GENERAL INTERNATIONAL 40-040 Router Table Instruction Manual

GENERAL INTERNATIONAL 40-040 Router Table

Product Information

• Independently adjustable left and right fences
• Sturdy 32 x 24 tabletop made of heavy 1″ melamine surface MDF
• Includes 12 x 9 router insert plate, starting pin, and 2 removable insert rings (permitting 3 different diameters: 1 1/4″, 2 5/8″, and 3 7/8″)
• Two convenient front access storage shelves
• Graduated scale and adjustment knobs for precision fence setting
• Movable switch with outlet for convenient operation
• Overall dimensions : 32 x 24 x 39 (812 x 609 x 990 mm)
• Table size: 32 x 24 (812 x 609 mm)
• Table height : 36″ (914 mm)
• Fence size (each): 3 x 16 x 1″ (76 x 406 x 25 mm)
• Maximum fence travel : 6 1/2″ (165 mm)
• Dust outlet : 2 1/2″ (67 mm)
• Distance between T-slot & spindle center: 6″ (152 mm)
• T-slot dimensions : 3/4 x 3/8″ (19 x 9.5 mm)
• Router insert plate : 12 x 9″
• Table insert openings : 1-1/4″, 2-5/8″, & 3-7/8″ (32, 67 & 98mm) diameter
• Weight : 61 lbs (28 kg)

Product Usage Instructions

1. Before assembling, installing, and operating the router table, read the manual carefully.
2. Ensure the operator has been properly trained and understands the Owner’s Manual.
3. Keep the work area well lit, clean, and free of debris.
4. Stay alert and give your work your undivided attention to avoid serious injury.
5. Avoid wearing loose clothing, gloves, bracelets, necklaces, or other protection devices. Wear a protective hair covering and non-slip footwear.
6. Keep hands and other body parts away from bits or cutting tools. Use a feather board or push-stick to hold or guide the workpiece when working close to the cutting tool. Do not clear chips and sawdust away with hands; use a brush.
7. Work in a well-ventilated area and use a dust collector whenever possible to minimize health hazards from fine particulate dust.
8. Ensure the router is running up to speed before feeding the workpiece.
9. If the stock does not have a flat surface, use a suitable support.
10. Childproof and secure your shop and all machinery with locks, master electrical switches, and switch keys to prevent unauthorized or unsupervised use.

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® International disclaims any real or implied warranty and holds itself harmless for any injury that may result from improper use of its equipment.

1. Make sure that the operator has been properly trained and has read and understands the Owner’s Manual before operating any machinery.
2. Be sure to read, understand, and follow all instructions, warnings, and safety guidelines supplied with your router.
3. Keep the work area well lit, clean, and free of debris.
4. STAY ALERT! Give your work you undivided attention. Even a momentary distraction can lead to serious injury.
5. Do not wear loose clothing, gloves, bracelets, neck-laces, or other protection devices. Wear protective hair covering to contain long hair and wear non-slip footwear.
6. Keep hands and other body parts well away from bits or cutting tools. When working close to the cutting tool, always use a feather board or push-stick to hold or guide the workpiece. Do not clear chips and sawdust away with hands; use a brush.
7. Fine particulate dust is a carcinogen that can be haz-ardous to health. Always work in a well ventilated area and whenever possible use a dust collector to mini-mize health hazards.
8. Be sure the router is running up to speed before feed-ing the workpiece.
9.  Use a suitable support if stock does not have a flat surface.
10. Keep children and visitors at a safe distance when the router is in operation – do not permit them to operate the router and/or table.
11. Childproof and taper proof your shop and all machin-ery with locks, mater electrical switches and switch keys, to prevent unauthorized or unsupervised use.
12. Secure the table to a work surface and never stand or lean on it. Serious injury can occur if the table is tipped or if unintentional contact is made with the spinning router bit.
13. Keep all guards and safety devices in place and in good working order. If a guard must be removed for maintenance or cleaning make sure it is properly rein-stalled before using the machine again.
14. Hold the workpiece firmly against the table and use suitable support if the workpiece does not have a flat surface.
15. Feed the stock into the bit against the rotation direc-tion of the bit. Never run the stock between the fence and the bit.
16. Do not operate with a damaged bit in the router.
17. Always disconnect the router from the power source before changing accessories or before performing any maintenance and adjustments or if the machine will be left unattended.
18. Be sure that all adjustment tools, wrenches, or other clutter are removed from the table surface and safely stored before routing.
19. Make sure the router’s switch is in the “OFF” position before plugging in to a power source.
20. Avoid working from awkward or off-balance positions. Do not overreach and always keep both feet firmly on the floor.
21. Never leave the router unattended while running or with the power “ON”.
22. Do not use this router table for any purposes 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 such use.

