Excalibur EX-16 Parts list manual

REVISION 1 - JUNE 28/10
Head tilts 45° left and right, tilting the
blade, not the table keeping the work-
piece level for better control & more
accurate cuts.
16" throat capacity.
2" cutting thickness capacity.
Large 12” x 18 1/2” (305 x 470 mm) table
surface.
Quick blade changes with finger operat-
ed blade clamps, no tools required.
Easy access speed and tension controls.
Onboard dust blower.
LENGTH
27” (686 mm)
WIDTH
15” (380 mm)
HEIGHT
17” (432 mm)
BLADE TILT RANGE
0° TO 45° (TO RIGHT OR LEFT)
THROAT
16”(406 mm)
MAXIMUM CUTTING DEPTH
2” (53 mm)
SPEED (VARIABLE)
400 TO 1400 STROKES/MIN
TABLE SURFACE
12” x 18 1/2” (305 x 470 mm)
MOTOR
120 V, 1.3 A
WEIGHT
68 LBS (31 kg)
© COPYRIGHT GENERAL INTERNATIONAL 06/2010

THANK YOU for choosing this Excalibur by General®International model
EX-16, 16" Scroll Saw. This scroll saw 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 scroll saw as well as the set-up, maintenance and identification of its parts and compo-
nents. 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 per-
forming a certain operation or procedure, do not proceed until you can confirm, from know-
ledgeable 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 commit-
ted to making constant improvements, General®Inter-
national reserves the right to make changes to compo-
nents, 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 specifica-
tions and information in this manual corresponds with
that of the unit with which it was supplied. However, spe-
cial 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 sroll saw and several versions of this manual
may be in circulation, if you own an earlier or later ver-
sion 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 seri-
al number of your unit for clarification.
GENERAL® INTERNATIONAL
8360 Champ-d’Eau, Montreal (Quebec) Canada H1P 1Y3
Telephone [phone] • Fax [phone] • www.general.ca

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 1-888-
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 expla-
nation 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 con-
sumable parts or components.
Repairs made without the written consent of General® International l will void all warranty.

TABLE OF CONTENTS
Rules for safe operation . . . . . . . . . . . . . . . . . .5
Additional Safety Instructions for Scroll Saw .6
Electrical requirements . . . . . . . . . . . . . . .7
Grounding instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Extension cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Identification of main parts and components .8
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . .9
List of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Installation & Assembly . . . . . . . . . . . . . . .9
Attaching the power cord . . . . . . . . . . . . . . . . . . . . . . . . .9
Install the saw on a stable surface . . . . . . . . . . . . . . . . . .9
Attaching the leveling feet . . . . . . . . . . . . . . . . . . . . . . . .10
Installing the optinal stand . . . . . . . . . . . . . . . . . . . . . . . .10
Mounting to a work surface . . . . . . . . . . . . . . . . . . . . . . .10
Choosing & Installing a Saw Blade . . . . . . .10
Blade selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Installing or changing blades . . . . . . . . . . . . . . . . . . . . .11
Operating Instructions . . . . . . . . . . . . . . .12
On/Off switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Adjusting the blade speed . . . . . . . . . . . . . . . . . . . . . . .12
Adjusting the blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Workpiece hold-down . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Basic 90º straight or curved cuts . . . . . . . . . . . . . . . . . . .13
Fret cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Angle or bevel cutting . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Maintenance, Adjustments & Servicing . . .16
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Blade clamping thumbscrews/set screws . . . . . . . . . . .16
Upper arm tension adjustment . . . . . . . . . . . . . . . . . . . .16
Squaring the bade to the table . . . . . . . . . . . . . . . . . . .17
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Recommended optional accessories . . . . . .17
Parts list & diagrams . . . . . . . . . . . . . . . .18-23

