General Excalibur 40-200C Parts list manual

SETUP & OPERATION MANUAL
MODEL
#40-200C
DELUXE ROUTER TABLE KIT
(Floor model)
© Copyright General® International
FEATURES
Heavy-duty massive router lift with 9 1/4” x
11 3/4” aluminum top plate.
Stable 4 post/lift screw design & chain drive
lifting system controlling all 4 corners simul-
taneously.
Fits all fixed base router motors*.
Smooth above-the-table adjustment mech-
anism for fast tool changes & precision bit
setting.
Available with table in either cast-iron (40-
200C), MDF (40-200M) or Phenolic (40-200P).
Stand made of tubular steel, includes,
mobility kit, adjustable leveling feet and
easy access on/off safety switch with
removable lock-out key.
Fence has 2 1⁄4” dust collection outlet and
adjustable scales.
Under table steel dust enclosure with
access door, adjustable air vent, power
cord grommet and 4” dust port with 2 1⁄4”
branch inlet to the fence. Includes 2 1⁄4”
dust hose and 2 hose clamps.
Some router models may require reducer
collars/adaptors.
*
SPECIFICATIONS
OVERALL DIMENSIONS
35 1/2” X 24” X 41”(902 X 609 X 1041 MM)
TABLE SIZE/HEIGHT
32” X 24”(812 X 609 MM) /36 1/2” (927 MM)
FENCE SIZE (EACH)
3” X 17 3/4” X 3/4” (76 X 451 X 19 MM)
MAXIMUM FENCE TRAVEL
9” (229 MM)
DUST OUTLET
4” (102 MM)
DISTANCE BETWEEN T-SLOT & SPINDLE CENTER
3/4”: 5 5/8” (143 MM)
3/8”: 7 3/16” (183 MM)
DISTANCE FROM SPINDLE
CENTER TO FRONT EDGE OF TABLE
12” (305 MM)
T-SLOT DIMENSIONS
3/4” X 3/8” (19 X 10 MM) /
3/8” X 1/4” (10 X 7 MM)
ROUTER INSERT PLATE
9 1/4” X 11 3/4” (235 X 298 MM)
TABLE OPENING SIZES - DIAMETER
PLATE: 3 3/4” (95 MM)
INSERT RING: 1 1/2” (38 MM)
NET WEIGHT (40-200C MODEL)
179 LBS (81 KG)

THANK YOU for choosing this Excalibur by General®International model
40-200 Deluxe Router Table Kit (floor model). This router table 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 router table as well as the set-up, maintenance and identification of its parts and com-
ponents. 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 com-
mitted 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 manu-
al corres-ponds with that of the unit with which it was
supplied. However, special orders and “after factory”
modifications may render some or all information in this
manual inapplicable to your machine. Further, as sever-
al gene-rations of this model of router table and several
versions of this manual may be in circulation, if you
own an earlier or later version of this unit, this manual
may not depict your machine exactly. If you have any
doubts or questions contact your retailer or our support
line with the model and serial number of your unit for
clarification.

GENERAL®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 com-
pletion 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 Warran-
ty, 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 Gener-
al® 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 lo-
cation 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 trans-
port, 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
Placement within the shop /
Establishing a safety zone ........................... 6
Safety ........................................................ 6
Identification of main parts
and components......................................... 7
Unpacking ................................................. 8
List of contents - 40-085 Stand .................................. 8
List of contents - 40-080 Router fence...................... 8
List of contents - 40-125 Router lift ............................ 9
List of contents - 40-130 Dust collection kit.............. 9
List of contents - Table ............................................. 10
Additional requirements for set up........................ 10
Assembly instructions .......................... 11-22
40-085 Router table stand ............................... 11
Table 40-0708/40-049/40-045 ........................ 13
Cleaning the cast-iron table (for #40-200 only)... 13
Install the table (cast-iron table #40-200C and
phenolic table # 40-200P only) ............................. 13
Attach the stand to the table.......................... 14
Engaging/disengaging the stand casters .......... 14
40-080 Router fence ........................................ 15
Prepare the table for router lift........................ 18
40-130 Dust collection kit ................................ 19
Mounting a router ............................................ 20
Leveling and locking the router plate.................. 22
Insert ring removal................................................... 22
Installing the starting pin......................................... 22
Basic adjustments & controls................ 23-24
Adjusting the fence along the rails ....................... 23
Adjusting the sliding scale on the rails ................. 23
Adjusting the fence faces....................................... 23
Connecting the router to the safety switch.......... 24
Using the safety switch ............................................ 24
Connecting to a dust collector ............................. 24
Operating instructions...................................25-27
Before starting .......................................................... 25
Using the spacer bars for jointing ......................... 25
Jointing...................................................................... 26
Groove cutting ......................................................... 26
Profile cutting............................................................ 27
Tensioning the drive chain ..................................... 27
Recommended optional accessories ..........28
Parts list & diagrams............................. 30-37
Contact information...................................38