IDENTIFICATION OF MAIN PARTS & COMPONENTS

UNPACKING & SETUP
ROUTING MAY PRESENT SERIOUS INJURY HAZARDS TO UNTRAINED USERS. BE SURE TO READ, UNDER-STAND, AND FOLLOW ALL INSTRUCTIONS AND SAFETY GUIDELINES SUPPLIED WITH THE ROUTER YOU WILL INSTALL ON THIS TABLE.

ADDITIONAL REQUIREMENTS FOR SETUP

• Socket Wrench
• Pencil
• Philips Screwdriver
• Cordless Drill
• Drill Bit
• Countersink Bit
• Machinists Square or a Straightedge

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: Report any missing or damaged items to your General International distributor immediately.

ASSEMBLING THE ROUTER TABLE

Note: Secure all hex nuts hand-tight only until assembly has been completed. Then place the stand on a flat surface to square it up and tighten all the nuts.

1. Remove the table insert plate from the table top and set it aside for now.
2. Place the table top upside down on a smooth flat surface.
3. Using the supplied wood screws attach the brackets to the underside of the table (Fig. 1). Make sure you do not com-pletely tighten the wood screws, the wood screws will be tightened in a later step.
4. Using a bolt, washer, and nut attach the side panels to the brackets as shown in Fig. 2 with the panels between the brackets. Note: The side panels have pre-drilled holes at one end, for the leveling feet. Make sure when installing the side panels that these holes remain visible, if you cannot see them the panel was installed upside down.
5. With the side panels secured to the brackets, fully tighten the wood screws mentioned in step 3.
6. Using 8 bolts, washers, and nuts per shelf, secure the shelves to the side panels (Fig. 3). Place the top shelf into place first fol-lowed by the lower shelf.
7. Thread the leveling feet into the bottom of the side panels.
8. Turn the table over and place it on a flat level surface; tighten all hex nuts and adjust the leveling feet if needed.

MOUNTING A ROUTER

1. Make sure the router is “OFF” and disconnected from the power source.

2. Flip the table insert plate upside down (concentric circle ridges facing you) making sure to lay it on a flat surface.

3. Remove the slide plate from the base of your router (Fig. 4) and then set the router on the insert plate.

4. Align the router base on the insert plate using the concentric circle ridges on the Insert Plate (Fig. 5). Transfer the router mounting hole locations onto the table insert plate using a pencil.

5. Set the router aside; drill and countersink the holes you marked in the previous step to the table insert plate.

6. Secure your router base to the insert plate using the screws supplied with your router into the holes you just drilled in the plate.
   MAKE SURE THE HEADS OF THE SCREWS ARE SLIGHTLY BELOW THE SURFACE OF THE PLATE. (FIG. 6.1)

7.  Set the plate with the router attached into the opening on the table and secure the plate to the table using the 2 screws and fixing plates at diagonally opposite corners of the plate (Fig. 6).

TABLE INSERT

SETUP
Using the supplied allen key install a leveling setscrew into each of the 4 corners on the table insert plate.

LEVELING THE TABLE INSERT PLATE

1. Using a straightedge check that the table insert plate is level with the table.
2. Adjust the leveling setscrews in the 4 corners of the insert plate as needed using the supplied allen key (Fig. 7).

TABLE INSERT RINGS

The table insert is supplied with 2 removable insert rings (1 red & 1 yellow) allowing the opening in the table to be changed to suit the most common sizes of router bits (Fig. 8).
With both rings in place the opening is 1 1/4” (32 mm) in diameter.
With the red inner ring removed, the opening is 2 5/8” (67 mm) and with the yellow outer ring removed the opening is 3 7/8” (98 mm).

ASSEMBLING AND INSTALLING THE FENCE

1. Stand the fence frame upright (Fig. 9); thread a T-bolt, thick washer, and a locking lever into the predrilled holes on the fence frame. Make sure that the washers are in-between the fence frame and the locking levers. Do not fully tighten the T-bolts and/or locking levers.
2. Attach the fence frame to the table by sliding the t-bolts (installed in the previous step) into the T-Slots on the table top (Fig. 10).

USING THE LOCKING LEVERS
This router table uses spring-loaded levers. These levers allow for easy tightening and loosening without having to turn the lever a full 360°.
To Tighten / Loosen the Levers
Turn the lever in the desired direction till it meets an obstruction. Lift and turn in the opposite direction while always keeping the lever held up. Release the handle, return to the first step and repeat unit the lever is tightened or loosened.
3. Loosely thread a T-bolt, washer and knob into the fence frame. Allow the T-bolt to protrude approximately 1/4” to 1/2” (Fig 11.1). Slide a fence face into the protruding T-bolt making sure that the T-bolt slides into the aluminum T-slot (Fig. 11.2), finish by tightening the knob. Repeat this step for the second fence face.