1. Be sure to read, understand and follow all safety
warnings and instructions in the supplied
Operator’s Manual.
2. Do not operate the saw when tired, distracted, or
under the effects of drugs, alcohol or any medica-
tion that impairs reflexes or alertness. Stay alert!
Give your work your undivided attention.
3. Keep the work area well lit, clean and free of
debris. Cluttered areas and benches invite injuries.
4. Keep children and shop visitors at a safe distance
while operating the saw; do not permit them to
operate the scroll saw.
5. Childproof and tamper proof your shop and all
machinery with locks, master electrical switches
and switch keys, to prevent unauthorized or unsu-
pervised use.
6. Fine particulate dust is a carcinogen that can be
hazardous to health. Work in well ventilated area
and use a dust collector whenever possible.
7. Wear approved safety glasses, dust mask and non-
skid footwear. Do not wear loose clothing, gloves,
bracelets, necklaces or jewellery while operating
the saw. Keep long hair contained by wearing pro-
tective hair covering.
8. Be sure all adjustment tools, wrenches or other clut-
ter are removed from the machine and/or the
table surface before operation. When not in use,
tools should be locked-up in a dry place, out of
children’s reach and away from flammable sub-
stances.
9. Keep hands well away from saw blade and all
moving parts. Use a brush, not hands, to clear away
chips and sawdust.
10. Be sure that saw blade is properly installed, and in
proper cutting direction, before operation. Always
use a clean, properly sharpened blade. Dirty or dull
blades are unsafe and can lead to accidents. Also,
be sure the blade has gained full operating speed
before beginning to cut.
11. Do not push or force stock into the blade. The saw
will perform better and more safely when working
at the rate for which it was designed. Do not use for
purposes not intended.
12. Avoid working from awkward or off balance posi-
tions. Do not overreach while cutting; keep both
feet on floor. Never lean over or reach behind the
blade and never pull the workpiece through the cut
from behind.
13. Never stand or lean on the saw. Serious injury could
occur if the unit is tipped over or if the blade is unin-
tentionally contacted.
14. Use of parts and accessories NOT recommended
by General® International may result in equipment
malfunction or risk of injury.
15. Never leave the machine unattended while run-
ning or with the power “ON”.
16. Always turn off and disconnect from power source
before servicing or changing accessories, blades,
bits, and cutters, or before performing any mainte-
nance or adjustments.
17. Make sure that switch is in the "OFF" position before
plugging in the power cord. Do not use the saw if
the power switch is defected, have defective switch-
es replaced by an authorized service center.
18. Make sure saw is properly grounded. If equipped
with a 3-prong plug it should be used with a three-
pole receptacle. Never remove the third prong.
Avoid body contact with grounded surfaces (e.g.
pipes, radiators, stoves, refrigerators).
19. Repairs to the saw should only be carried out by
qualified people using original spare parts. A
guard or other damaged part should be properly
repaired or replaced by an authorized service
center.
20. Inspect power cords and extension wires periodi-
cally. If damaged, have them repaired by an
authorized service facility. Never yank cords and
wires and keep away from heat, oil, and sharp
edges.
21. This tool is for indoor use only. Do not expose to rain
or use in wet or damp locations.
Rules for Safe Operation
To help ensure safe operation, please take a moment to learn the machine’s applications and limita-
tions, as well as potential hazards. General® International disclaims any real or implied warranty and
hold itself harmless for any injury that may result from the improper use of its equipment.
5

Additional Safety Instructions
Specific to this Scroll Saw
Because each shop situation is unique, no list of safety guidelines can ever be complete. The most
important safety feature in any shop is the knowledge and good judgement of the user. Use com-
mon sense and always keep safety considerations, as they apply to your individual shop situation
first and foremost in mind. If you have any doubts about the safety of an operation you are about
to perform: STOP! Do not perform the operation until you have validated from qualified individuals
if the operation is safe to perform and what is the safest method to perform it.
11. Do not attempt to saw stock that does not have a
flat surface unless a suitable support is used.
12. Turn off motor if the material resists being backed
out of an incomplete cut. Use appropriate speed
for applications.
13. CAUTION: Some wood contains preservatives such
as copper chromium arsenate (CCA) which can
be toxic. When cutting these materials, extra care
should be taken to avoid inhalation and to mini-
mize skin contact.
14. Always use a dust mask and safety glasses when
sawing.
15. Keep guards in place and in working order.
16. Make sure your fingers do not contact the terminals
of the power cord plug when plugging in or unplug-
ging the saw.
17. Never overfeed or force work into the blade.
18. Check for alignment and binding of all moving
parts, broken parts, mounting and any other con-
ditions that may affect the saw’s operation.
19. Keep handles dry and free from oil and grease.
6
1. Material hold-down must be properly set and
remain in position during use.
2. Never reach under the table when operating or
make any adjustments while the scroll saw is run-
ning.
3. Secure the saw to the work bench with clamps or
mounting hardware.
4. Where possible, use clamps or a vice to secure your
workpiece. It is safer than using your hand.
5. Do not lift or carry the saw by the upper arm.
6. Make sure blade tension is properly adjusted.
7. Avoid awkward hand positions where a sudden slip
could cause a hand to move into the saw blade.
Do not place fingers or hands in the path of the saw
blade.
8. When removing short workpieces, or cleaning up
around the table, be sure that the switch is in the
OFF position and that the blade has come to a
complete stop.
9. Never turn the saw ON before making sure that the
table is clear except for the workpiece and related
feed or support devices for the operation planned.
10. Check for proper blade size and type.
TO AVOID ELECTRICAL SHOCK, ENSURE MACHINE IS PROPERLY GROUNDED. DO NOT OPERATE IN DAMP
CONDITIONS. DISCONNECT FROM POWER SUPPLY BEFORE SERVICING. REPLACE FUSE WITH THE SAME
TYPE AND RATING ONLY - 3 AMP.
BE SURE TO READ AND UNDERSTAND OWNER’S MANUAL BEFORE OPERATING.