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 instruc-
tions, warnings and safety guidelines supplied with
your router.
3. Do not operate this router table when tired,distracted,
or under the effects of drugs, alcohol or any medica-
tion that impairs reflexes or alertness.
4. Keep the work area well lit, clean and free of debris.
5. Stay Alert! Give your work your undivided attention.
Even a momentary distraction can lead to serious
injury.
6. Do not wear loose clothing, gloves, bracelets, neck-
laces, or other jewelry. Wear face, eye, ear, respirato-
ry and body protection devices.Wear protective hair
covering to contain long hair and wear non-slip
footwear.
7. Keep hands and other body parts well away from
bits or cutting tools. When working close to the cut-
ting 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.
8. 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.
9. Be sure the router is running up to speed before feed-
ing the workpiece.
10. Use a suitable support if stock does not have a flat
surface.
11. Keep children and visitors at a safe distance when
the router is in operation – do not permit them to
operate the router and table.
12. Childproof and tamper proof 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 limita-
tions, as well as potential hazards. GENERAL® INTERNATIONAL disclaims any real or implied war-
ranty and holds itself harmless for any injury that may result from improper use of its equipment.
5
13. Secure the table to a work surface and never stand
or lean on it. Serious injury could occur if the table
is tipped or if unintentional contact is made with
spinning router bit.
14. Keep all guards and safety devices in place and
ingood working order. If a guard must be removed
for maintenance or cleaning make sure it is proper-
ly reinstalled before using the machine again.
15. Hold the workpiece firmly against the table and use
suitable support if the workpiece does not have a
flat surface.
16. Feed the stock into the bit against the rotation direc-
tion of the bit. Never run the stock between the fence
and the bit.
17. Do not operate with a damaged bit in the router.
18. Always disconnect the router from the power source
before changing accessories or before performing
any maintenance and adjustments or if the ma-
chine will be left unattended.
19. Be sure that all adjustment tools, wrenches or other
clutter are removed from the table surface and safe
ly stored before routing.
20. Make sure the routers switch is in the “OFF” position
before plugging in to a power source.
21. Avoid working from awkward or off balance posi-
tions. Do not overreach and always keep both feet
firmly on the floor.
22. Never leave the router unattended while running or
with the power on.
23. Do not use this router table for any purpose other
than its intended use. If used for other purposes,
GENERAL® INTERNATIONAL disclaims any real or im-
plied warranty and holds itself harmless for any inju-
ry which may result from such use.

