mm.
A
B
1. Unplug the machine from the power source and
remove the lock-out key from the switch. Tilt the machine back to access the motor and remove
2. Remove the motor brush from its housing as shown.
Install the new brush in its housing, then re-install the cap B.
the brush cap A with a screwdriver.
BELT REPLACEMENT
Inspect the belt afler every 100 hours of service. Belts that show visible signs of wear such as cracks or fraying at the edges should be replaced immediately.
TO REDUCE RISK OF INJURY KEEP FINGERS ON TOP OF THE THE BELT
1. Remove the fence with a 4 mm Allen key, then re-
move the belt cover with the same key.
2. Pull back on the belt while turning one of the pul-
leys counterclockwise until the belt comes off the pulley.
TO REDUCE RISK OF INJURY KEEP FINGERS ON TOP OF THE THE BELT
3. Install the belt on the lower pulley, then slide the
belt onto the edge of the upper pulley. Turn the up­per pulley until the belt snaps into place.
4. Re-install the blade guard and the pulley cover be-
fore starting the machine
21
MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORM­ING ANY MAINTENANCE OR ADJUSTMENTS.
PERIODIC MAINTENANCE
To prolong the service life of your jointer and to maintain optimum performance, the following basic maintenance procedures should be practiced and become part of your shop routine.
Inspect/test the ON/OFF switch before each use. Do not operate the jointer with a damaged switch; replace a damaged switch immediately.
Keep the machine as well as the infeed outfeed tables clean and free of saw dust, woodchips, pitch or glue. Vacuum or brush off any loose debris and wipe down the machine and the tables occasionally with a damp rag.
An occasional light coating of paste wax can help protect the tables surface and reduce workpiece friction. Ask your local distributor for suggestions on aftermarket surface cleaners, protectant and dry lubricants based on what is readily available in your area.
Avoid using silicon based products that may affect or react with wood finishing products such as oil, solvent or water-based stains, varnishes and lacquers.
Periodically inspect the power cord and plug for damage. To minimize the risk of electric shock or fire, never operate the jointer with a damaged power cord or plug. Replace a damaged power cord or plug at the first visible signs of damage.
All bearings are sealed and permanently lubricated and no further lubrication is required. The fence assembly and table ways also should not be lubricated. If you should encounter a “sticking” problem, simply disassemble and clear away any obstructions from the ways.
Regularly inspect jointed workpieces for signs of inserts damage or wear and replace damaged or worn inserts immediately.
RECOMMENDED OPTIONAL ACCESSORIES
Here is a sampling of optional accessories available from your local General International dealer that can be used with this product. For more information about our products, please visit our website at www.general.ca
REPLACEMENT INSERTS #30-006
Reversible two-sided carbide inserts (sold in sets of ten).
REPLACEMENT INSERTS #30-007
Reversible two-sided high-speed steel inserts (sold in sets of ten).
Item #95-054
BIRCH WORKBENCH
54" x 21" with both front and end vises and a large storage shelf.
Item #30-008
SET OF TEN M5 SCREWS (FOR 30-007)
DUST COLLECTORS
Dust collectors contribu­te to a cleaner more healthful workshop envi­ronment.
We offer a wide selec­tion of top quality dust collectors to suit all your shop needs.
22
DIAGRAM
23
PARTS LIST
JOINTER
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.