7
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 con-
necting 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 120V single phase operation and is equipped with a 3-conduc-
tor cord and a 3-prong grounded plug to fit a grounded type
receptacle, A.
Do not remove the 3rd prong (grounding pin) to make it fit into an
old 2-hole wall socket. If an adaptor plug is used, B, 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.
EXTENSION CORDS
USE ONLY 3-WIRE EXTENSION CORDS THAT HAVE 3-PRONG GROUNDING PLUGS AND 3-POLE RECEPTACLES THAT ACCEPT
THE TOOLS’ PLUG. REPAIR OR REPLACE A DAMAGED OR WORN POWER 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 heav-
ier the gauge.
DO NOT MODIFY THE PLUG PROVIDED.
If it will not fit your receptacle, 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 instruc-
tions, or if you are not sure the tool is properly grounded.
AMPERES
(AMPS) EXTENSION CORD LENGTH
25 FEET 50 FEET 75 FEET 100 FEET 150 FEET 200 FEET
<5 16 16 16 14 12 12
5 TO 8 16 16 14 12 10 NR
8 TO 12 14 14 12 10 NR NR
12 TO 15 12 12 10 10 NR NR
15 TO 20 10 10 10 NR NR NR
21 TO 30 10 NR NR NR NR NR
*Based on limiting the line voltage drop to 5V at 150% of the rated amperes.
NR = Not Recommended
A
B

IDENTIFICATION OF MAIN PARTS AND COMPONENTS
A- UPPER ARM TENSIONER
B- VARIABLE BLADE SPEED CONTROL KNOB
C- ON/OFF SWITCH
D- BLADE TENSION LEVER
E- BLADE CLAMP
F- BLADE
G- WORKPIECE HOLD DOWN
H- TABLE
I- BLADE TILT LOCKING LEVER
J- TILT HANDLE
K- ANGLE INDICATOR
L- ANGLE ADJUSTMENT SCALE
M- MOUNTING HOLES (4)
N- BLOWER
O- UPPER ARM
P- MOTOR
OPPOSITE SIDE VIEW
16” SCROLL SAW
EX-16
ABC
D
E
F
G
H
I
J
K
L
M
P
N
O
8

UNPACKING
Carefully unpack and remove the scroll saw and its
components from the box and check for damaged
or missing items as per the list of contents below.
NOTE: Please report any damaged or missing items to
your General International distributor immediately.
INSTALLATION & ASSEMBLY
For your convenience this scroll saw is shipped from the factory partially assembled and requires only minimal
assembly and set-up before being put into service.
BEFORE STARTING THE ASSEMBLY, 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 SCROLL
SAW UNTIL YOU HAVE COMPLETED THE ASSEM-
BLY AND INSTALLATION STEPS DESCRIBED IN
THIS SECTION OF THE MANUAL.
NOTE: Unscrew the 4 shipping bolts and remove the saw
from the protective plywood shipping base.
LIST OF CONTENTS QTY
A- SCROLL SAW..............................................................1
B- POWER CORD ...........................................................1
C- HEX NUT .....................................................................8
D- LEVELING FOOT.........................................................4
E- 3 MM ALLEN KEY.......................................................1
F- BLADE.........................................................................1
The unit should be installed on a flat, sturdy and stable
surface able to support the weight of the machine and
the workpiece with ease.
Never install the machine over the edge of a table or
workbench.
A
CE
F
B
D
Plug the female end of the power cord into the socket
at the rear of the saw as shown.
ATTACHING THE POWER CORD
9
INSTALL THE SAW ON A STABLE SURFACE