PLACEMENT WITHIN THE SHOP /
ESTABLISHING A SAFETY ZONE
PLACEMENT WITHIN THE SHOP
This machine should be installed and operated
only on a solid, flat and stable floor that is able
to support the weight of the router table and the
operator.
Using the dimensions shown as a guideline, plan
for placement within your shop that will allow the
operator to work unencumbered and unobstruct-
ed by foot traffic (either passing shop visitors or
other shop workers) or other tools or machinery.
ESTABLISHING A SAFETY ZONE
For shops with frequent visitors or multiple oper-
ators, it is advisable to establish a safety zone
around shop machinery. A clearly defined “no-
go” zone on the floor around each machine can
help avoid accidents that could cause injury to
either the operator or the shop visitor.
It is advisable to take a few moments to either
paint (using non-slip paint) or using tape, define
on the floor the limits or perimeter of each
machines safety zone. Take steps to ensure that
all operators and shop visitors are aware that
these areas are off limits whenever a machine is
running for everyone but the individual operating
the unit.
6
THE MACHINE IS HEAVY (179 LBS - 81 KG). DO NOT OVEREXERT. ARRANGE TO HAVE HELP NEARBY AND READY FOR UNPACK-
ING AND SET UP.
SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COM-
PLETED THE INSTALLATION AND ASSEMBLY STEPS. DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED
TO DO SO.
SAFETY
ROUTING MAY PRESENT SERIOUS INJURY HAZARDS TO UNTRAINED USERS. BE SURE TO READ, UNDERSTAND, AND
FOLLOW ALL INSTRUCTIONS AND SAFETY GUIDELINES SUPPLIED WITH THE ROUTER YOU WILL INSTALL ON THIS TABLE.
MAKE SURE THAT ADEQUATE HEARING PROTECTION IS USED AND THAT THE OVERALL SOUND LEVEL WITHIN THE
WORKING ENVIRONMENT IS TAKEN INTO CONSIDERATION.

DELUXE ROUTER TABLE KIT (Floor model)
MODEL #40-200C
IDENTIFICATION OF MAIN PARTS AND COMPONENTS
A- ON/OFF SWITCH WITH REMOVABLE SAFETY KEY
B- TABLE*
C- FENCE RAIL WITH SLIDING SCALE
D- OUTFEED FENCE FACE
E- FENCE LOCKING HANDLE
F- ROUTER LIFT CRANK HANDLE
G- DUST SHIELD LOCK KNOB
H- DUST SHIELD
I- FENCE BODY
J- INSERT RING WRENCH
K- INFEED FENCE FACE
L- 3/4” X 3/4” MITER T-SLOT (FOR MITER GAUGE)
M- 3/8” MITER T-SLOT (FOR SELF MADE JIGS)
N- INSERT RING WRENCH STORAGE
7
T
O- DUST ENCLOSURE BOX ACCESS DOOR
P- AIR VENT
Q- ROUTER LIFT HANDLE HOLDER
R- STAND
S- STAND CASTER PEDAL
T- LEVELING FEET
U- CASTERS
V- 2 1⁄4” BRANCH INLET
W- DUST HOSE
X- 4” DUST PORT
Y- DOVETAIL SLOT
L
* Model 40-200C Cast-iron table shown.
V
X
W
Y
REAR VIEW
DOVETAIL SLOT
L
* Model 40-200C Cast-iron table shown.

Carefully unpack and remove the components of the following 5 boxes - that make up a complete Excalibur Router
Table - 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.
UNPACKING
LIST OF CONTENTS QTY
40-080 ROUTER FENCE (40-200)
a- DUST SHIELD...................................................... 1
b- 2 1⁄4” dust collection outlet........................... 1
c- FENCE LOCKING HANDLE ............................... 2
d- FENCE BODY .................................................... 1
e- FENCE FACE.........................................................2
f- FENCE SIDE RAIL W/SCALE ................................ 2
g- FENCE MOUNTING BRACKET .......................... 2
h- SPACER BARS (FOR JOINTING WORK) ........... 2
i- LOCK KNOB ..................................................... 8
j- T-BOLT (LONG) ................................................. 6
k- CAP SCREW...................................................... 6
l- PLASTIC SPACER............................................... 2
m- FLAT WASHER (SMALL)................................... 14
n- T-BOLT (SHORT)................................................. 2
o- PHILLIPS HEAD SCREW ..................................... 2
p- HEX NUT (LARGE)............................................. 2
q- FLAT WASHER (LARGE)..................................... 2
r- SQUARE NUT ..................................................... 8
s- HEX HEAD BOLT................................................ 6
8
40-080 ROUTER FENCE (40-200)
a
b
c
e
g
f
h
d
jnpq
s
r
k
l
o
m
i