PART # REFERENCE # DESCRIPTION SPECIFICATION QTY
80025-03 1345881 OUTFEED TABLE SUPPORT 1 80025-04 1243339 SET SCREW M6 X 8L 8 80025-05 1345875 END COVER 1 80025-06 1345859 CAP SCREW M6 X 12L 16 80025-07 1345874 SELF-TAPPING SCREW 1/4” X 5/8” 4 80025-08 1340106 WARNING LABEL 1 80025-09 1345872 FOAM SEAL 1 80025-10 1345873 DUST CHUTE 1 80025-11 1340103 NAME PLATE 1 80025-12 1345886 FRONT FRAME 1 80025-13 DUST PORT 1 80025-14 1345865 BEARING RETAINER 1 80025-16 920-04-011-6611 BEARING 6201ZZ 2 80025-17 1243497 RETENTION RING STW12 1 80025-20 1345860 POINTER 1 80025-21 1345861 GEAR 1 80025-22 1345851 DEPTH SCALE 1 80025-23 1345862 LOCK KNOB M8 X P1.25 X 18L 2 80025-24 1344330 FLAT WASHER M8 X 23 X 2T 3 80025-25 1345863 FOOT 4 80025-26 1246028 RETENTION RING STW16 1 80025-27 PHILLIPS SCREW M5 X P0.8 X 8L 2 80025-27A LOCK WASHER M5 2 80025-27B NUT M5 2 80025-28 CAP SCREW M5 X P0.8 X 25L 4 80025-28A NYLOCK NUT M5 4 80025-29 SWITCH BOX 1 80025-34 1345892 REAR FRAME 1 80025-35 1345866 PLASTIC CAP 4 80025-36 1345895 BEARING RETAINER 1 80025-38 1345897 DRIVE PULLEY 1 80025-39 1345896 CUTTERHEAD PULLEY 1 80025-40 1345898 BELT 125J5 .PU 1 80025-41 1345899 BELT COVER 1 80025-43 1345882 TABLE 2 80025-43A SET SCREW M12 X P1.25 X15L 8 80025-45 FLAT WASHER M6 X 18 X 2T 8 80025-46 CAP SCREW M6 X P1.0 X 25L 8 80025-48 1345893 FLANGE NUT M6 X P1.0 . 16 80025-49 1345885 SUPPORT ROD 8 80025-50 1345891 CORD CLAMP 1 80025-51 1345883 INFEED SUPPORT 1 80025-54 1243339 CAP SCREW M6 X 8L 1 80025-55 1345884 BRACKET 1 80025-56 1246161 CAP SCREW M6 X 16L 1 80025-57 1243456 NUT M6 X P1.0 1 80025-58 1345887 ADJUSTING ROD 1 80025-59 1345888 SHAFT 1 80025-62 1345889 RIGHT COVER 1 80025-64 1243398 NUT M8 X P1.25 X 13 1
24
PARTS LIST
JOINTER
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.
PART # REFERENCE # DESCRIPTION SPECIFICATION QTY
80025-70 37-108 PUSH BLOCK 2 80025-71 428-06-101-0003 ALLEN KEY 2.5 MM 1 80025-72 422-29-101-0002 ALLEN KEY 4 MM X 100L 1 80025-100 1345871 PLASTIC CAP 1 80025-101 1345937 GUARD ASSEMBLY 1 80025-102 1340104 WARNING LABEL 1 80025-103 1345870 SHOCK ABSORBER 1 80025-104 1345868 SPRING 1 80025-105 1345867 MOUNTING BRACKET 1 80025-106 1246058 RETENTION RING ETW8 1 80025-125 1345904 FENCE 1 80025-126 1340105 CAUTION LABEL 1 80025-128 1345932 BEVEL BRACKET 1 80025-129 1342697 SQUARE NUT M6 2 80025-130 1345900 RECTANGULAR NUT 2 80025-131 1347657 CAP SCREW M5 X 8L 2 80025-132 1345933 INTERMEDIATE BRACKET 1 80025-133S LOCK LEVER 1 80025-135S LOCK LEVER 1 80025-136 1345902 FENCE SLIDE BRACKET 1 80025-137 1345901 FENCE MOUNTING BRACKET 1 80025-139 1345880 CAP SCREW M6 X 16L 9 80025-140 ID PLATE 1 80025-160S HELICAL CUTTER HEAD 1 80025-162 INSERT 12 80025-163 TORX™ SCREW 12 80025-166 TORX™ WRENCH 1
NOTES
25
80025-300S
PARTS LIST
MOTOR ASSEMBLY
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.
PART # DESCRIPTION SPECIFICATION QTY
80025-300S COMPLETE MOTOR ASSEMBLY 120V 1 80025-300 MOTOR COVER 1 80025-301 SET SCREW M5 X 10L 2 80025-302 FLANGE SCREW M5 X 20L 3 80025-303 LOCK WASHER 1 80025-304 BEARING 6200LB 1 80025-305 STATOR 1 80025-307 SPROCKETE WASHER M5 1 80025-308 CAP SCREW M4.8 X 55L 2 80025-309 ROTOR 1 80025-315 BEARING 6201LB 1 80025-316 MOTOR COVER 1 80025-317 FLAT WASHER M6 X 12.5 3 80025-319 BRUSH HOLDER 2 80025-320 BRUSH 2 80025-321 BRUSH COVER 2 80025-322 STRAIN RELIEF 6B3-2R 3 80025-323 SWITCH PANEL 1 80025-323-1 SWITCH COVER 3 80025-324 SWITCH KEY 1 80025-325 ELECTRIC CORD 1 80025-325-1 GROMMET 1 80025-325-2 SLEEVE 12 X 22L X 0.8T 1
26
NOTES
8360 Champ-d’Eau, Montreal (Quebec) Canada H1P 1Y3
Tel.: (514) 326-1161
Fax: (514) 326-5565 - Parts & Service / (514) 326-5555 - Order Desk
orderdesk@general.ca
www.general.ca
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