10
ATTACHING THE LEVELING FEET
If you prefer, an optional stand (item EX-21BS) is avail-
able from your local General International dealer. The
stand is equipped with mounting holes allowing the
saw, after removing the leveling feet, to be bolted
directly to the stand.
INSTALLING THE OPTIONAL STAND
B
A
Install the leveling feet as shown. Loosen the upper A
and lower B nuts as needed to adjust the height of the
foot.
FOR YOUR SAFETY IT IS ESSENTIAL THAT THE MACHINE DOES NOT ROCK OR TIP DURING OPERATION. UPON START-
UP OR DURING OPERATION, IF YOU NOTICE ANY ROCKING, TIPPING OR CHATTERING OF THE BASE TURN THE
MACHINE OFF IMMEDIATELY AND READJUST THE LEVELING FEET AS NEEDED TO STABILIZE THE SCROLL SAW ON THE
BENCH OR WORK SURFACE
MOUNTING TO A WORK SURFACE
If a permanent shop placement is practical, consider
removing the leveling feet on the base and drilling
matching through holes in the mounting surface of your
workbench or stand to bolt the saw in place (hardware
not included) on your workbench.
If a permanent installation is not practical, clamps can
also be used to secure the saw to a bench or work
table.
ORDER OF ASSEMBLY
A- Saw
B- Hex head bolt
C- Flat washer
D- Workbench or stand
E- Flat washer
F- Lock washer
G- Hex nut
D
A
C
EF
G
Blade selection is dependent on the type and thickness of the material being cut, but is also a matter of experi-
ence and personal preference. There are numerous types of blades available on the market specifically suited
for various cutting applications such as metal-cutting and spiral blades which cut in all directions. Try test-cutting
with a sample of each to determine which blade works best for you with different materials. Replacement and
specialty blades can be purchased from a variety of sources. Ask your local tool or scroll saw dealer for sugges-
tions for unpinned 5” scroll saw blades based on what is available in your area.
BLADE SELECTION
CHOOSING & INSTALLING A SAW BLADE
Some general guidelines to consider when choosing blades:
• Wide, thick blades with coarse teeth are suited to cutting straight lines and sweeping curves, but will not turn
tight corners. They will cut aggressively and leave a fairly smooth finish, but may leave burn marks if the work
piece is turned too tightly.
• Narrower, thinner blades with finer teeth will cut more slowly, but will turn much tighter corners for cutting very
intricate work. They will impart a very smooth, burnished finish that requires no sanding.
• Consider material thickness when selecting blades. Ensure that a minimum of two or three teeth are in con-
tact with the workpiece at all times. For example, when cutting 1/8” thick material, use a blade with a mini-
mum of of 16 20 teeth per inch.
B

BLADE WIDTH THICKNESS TEETH/INCH
#2/0 .022 .010 28 For extremely intricate sawing. Very tight cuts in 1/16”
- 1/4” wood veneer, plastic, hard rubber, pearl, etc.
#0 .024 .011 25
#2 .029 .012 20 For tight radius work with thin materials, 3/32” - 1/2”
wood veneer, wood, bone, fiber, plastic, etc.
#4 .035 .015 15
#5 .038 .016 12.5 For close radius work in materials 1/8” or thicker.
Good for sawing hard and soft woods, bone, horn,
plastic, etc.
#6 .041 .016 12.5
#7 .045 .017 11.5
Popular sizes for cutting hard and soft woods, 3/16”
up to 2”. Also cuts plastic, paper, felt, bone, etc.
#9 .053 .018 11.5
#11 .059 .019 9.5
#12 .062 .024 9.5
BLADE WIDTH THICKNESS TEETH/INCH Same appli-
cations as
Skip Tooth
blades.
#2/0R .026 .011 28/20
#2R .029 .012 20/13
#5R .038 .016 12.5/9
#7R .049 .018 11.5/8
#9R .054 .019 11.5/8
#12R .062 .062 9.5/6
Reverse teeth at the bottom of the blades prevent splintering
to the underside of the workpiece.
Regular evenly spaced tooth pattern. Considered the most common of scroll saw blades, they are available in
the widest range of sizes and provide a good combination of fast cutting action with good chip clearance
and a relatively smooth finish.
SKIP TOOTH
REVERSE TOOTH
BLADE WIDTH THICKNESS TEETH/INCH Same appli-
cations as
Skip Tooth
blades.
#1D .026 .013 30
#3D .032 .014 23
#5D .038 .016 16
#7D .044 .018 13
#9D .053 .018 11
#12D .061 .022 10
DOUBLE TOOTH
Fast, clean cutting and very efficient chip clearance.
INSTALLING OR CHANGING BLADES
ALWAYS TURN OFF AND UNPLUG THE MACHINE
BEFORE REMOVING, HANDLING OR CHANGING
BLADES.
1. Remove an installed, worn or broken blade by flip-
ping the blade tension lever forward (position 1), then
loosening the thumbscrews Aand Con the upper
and lower blade mounts Band D.
2. Remove the blade.
3. With the blade teeth facing forward, slip one end of
the blade through the hole in the table and fit each
end of the blade into the corresponding upper and lower blade mounts, then tighten the thumbscrews, only
enough to secure the blade and prevent it from slipping.
Note: Overtightening the blade clamp thumbscrews can cause premature wear to the blades gripping surface and result
in blade slippage or cause premature wear of the threads in the blade clamp housing.
12
A
B
D
C
11