Carefully unpack and remove the components of the following 5 boxes - that make up a complete Excalibur Router
Table - 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.
UNPACKING (CNT’D)
40-125 ROUTER LIFT
LIST OF CONTENTS QTY
40-125 ROUTER LIFT
a- ROUTER LIFT ...................................................... 1
b- ROUTER LIFT CRANK HANDLE .......................... 1
c- INSERT RING WRENCH ..................................... 1
d- STARTER PIN....................................................... 1
e- HEX SOCKET HEAD BOLT....................................2
f- 2.5 MM ALLEN KEY........................................... 1
g- 3 MM ALLEN KEY.............................................. 1
h- 4 MM ALLEN KEY.............................................. 1
i- 6 MM ALLEN KEY.............................................. 1
LIST OF CONTENTS QTY
40-130 DUST COLLECTION KIT
a- RIGHT SIDE PANEL ............................................ 1
b- BOTTOM PANEL................................................ 1
c- REAR PANEL...................................................... 1
d- LEFT SIDE PANEL ................................................ 1
e- FRONT PANEL....................................................... 1
f- DUST HOSE ........................................................... 1
g- DUST PORT ........................................................ 1
h- HOSE CLAMP.................................................... 2
i- HEX HEAD BOLT................................................ 6
j- LOCK WASHER ................................................. 6
k- FLAT WASHER.................................................... 6
l- PHILLIPS HEAD SCREW (SHORT) ....................
m- PHILLIPS HEAD SCREW (LONG).......................
a
bc
de
f g hi
40-130 DUST COLLECTION KIT
a
b
c
de
f
g
h
i
k
j
l
m
9
36
........................................................
8
2

Carefully unpack and remove the components of the following 5 boxes - that make up a complete Excalibur Router
Table - 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.
UNPACKING (CNT’D)
40-075 CAST-IRON TABLE (40-200C) *
LIST OF CONTENTS QTY
a- 24” X 32” CAST-IRON TABLE........................... 1*
b- HEX NUT ........................................................ 10*
c- LEVELER SCREW............................................ 10*
d- FLAT WASHER.................................................. 6*
e- LOCK WASHER ............................................... 6*
f- HEX SOCKET CAP SCREW.............................. 6*
Note: Supplied hardware is the same for 40-200C or
40-200P with cast-iron or phenolic table.
For 40-200M with MDF table, the following hardware
is supplied:
a- WOOD SCREW ............................................... 10
b- WOOD NUT....................................................... 2
c- SELF TAPPING SCREW .................................... 32
* Model #40-075 for 40-200C Cast-iron
table shown.
*
a
b
c
d
e
f
10
mounting hardware for #40-075 cast-iron
and #40-045 phenolic table
ADDITIONAL REQUIREMENTS FOR SET UP
• Extra person for help with lifting
(cast-iron table)
• Straight edge
•Phillips screwdriver
• Socket wrench set
• Wrench set
• Allen key set
*
a
c
mounting hardware for #40-049
MDF table
b

ASSEMBLY INSTRUCTIONS - 40-085 ROUTER TABLE STAND
SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COM-
PLE-TED THE INSTALLATION AND ASSEMBLY STEPS. DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED
TO DO SO.
A
B
D
B
4. Using the supplied socket head screws with wash-
ers A, attach a caster bracket to the front and
rear right side legs as shown in B.
6. Using the supplied
ers, attach the bottom side brace with black swivel
caster assembly to the 2 legs without casters as
shown in A, Then attach a top side brace to the top
of the legs, B.
7. Attach the other bottom side brace to the bottom of
the two remaining legs Cand the other top side bra-
ce to the top of the legs D.
RIGHT SIDE STAND SUB ASSEMBLY LEFT SIDE STAND SUB ASSEMBLY
A
B
AC C
D
A
3. Attach the swivel caster assembly to a bottom side
brace as shown in A, using the 2 supplied socket
head screws with washers B.
2. Attach the pedal caster assembly A to the black
brace B using the 4 supplied socket head screws
with washers Cas shown in D.
1. Insert an adjustable leveling foot into each leg as
shown in A.
Note: The four legs need to be positioned with the mount-
ing holes on both faces on the corners B.
LEGS BOTTOM SIDE
CROSS BRACE
TOP SIDE
CROSS BRACE
FRONT/REAR
BOTTOM CROSS
BRACE
FRONT / REAR
TOP CROSS
BRACE
You will find two different brace lengths and styles; the
4 shorter ones are for the sides. All the narrow braces
are for the top of the stand, and the wider ones are for
the bottom.
C
11
B