DUST SHIELD AND STARTING PIN

INSTALLING THE DUST SHIELD

1. Install the dust shield to the fence by sliding the T-bolts into the T- slots.
2. Loosen knobs to slide the dust shield to the desired height –retighten knobs to hold the shield in place (Fig. 12).

INSTALLING THE STARTING PIN
Install the starting pin into one of the predrilled holes on the table insert plate (Fig 13 or see page 7 – Fig. 8). For use as need-ed when freehand or template routing only.

INSTALLING AND USING THE MOVEABLE SWITCH BOX
The supplied switch box features a magnetic back that allows the switch to be placed anywhere on the metal surface of the cabinet to best suit your needs or preferences.
With the switch on the box in the “off” position plug any 110V router into the outlet on the switch box (Fig. 14) turn the switch on your router to the on position and then plug the cord from the switch box into a standard 110V outlet. You can then turn the router on or off using the switch box rather than having to reach under the table to access the switch on the router.

BEFORE TURNING ON THE SWITCH ON YOUR ROUTER, MAKE SURE THE SWITCH ON THE SWITCH BOX IS IN THE OFF POSITION AND THAT THE SWITCH BOX IS NOT YET CONNECTED TO A POWER SOURCE.

The moveable switch box is equipped with a simple rocker style “on/off” switch featuring a removable lock out safety key.
To prevent unauthorized use or unintentional start-up, remove the safety key and store it in a safe place when-ever the router table is not in use.

CONNECTING A DUST COLLECTOR
BEFORE ROUTING CONNECT THE MACHINE TO A DUST COLLECTION SYSTEM.
ALWAYS TURN ON THE DUST COLLECTOR BEFORE STARTING THE ROUTER AND ALWAYS STOP THE ROUTER BEFORE TURNING OFF THE DUST COLLECTOR.

There is a 2 1/2” dust outlet on the rear of the fence assembly allowing for the connection of a dust collector (not included).
Be sure to use an appropriate size hose and fittings (not included) and check that all connections are sealed tightly to 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 or visit our website at: www.general.ca

OPERATING INSTRUCTIONS
MAKE SURE TO READ, UNDERSTAND, AND FOLLOW ALL OPERATING INSTRUCTIONS AND SAFETY GUIDELINES THAT CAME WITH YOUR ROUTER – FAILURE TO DO SO MAY LEAD TO SERIOUS INJURY AND/OR DAMAGE TO THE ROUTER, ROUTER TABLE, OR WORKPIECE.

BEFORE STARTING

• Install the required bit in your router according to the instructions supplied with your router.
• Make sure that the router is firmly attached to the insert plate and that the plate is properly fitted and level in the table opening.
• The router table should be installed on a flat, sturdy, and stable surface.
• When jointing, groove cutting, and/or profile cutting always perform a test cut on a scrap piece of wood before cutting your final piece.

WHEN JOINTING, GROOVE CUTTING, AND/OR PROFILE CUTTING BE SURE TO ATTACH THE SUPPLIED DUST SHIELD.

JOINTING AN EDGE
Jointing the edge of a board involves using a straight cutting router bit to remove wood from the edge face of a board. The result is a perfectly flat and square edge.

1. Install a straight cutting router bit into your router according to the manufacturer’s instructions.
2. Snap the smallest table insert into the recessed hole that still allows the router bit to rotate freely.
3. Loosen the locking lever and using the fence adjustment knob adjust the outfeed fence lever so that it is flush with the edge of the router bit.
4. Loosen the knobs and adjust the opening between the fences to allow the bit to clear the edge of both fences.
5. Raise or lower the bit slightly so that the bit is higher than the board’s thickness.
6. Adjust the infeed fence to the router bit center, so that the distance is equal to the desired depth of the cut.

GROOVE CUTTING
Beading is commonly defined as cutting a groove or bead in the face of a board.

1. Mount a router bit into your router according to the manufacturer’s instructions.
2. Snap the smallest table insert into the recessed hole that still allows the router bit to rotate freely.
3. Raise or lower the router bit to the desired height.
4. Loosen the knobs and adjust the opening between the fences to allow the bit to clear the edge of both fences.
5. Adjust the main fence until the center of the bit has reached the desired distance.
6. Align the infeed and outfeed fences parallel to each other using a machinist square or a straightedge (Fig. 16).

PROFILE CUTTING
Profile cutting is usually performed using a bit with a guide bearing. The guide bearing controls the depth of cut into the edge face of a board. A good example would be a chamfer bit (Fig. 17).
The bearing rides along the uncut edge of the board while the cutter removes the wood.