To avoid kinking or damaging the blade in the holder, E, when
making adjustments make sure the set screw F (opposite the
thumbscrew G ) is threaded into the holder to protrude slight-
ly beyond the blade slot H .
4. Push the blade tension lever back (position 2) to
apply tension on the blade.
Helpful Hints on blade tension
Determining correct blade tension is somewhat sub-
jective. It is learned through experience and is some-
what dependant on personal preference. A properly
tensioned blade will last longer and be much less like-
ly to break prematurely. If the blade tension is too
loose, you will notice that the blade will have a ten-
dency to drift or slip off-line when cutting and you may
also experience excessive vibration or unusual noise.
A blade that is too tight will break prematurely.
Assuming the blade has been properly installed in the
blade mounts, when the blade tension lever is pushed fully back towards the rear of the saw, the blade should
be properly tensioned.
Test the blade tension by lightly plucking on the blade, like you would a guitar string, with your finger. If the
blade is tight and tensioned correctly you will get a clear and even note. If so, you are ready to proceed to
operating and cutting with the saw.
This saw has an adjustment knob in the rear that can raise the blade mount up to 1” (25mm). This allows you to
reposition the saw blade at a point where you can use a different part of the blade in the cutting area. This also
allows you to use a piece of band saw blade cut to a length of 5”- 6” (127-150mm ) in your saw and gives you
up to 3 inch cutting capacity when needed.
Note: Do not over tension the knob as this can cause premature wear and damage to the machine.
RAISE
LOWER
G
F
H
E
OPERATING INSTRUCTIONS
ON / OFF SWITCH
The Ex-16 Scroll Saw is equipped with a variable blade
speed control which allows you to select or fine-tune to
the exact blade speed required (from 400-1400 strokes per
minute) for best results based on the type and thickness of
material and type of blade being used.
The blade speed control knob Bis located on the top of
the machine.
• To increase blade speed, turn the control knob
clockwise.
• To decrease blade speed turn the control knob
counterclockwise.
A simple, dust protected rocker style on/off switch Ais
located on the top of the saw.
ADJUSTING THE BLADE SPEED
increase speed
reduce speed
B
A
12

Blade speed selection is subjective and is dependant on a variety of factors: type and thickness of material being
cut, type of blade being used, feed rate, required finish quality as well as experience, personal preference and com-
fort level of the user. There are no hard and fast rules. Be patient – practice and experience will be your best teacher.
Here are some general guidelines to consider when selecting/adjusting blade speed:
• For best results and smoothest most efficient cutting, always select the highest blade speed that you are comfort
able using based on your experience and skill level.
• Generally speaking, harder or denser workpiece material requires slower blade speeds.
• Slower speeds also work better with very thin blades, or when cutting most metals as well as for brittle or delicate
material such as fine veneers.
• Some wood species will have a tendency to burn quicker at higher blade speeds. To avoid additional sanding
later, reduce blade speed and feed speed at the first signs of burn marks on the workpiece.
ADJUSTING THE BLOWER
The workpiece hold-down B can be adjusted to assist in
preventing the blade from lifting the workpiece up from
the table during the cut. Loosen the thumbscrew C to set
the height to your convenience based on the thickness of
the workpiece. Before cutting, test to make sure that the
hold-down is not adjusted too tightly to the workpiece or
that it obstructs the movement of the workpiece.
The EX-16 is equipped with a built-in blower to help clear
cutting dust from the workpiece surface in front of the
blade and on any reference lines. Adjust the blower tube
A as needed to point the nozzle at the blade to set it at a
comfortable distance so as not to obstruct your hand
movement as you work.
WORKPIECE HOLD-DOWN
C
B
BASIC 90° STRAIGHT OR CURVED CUTS
All cuts made with the blade at 90° to the table follow the same basic principals. Start by marking or transferring
your pattern or reference lines onto you workpiece.
Note: The EX-16 has a 16” throat that allow for a workpiece of up to 16” of clearance to swing completely around without
hitting the back of the saw. If necessary, rough-cut the workpiece down to a workable size before starting intricate work on
the scroll saw.
Maximum workpiece
size from blade to
rear of saw
13
16”
A