8.
the two sub assemblies using the front/rear bot-
tom A and top B braces.
Do not tighten the stand bolts until after you have
fastened the stand to the router table top. (See
step 3 on page 14.)
The router lift crank handle may be stored on the holder
as shown above.
B
12. Insert a phillips head screw with hex nut through
one of the holes on the left top cross brace, and
from the other side of the brace, lightly thread a
second hex nut to lock the screw in position.
The insert ring wrench may be stored on the screw as
shown above.
A
12
AB

ASSEMBLY INSTRUCTIONS - TABLE 40-075/40-049/40-045
There are 3 different table options for Deluxe Router Table Kit, model 40-200:
SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COM-
PLE-TED THE INSTALLATION AND ASSEMBLY STEPS. DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED
TO DO SO.
Cast-iron table (#40-075) for 40-200C MDF table (#40-049) for 40-200M Phenolic table (#40-045) for 40-200P
The protective coating on the cast-iron table, prevents
rust from forming during shipping and storage. Remove
it by rubbing with a rag dipped in kerosene, mineral
spirits or paint thinner. (Dispose of potentially flammable
solvent-soaked rags according to manufacturer’s safety
recommendations.)
A putty knife, held flat to avoid scratching the surface,
may also be used to scrape off the coating followed by
clean-up with solvent.
To prevent rust, apply a light coating of paste wax or
use regular applications of any after-market surface pro-
tectant or rust inhibitor.
Tip: With a screw driver, push a solvent-saturated rag
into the T-slots to remove the grease.
CLEANING THE CAST-IRON TABLE FOR #40-200C ONLY)
INSTALL THE TABLE (CAST-IRON TABLE #40-200C AND PHENOLIC TABLE#40-200P ONLY)*
* For #40-049 MDF table (for #40-200M), only thread in all leveler screws and nuts as shown below. You will use
the wood screws supplied with your table in the upcoming steps to attach the table and dust collection box
to the stand, and the fence mounting rails to the table.
5. As a precaution, thread in all fasteners as shown to
make sure there are no filings in any of the threaded
holes, and leave the fasteners in the underside of the
table. Only remove as assembly is taking place.
Note 1: The leveler screws need to be inserted from the
bottom of the table. The nut will sit on the top side of the
flange that the router lift/plate will rest on, A.
Note 2: There are 3 holes on each side of the table open-
ing, C. The two outside holes are for the leveling screws,
A, and the middle hole is used to secure a plate, or the
lift, to the table.
13
CAST-IRON TABLE 27”X 16”
#40-070
C
B
A