1. Mount a router bit into your router according to the manufacturer’s instructions.
2. Snap the smallest table insert into the recessed hole that still allows the router bit to freely rotate.
3. Raise or lower the router bit to the desired height.
4. Loosen the knobs and adjust the opening between the fences to allow the bit to clear the edge of both fences.
5. Adjust the fence back and away from the bit only enough to allow the guide bearing to control the depth of cut.
6. Adjust the fence as close as possible to the bearing. The fence will serve as a backup support, reducing the chance of an accident.

USING THE MITER GAUGE
The supplied miter gauge can be swiveled left or right to any angle between 90° and 30° and has adjustable index stops at 90° and 45°.
To use a setting other than 90°, loosen the lock knob, , by turning it counter-clockwise, flip down the stop-lock tab, , and swiv-el the head of the gauge to the desired angle as shown on the scale. Turn the lock knob clockwise to tighten it.
If any of the miter gauge stops need adjusting turn the adjusting screws (Fig. 20) in or out as needed while using a combination square to check the 90 or 45 degree angles between the face of the gauge and the guide bar. Once set, tighten down the lock nuts to secure the adjusting screws in place.

ADDING AN AUXILIARY FENCE TO THE MITER GAUGE
To ensure safe accurate routing when using the miter gauge with long narrow pieces the workpiece will require more support than the narrow head of the gauge can provide and a home-made auxiliary hardwood fence should be attached to the face of the gauge.
Make sure the wood for the fence is straight, not bowed, and of an even thickness. Is should be at least 2” tall and extend far enough from either side of the miter head to support more than 50% of the workpiece and come as close to the router bit as pos-sible without touching. Drill 2 countersunk holes in the wood (Fig. 21.1) corresponding to the mounting holes on the face of the miter head (Fig. 21) tand use bolts and nuts (not supplied) to secure the wood fence to the face of the miter head.

PARTS LIST 40-040

 | REF. DIAG.| PART N0.| DESCRIPTION| SPECIFICATION| QTY
1| 40040-01| POINTER|  | 2|
2| 40040-02| SCALE|  | 2
3| 40040-03| FENCE|  | 2
4| 40040-04| WASHER|  | 4
5| 40040-05| KNOB|  | 4
6| 40040-06| SCREW| 3/16”| 2
7| 40040-07| TABLE INSERT PLATE|  | 1
8| 40040-08| FIXING PLATE|  | 2
9| 40040-09| SET SCREW| M6| 4
10| 40040-10| TABLE|  | 1
11| 40040-11| BRACKET|  | 2
12| 40040-12| SIDE PANELS|  | 2
13| 40040-13| NUT|  | 20
14| 40040-14| LOCK WASHER|  | 20
15| 40040-15| FLAT WASHER|  | 20
16| 40040-16| CARRIAGE BOLT|  | 20
17| 40040-17| LEVELING FOOT|  | 4
18| 40040-18| SHELF|  | 2
19| 40040-19| SCREW|  | 4
20| 40040-20| DUST SHIELD|  | 1
21| 40040-21| T-BOLT|  | 4
22| 40040-22| FENCE BRACKET|  | 2
23| 40040-23| RATCHET LEVER|  | 2
24| 40040-24| BOLT|  | 2
25| 40040-25| ADJUSTMENT KNOB|  | 2
26| 40040-26| SET SCREW|  | 2
27| 40040-27| DUST HOUSING|  | 1
28| 40040-28| T-SLOT|  | 1
29| 40040-29| MITER GAUGE ASSEMBLY|  | 1
30| 40040-30| HANDLE|  | 1
31| 40040-31| FLAT WASHER|  | 1
32| 40040-32| MITER GAUGE BODY|  | 1
33| 40040-33| SET SCREW| 3/16” X 3/4”| 3
34| 40040-34| NUT| 3/16”| 3
35| 40040-35| POINTER|  | 1
36| 40040-36| STOP TAB|  | 1
37| 40040-37| SET SCREW| M5 X 8mm| 1
38| 40040-38| PIN|  | 1
39| 40040-39| GUIDE BAR|  | 1
40| 40040-40| PHILLIPS HEAD SCREW|  | 1
41| 40040-41| GUIDE WASHER|  | 1
42| 40040-42| STARTING PIN|  | 1
43| 40040-43| T-BOLT|  | 2
44| 40040-44| T-SLOT|  | 2
45| 40040-45| RATCHET LEVER|  | 2
46| 40040-46| FLAT WASHER|  | 4
47| 40040-47| SWITCH ASSEMBLY|  | 1
 | 13

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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