1. With the saw turned off and unplugged, install the
appropriate blade for the type of material to be
cut and the type of cut to be made (Refer to the
section “Choosing and Installing a Saw Blade” on
page 10).
2. Adjust the workpiece hold-down and the blower
nozzle to your liking.
3. Turn on the saw and set the speed controller to
the desired blade speed.
4. With your fingers holding the piece firm to the ta-
ble, and using your thumbs for directional control,
feed the workpiece into the blade using steady,
even pressure.
5. Make sure that the blade is cutting on the waste
side of your reference line and adjust feed direc
tion slighty as needed to compensate for blade
drift.
Cutting Tips: To stay in control on tight curve cuts, slow down your feed rate as needed to allow the blade teeth time to
make the cut. Avoid coming to a complete stop whenever possible as this can leave burn marks on the workpiece and
also makes it more difficult to get the piece re-started and moving through the cut again. Avoid forcing through a curve
cut as this can cause the blade to twist and cut off-track or may even cause the blade to break.
FRET CUTTING
Fret or inside cutting is an operation that can only be performed
on a scroll saw. Fret cutting involves drilling a small guide or pilot
hole through the interior of your pattern on the workpiece, then
disconnecting one end of the blade which is fit through the
guide hole and re-connected; essentially using this guide hole
as the starting point to cut out the piece from within. A typical
example of fret cutting would be removing the center portion of
lettering A.
The EX-16 is a great tool for fret cutting because unlike most
scroll saws it allows you to raise the upper arm with the blade
attached, line up the guide hole in your workpiece with the
hole in the table and then lower the arm while guiding the
blade through the hole from above (see step by step instruc-
tions below).This can be a very useful time saving feature, par-
ticularly for intricate or complex fret designs that can involve
dozens or even hundreds of holes.
Note: The upper arm locks in place in the raised position for easi-
er insertion of the blade through the hole in the workpiece and for
easier blade changes.
1. With the saw turned off and unplugged, install the
appropriate blade for the type of material to be cut and the
type of cut to be made (Refer to the section “Choosing and
Installing a Saw Blade” on page 10 of this manual).
2. With your pattern or design transferred onto the workpiece,
drill a guide hole in the inside waste portion of the work-
piece B. Make sure that the hole is large enough for the
blade to fit through.
Helpful hints on drilling guide holes: If multiple fret cuts are
requi-red on the same workpiece, drill all of your required
guide holes before taking the workpiece to the scroll saw.
This will keep you from going back and forth from the saw
to the drill press.
To prolong blade life by limiting unnecessary cutting, drill
your guide holes as close as possible to your reference
lines
C .
remove portion
A
B
C
14