ASSEMBLY INSTRUCTIONS - ATTACH THE STAND TO THE TABLE
SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COM-
PLETED THE INSTALLATION AND ASSEMBLY STEPS. DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED
TO DO SO.
CAST-IRON TABLE #40-200C AND PHENOLIC TABLE #40-200P ONLY)*
* For #40-049 MDF table (for #40-200M), use the wood screws supplied with your table to attach the stand to the
table.
1. With the table upside down, remove the 4 mounting
screws and washers, A for the stand.
2. Attach the stand to the table using the four socket
head cap screws and washers, B, then tighten.
CAST-IRON TABLE 27”X 16”
#40-070
Note: If you previously threaded all the fasteners into the
underside of the cast-iron table, the leveler screws will
already be in place. If you didn’t, thread them in now. The
nut will sit on the top side of the flange that the router lift/
plate will rest on.
A
B
The stand caster system allows you to engage/dis-
engage the stand casters in order to move the router
table as needed within the shop.
- Push the pedal down to engage the stand casters.
- Pull the pedal up to disengage the stand casters.
ENGAGING/DISENGAGING THE STAND CASTERS
NEVER MOVE THE ROUTER TABLE WHILE THE ROUTER
IS RUNNING AS THIS CAN LEAD TO SERIOUS INJU-
RIES. ALWAYS MAKE SURE THAT THE WHEELS OF
THE STAND HAVE BEEN DISENGAGED AND THAT THE
STAND HAS BEEN COMPLETELY IMMOBILIZED BEFORE
TURNING ON THE ROUTER AND STARTING TO CUT.
14
3. Turn the stand and table assembly upright and
tighten all bolts, checking that the table is level with
the floor. Adjust the leveling feet as needed.

ASSEMBLY INSTRUCTIONS - #40-080 ROUTER FENCE
SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE
COMPLETED THE INSTALLATION AND ASSEMBLY STEPS. DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL
INSTRUCTED TO DO SO.
2. Remove the original 8 fence bracket mounting bolts
Afrom the table and attach the fence mounting
brackets to the underside of the table, B.
4. Insert an orange plastic spacer Awith the short end
down on one short T- bolt B, then insert the head of
the bolt in the front upper slot in the fence body as
shown in C.
A
B
C
A
B
D
1. Attach the two fence side rails with scale Ato their
mounting brackets B, using 3 hex head bolts with flat
washers and square nuts C, in the assembly order
shown in D.
Note: The hex head bolts and square nuts supplied with the
fence are coarse thread and the hex head bolts supplied
to attach the #40-130 Dust Enclosure are fine thread.
15
A
B
Before opening the fence, have a clear work area to prevent the mixing of hardware.
C
3. Attach the second mounting bracket to the oppo-
site side of the table, A.
Note: Adjust the height of the 3 bolts in the slotted holes in
the rail bracket so that the rail is leveled with the table, B.
CAST-IRON TABLE #40-200C AND PHENOLIC TABLE #40-200P ONLY)*
Note: You will find 6 additional side bracket mounting fasteners in the fence hardware to attach the side brackets to the
cast iron table. These will not be required if you have purchased a complete kit, because the same fasteners have been
supplied with the table top.
For #40-049 MDF table (for #40-200M), use the wood screws supplied with your table to attach the mounting brackets
to the table.
*
A
B

7. Secure the dust shield in place by tightening the two
lock knobs.
Note: The dust shield can be adjusted in height along the
T-slots.
8. Insert a long T-bolt A through all 6 holes in the fence
body B and, from the other side of the fence, loosely
C and lockknob D
.
Note: Do not tighten down the lock knobs; leave the T-
head of the bolts protruding from the fence.
B
C
D
A
9. Slide the slot of one fence face onto the 3 elongat-
ed bolt heads, then tighten the lock knobs on the
other side of the fence.
10. Repeat with the second fence face on the other
side of the fence body.
5. Slide the 2 bolts and spacers to the middle of the
fence body (approx.)
6. Install the orange dust shield A on the two bolts and
secure in place using two flat washers B and 2 lock
knobs Cas shown in D.
AD
BC
16
attach a flat washer

17. Slide the hex nut in the fence rail as shown.
18. Repeat steps 16 and 17 on the other end of the
fence, then fully tighten the locking handle to lock
the fence in position.
11. Insert a Phillips head screw Athrough both dust
outlet mounting holes.
12. Loosely thread a square nut Bon both screws as
shown in C.
13. Insert the square nut in the fence body slot, A.
14. Insert the other square nut in the slot on the other
side of the fence, B.
A
B
CA
15. Center the dust outlet with the hole in the fen-
ce body A, then tighten the two phillips head
screws B.
A
16. Insert a locking handle Awith large flat washer B
in the T-slot at one end of the fence, then
from below, loosely thread a large hex nut C as
shown in D.
B
A
BC
D
B
CLOSE UP VIEW
17