3. Release tension on the blade by flipping the blade tension lever forward.
4. Loosen the thumbscrew on the lower blade mount, located under the table, to release the blade from the mount.
5. Raise the upper arm assembly which will lift the blade up through the hole and above the table.
6. Position the workpiece on the table so that the guide hole lines up with the hole in the table.
7. Lower the arm assembly with one hand while guiding the blade through the hole in the workpiece and table.
8. Re-install the bottom end of the blade in the lower blade mount and tighten the thumbscrew, only
enough to secure the blade in the lower blade clamp and prevent it from slipping.
Note: Overtightening the blade clamp thumbscrews can cause premature wear to the blades gripping surface and result
in blade slippage or cause premature wear of the threads in the blade clamp housing. (added this sincd Norm’s copy)
9. Flip back the blade tension lever to re-tension the blade and test the blade tension as described in
“Installing or Changing Blades” section of this manual.
10. To begin cutting follow the same steps as described in “Basic 90° straight or curved cuts” section on page 13 of
this manual.
TO REDUCE THE RISK OF INJURY, ALWAYS TURN OFF THE SAW AND WAIT FOR THE BLADE TO COME TO
A COMPLETE STOP BEFORE REACHING IN TO REMOVE WASTE MATERIAL FROM A FRET CUT.
ANGLE OR BEVEL CUTTING
One of the unique features of the EX-16 Scroll Saw is the ability
to tilt the head of the saw in order to make angle or bevel cuts.
The table and the workpiece always stay horizontal (parallel to
the floor) while the blade tilts, keeping your hands in the same
comfortable cutting position as they would normally be for
regular right angle cuts.
Because you are not fighting gravity or working with your
hands or wrists bent in awkward positions, it can be a huge
advantage and makes it easier and safer to make accurate
bevel cuts.
The blade tilt controls are located under the table at the front
saw. To tilt the blade for bevel cutting:
1. Release the locking lever A by turning counter-clockwise.
2. Turn the tilting handle B left or right to set the blade to the
desired angle.
Note: Push in and hold the spring loaded indexing pin C to locate
the following common angles: 90º, 45º, 30º & 22.5º both left and
right.
When tilting the blade to the left at extreme angles, it may be
necessary to remove and reverse the lower blade mount thumb-
screw assembly in order to maximize clearance under the table.
(D shows the lower blade mount in default position and E shows
it reversed).
3. Tighten the locking lever Ato secure the blade at the
desired angle.
4. To begin cutting, follow the same steps as described in
“Basic 90° straight or curved cuts” section on page 13 of
this manual. Letter Fshows the scroll saw in position for
bevel cutting.
BC
A
DE
F
15

16
MAINTENANCE, ADJUSTMENTS AND SERVICING
BLADE CLAMPING THUMBSCREWS - SET SCREWS
HANDLING
Never lift the saw by the upper arm assembly as this will
result in damage to the drivetrain. Rather lift the saw by the front of the table and by the
motor.
Over time with normal use and wear, especially when
doing a lot of internal cutting where one end of the
blade is frequently disconnected then reconnected to
fit into a hole, the contact end of the thumbscrews Awill
wear and can become smooth to the point were it will
no longer clamp the blade properly.
To avoid potentially costly downtime, consider keeping
a spare set of replacement thumbscrews and set screws
on hand for use if needed.
Note: If you begin to experience frequent blade slippage it may be a sign that it is time to replace the blade
clamp thumbscrew
B and/or the set screws opposite the thumbscrews C .
Note: Overtightening to compensate for blade slippage may damage, or in extreme cases strip, the
threads in the blade clamping block.
Note: Before replacing either, always double check visually to make sure that the blade is being held
between the set screw and the thumbscrew as shown in
D and is not being bent or kinked into the oppo-
site side of the blade clamping block because of a set screw that is adjusted too far back in the holder as
shown in
E .
A
C
D
E
UPPER ARM TENSION ADJUSTMENT
Over time and with normal wear, the upper arm tension
will require adjustment to hold the arm in the raised posi-
tion. To adjust the upper arm tension:
1. Loosen the lock nut E.
2. Adjust the tension screw until the arm stays in
raised position.
3. Re-tighten the lock nut.
E
B

RECOMMENDED OPTIONAL ACCESSORIES
Here is a sampling of optional accessories available from your local General International dealer to help you
increase convenience, productivity, accuracy and safety when using your scroll saw.
For more information about our products, please visit our website at www.general.ca
FOOT SWITCH - #EX-01
Enjoy hands-free on/off
control of your scroll saw
with this simple design,
easy to use momentary
style foot switch. Features
BLADE GUARD - #EX-02
Optional upper and lower bla-
de guard assembly will help
prevent unintentional or acci-
dental hand/finger contact
with the saw blade. Ideal for
professional and educational
users or in any shop environ-
ment where additional safety
features may be required.
Simple design, easy to install
with only basic tools and a
handheld power drill required.
a 6 1/2 Ft. 16 gauge grounded power cord with a
standard 110V 3-prong plug.
Constant "off" mode design: press and hold down
switch to turn the saw "on" and simply lift foot
from switch to turn the saw "off".
SQUARING THE BLADE TO THE TABLE
Depending on frequency of use and how much the tilting mech-
anism is used, normal wear will over time cause the blade to
come slightly out of alignment with the table. Periodically check
the blade for square with the table. When needed, adjust as
described in the following steps to re-align the blade square to
the table.
1. Turn off and unplug the saw.
2. Using the blade tilt controls at the front of the saw, set the
blade angle to read 0 - which is 90° vertical to the table.
3. Set a machinists square on the table and against the blade
to verify the blade angle, A.
4. If the blade angle requires adjustment loosen the 4 bolts in the
front trunnion B as well as the 4 bolts on the rear trunnions C.
5. By hand, move the entire head to bring the blade square to the
table.
6. With the blade square to the table hold the head in position
and re-tighten the bolts on the front and rear trunnions.
A
Front View
Back View
C
BB
C
MAINTENANCE
• Always release tension on the blade when the saw is not
in use.
• Clean the saw regularly with a soft bristle brush or by vac-
uuming to keep cutting dust from accumulating.
• An occasional application of a light dab of grease on
the front and rear trunnions Dwill keep the tilting mecha-
nism working smoothly. If you find the tilting mechanism
becoming more difficult to operate, thoroughly wipe off
any built-up cutting dust on the trunnions and re-apply a
little grease.
• The bearings in the drive mechanism are sealed and per-
manently lubricated and do not need to be oiled or
greased.
D
17
Underside View

79
4
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12
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18
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27
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70
28
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78
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67 68
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55
77
#EX-16 A
18

19
PARTS LIST - EX-16 (A)
PART N0. DESCRIPTION SPECIFICATION QTY
EX21-A04 ALLEN SCREW #10-32X1/4 4
EX21-A05 SWITCH COVER 1
EX21-A06 SWITCH 1
EX21-A12 AIR NOZZLE 1
EX21-A18 BOLT 1/4-20X1/2 2
EX21-A19 UPPER & LOWER TENSION PLATE 1
EX21-A20 HOLD DOWN MOUNT PLATE 1
EX21-A21 ALLEN SCREW #10-32X3/8 2
EX21-A22 HOLD DOWN CLAMP KNOB 1
EX21-A23 WASHER 1/4X16X1.8 4
EX21-A24 HOLD DOWN CLAMP SCREW 1
EX21-A25 HOLD DOWN BAR 1
EX21-A26 CAP SCREW #10-32X1/2 1
EX21-A27 HOLD DOWN FORKS 1
EX21-A28 DUST BLOWER 1
EX21-A29 TAP SCREW #8-32UNF3/8" 2
EX21-A30 VR KNOB 1
EX21-A31 VR 1
EX21-A33 SCREW M4X8 4
EX21-A34 MOTOR CONTROL SET CSA 1
EX21-A35 ALLEN SCREW 1/4-20X1/2 3
EX21-A37 LINE CORD SOCKET 1
EX21-A38 FUSE 1
EX21-A39 STRAIN RELIEF 1
EX21-A40 GEAR COVER 1
EX21-A41 NUT 3/8XT5.5 1
EX21-A45 ALLEN SCREW #10-32X2-1/4 4
EX21-A46 SCREW 3/8X5/8 1
EX21-A47 WASHER #8 1
EX21-A48 SCREW #8-32X1/4 1
EX21-A49 MOTOR LABEL 1
EX21-A50 WARNING LABEL 1
EX21-A51 NYLON NUT #10-32 4
EX21-A52 NYLON NUT 1/4-20UNC 2
EX21-A53 LOCK WASHER 1/4. 1
EX21-A54 FLAT WASHER 1/4.(O.D.13) 1
EX21-A55 LABEL 2
EX21-A56 SCREW 1/4X2-1/2 2
EX21-A57 UPPER ARM 1
EX21-A58 KNOB 1
EX21-A59 NUT M8 1
EX21-A60 ADJUSTING LEVER 1
EX21-A61 CONTROL BOX 1
EX21-A62 CROSS BLOCK RETAINER 1
EX21-A63 HOUSING CROSS BLOCK 1
EX21-A64 FLAT WASHER M6X16X2 1
EX21-A65 NYLON NUT M6 1
EX21-A66 ALLEN SCREW #10-32X1/2 1
EX21-A67 R FASTENER 1/4 1
EX21-A68 WASHER #10 1
EX21-A69 NYLON NUT #10-32 1
EX21-A70 ALLEN SCREW #10-32X5/16 7
EX21-A71 BUTTON 1
EX21-A72 SET SCREW M4X5 1
EX21-A77 LABEL 1
EX16-A78 MAIN BODY 1
EX16-A79 TOP COVER 1
EX16-A80 UPPER ARM 1
EX16-A81 CONTROL CABLE 1

19
6
7
98
29
42
29
43
19
19
19
35
10
12
11
15
11
17
18
14
13
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11
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18
3
1
41
44
4
1
19
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21
45
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20
13
26
27
28
37
22
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44
#EX-16 B
20