ASSEMBLY INSTRUCTIONS - PREPARE THE TABLE FOR ROUTER LIFT
SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COM-
PLETED THE INSTALLATION AND ASSEMBLY STEPS. DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED
TO DO SO.
4. Remove the lift and lock the adjuster screw in place
by turning the lock nut Aclockwise (tighten).
3. From the underside of the table, adjust the 4 phillips
head screws in the corners A- up or down until the
plate is flat and level with the table surface.
2. Use a straightedge to test the plate for level with the
table top.
1. Place the router lift into the opening in the table.
Note: Model #40-075 for 40-200C Cast-iron table shown. The following steps apply to all 3 table options.
5. After the four corners are set, proceed to set the
remaining 6 leveler screws and lock them in place.
Note: While tightening the lock nut, make sure that the
adjuster screw does not turn. Confirm by re-checking the
leveling of the lift and table surface.
A
18

ASSEMBLY INSTRUCTIONS - 40-130 DUST COLLECTION KIT
SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COM-
PLETED THE INSTALLATION AND ASSEMBLY STEPS. DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED
TO DO SO.
Note: There are three longer screws in the hardware kit that are required to attach the 4 inch hose adapter. Locate them
first. You will find additional mounting hardware to attach the 40-130 dust enclosure to the table. This additional hardware
will not be required with cast-iron table for 40-200C because the same fasteners are supplied with the table.
2. Assemble dust enclosure as shown, using the 22
short phillips head screws.
40-130 DUST COLLECTOR
SIDE SIDE BOTTOM
REARFRONT
19
7. Using the supplied hose clamps, secure one end
of the dust hose to the 2 1/2” inlet on the dust port
Aand the other end ot the dust outlet on the fence, B.
8. The vent on the dust enclosure allows you to adjust
airflow and maximize dust collection efficiency
based on the size of your dust collector. The smaller
the dust collector the wider the vents should be
opened to allow maximum airflow.
Note: To prevent overheating the router motor inside the
confined space of the enclosure, always use a dust col-
lector or vacuum to allow for air to flow.
B
A
40-130 DUST COLLECTOR
AB
5. Position and secure the dust enclosure into place A
using the 6 hex head bolts with lock washer and flat
washer B.
6. Turn the assembly back over to its upright and oper-
ating position.
3. Turn the assembled router table upside down.
4. Remove the 6 hex head bolts from the underside of
the table. (40-200C and 40-200P only)
Note: For #40-049 MDF table (for #40-200M), use the wood
screws supplied with your table to attach the dust collec-
tion box to the table.

This model 40-125 “fixed base” router lift, Ais designed to
accommodate the largest diameter router motor body
currently available.
Note: Based on our research this is the Porter Cable model
7518 and 7519 router motors which measure 4.200” in diam-
eter.
All other motors (smaller diameters) will require a shim C
(item # 40-626, available from you local General Intera-
tional dealer), or a reducer collar such as our model
40-312 (for 3 1/2” motors) or 40-314 (for 3 1/4” motors), B,
to center the router as well as prevent from overtightening
the clamping system.
ASSEMBLY INSTRUCTIONS - MOUNTING A ROUTER
SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COM-
PLETED THE INSTALLATION AND ASSEMBLY STEPS. DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED
TO DO SO.
Clean packing lubricant from the lift posts/screws F
and the chain G. Clean it by spraying with a solvant
which will dilute the grease, and then wipe clean or
use compressed air to “blow dry”. After degreasing,
reapply some dry lubricant.
Note: The factory installed adjusting screw on the Milwau-
kee motor must be lined up and inserted into the hole D
located in our clamping bracket E.
1. Insert the crank handle in the black hole sur-
rounded by digits as shown in H.
2. To raise the lifting carriage on the router lift to the
highest or maximum upward position, turn the
crank handle clockwise.
3. Remove the crank handle, and flip the lift over in
the table.
A
B
C
H
E
D
F
G
20
CLOSE UP VIEW
I