Introduction
This manual provides essential instructions for the safe and efficient operation, assembly, maintenance, and troubleshooting of your EXCALIBUR EX-16 16-inch Scroll Saw. Please read this manual thoroughly before using the tool to ensure proper function and safety.
Figure 1: The EXCALIBUR EX-16 16-inch Scroll Saw. This image shows the overall design of the scroll saw, highlighting its main body, table, and arm.
Safety Instructions
Always follow basic safety precautions to reduce the risk of fire, electric shock, and personal injury. Keep this manual for future reference.
- Wear appropriate safety gear: Always wear safety glasses, hearing protection, and a dust mask.
- Keep work area clean: Cluttered areas invite accidents.
- Avoid dangerous environments: Do not use power tools in damp or wet locations, or expose them to rain. Keep work area well lit.
- Keep children away: All visitors should be kept a safe distance from the work area.
- Secure workpiece: Always clamp or secure the workpiece to prevent movement during operation.
- Avoid accidental starting: Ensure the switch is in the OFF position before plugging in the tool.
- Integrated Blade Guard: The upper and lower blade guard assembly helps prevent accidental hand contact with the blade. The switch protection device prevents unintentional start-up.
- Disconnect power: Always disconnect the saw from the power source before changing blades, performing maintenance, or when not in use.
Unpacking and Assembly
Carefully remove all components from the packaging. Inspect for any damage during transit. Refer to the included assembly instructions for detailed steps.
- Place the scroll saw on a stable, level workbench.
- Ensure all feet are securely positioned.
- Connect the dust collection hose to the integral dust collection chute located under the table.
- Familiarize yourself with the controls before plugging in the unit.
Components Overview
The EX-16 scroll saw features several key components designed for precision and ease of use:
- Tilting Head: Allows for angled cuts while keeping the workpiece flat on the table.
- Large Steel Table: Provides a spacious and stable work surface.
- Variable Speed Control: Adjusts strokes per minute for optimal cutting across various materials.
- Blade Tension Knob: Located at the rear for precise blade tension adjustment.
- Finger-Operated Blade Clamps: Facilitate quick and easy blade changes without tools.
- Integrated Dust Collection: A chute under the table and a blower on top manage sawdust.
- On/Off Rocker Switch: Main power control.
Figure 2: Key components of the EXCALIBUR EX-16 Scroll Saw. This image provides a clear view of the saw's main parts, including the tilting head, table, and controls.
Setup
Blade Installation and Tension Adjustment
The EX-16 features finger-operated blade clamps for seamless blade changes.
- Ensure the saw is unplugged.
- Release the cam tension and the thumb screw on the blade clamps.
- Insert the blade into the lower clamp, then the upper clamp.
- Tighten the thumb screw to secure the blade.
- Adjust the final blade tension using the knob located on the rear of the machine.
Figure 3: Close-up of the blade area, showing the blade clamps and the workpiece. This image illustrates how the blade is secured and positioned for cutting.
Tilting Head Adjustment for Angle Cuts
Unlike traditional scroll saws, the EX-16's head tilts, keeping your workpiece flat for better control and accuracy.
- Loosen the locking mechanism for the tilting head.
- Tilt the head to the desired angle (up to 30° left or 45° right).
- Secure the head in place by tightening the locking mechanism.
- The angle can be set using index pins located below the table.
Figure 4: The tilting head mechanism of the scroll saw. This image demonstrates the saw's ability to tilt its head for angled cuts while the table remains flat.
Operation
Basic Cutting
- Place your workpiece flat on the table.
- Turn on the saw using the rocker switch.
- Adjust the variable speed control to the desired strokes per minute (400-1400 SPM) for the material being cut.
- Gently guide the workpiece into the blade, applying steady, even pressure.
Internal Cuts and Threading
The tilting head design simplifies internal cuts:
- Unplug the saw.
- Release the blade tension and remove the blade from the clamps.
- Lift the head out of the way.
- Drill a pilot hole in your workpiece where the internal cut will begin.
- Thread the blade through the pilot hole.
- Lower the head and re-secure the blade in the clamps.
- Re-apply blade tension.
- Proceed with cutting as usual.
Dust Management
The integrated dust collection system helps keep your work area clean:
- Connect a shop vacuum to the dust collection port under the table.
- The built-in blower directs sawdust away from the cutting line for improved visibility.
Product Demonstration Video
Video 1: Excalibur 16" Tilting Head Scroll Saw Demonstration. This video provides a visual guide to the features and operation of the EX-16 scroll saw, including blade changes, variable speed control, and the tilting head mechanism.
Maintenance
Regular maintenance ensures the longevity and optimal performance of your scroll saw.
- Cleaning: Regularly clean sawdust and debris from the table, blade area, and dust collection chute. Use compressed air for hard-to-reach areas.
- Blade Replacement: Replace dull or damaged blades promptly to maintain cutting quality and prevent strain on the motor.
- Lubrication: Refer to the detailed product manual for specific lubrication points and schedules.
- Inspection: Periodically check all fasteners for tightness. Inspect the power cord for damage.
Troubleshooting
| Problem | Possible Cause | Solution |
|---|---|---|
| Saw does not start | No power, switch in OFF position, faulty power cord. | Check power connection, ensure switch is ON, inspect power cord. |
| Blade breaks frequently | Incorrect blade tension, wrong blade type for material, excessive feed pressure. | Adjust blade tension, use appropriate blade, reduce feed pressure. |
| Inaccurate cuts | Loose blade, incorrect table/head angle, dull blade. | Ensure blade is tight, verify angle settings, replace blade. |
| Excessive vibration | Loose components, uneven surface. | Check all fasteners, ensure saw is on a stable surface. |
Specifications
| Feature | Detail |
|---|---|
| Brand | General International |
| Model Number | EX-16 |
| Blade Length | 16 Inches |
| Motor | 1.3A Variable Speed DC Permanent Magnet Motor |
| Voltage | 120 Volts |
| Wattage | 156 watts |
| Cutting Angle (Tilting Head) | 30° Left, 45° Right |
| Product Dimensions | 27"L x 15"W x 17"H |
| Item Weight | 54 Pounds |
| Surface Recommendation | Wood |
| Special Feature | Depth Adjustment |
Warranty & Support
The EXCALIBUR EX-16 Scroll Saw comes with a 2-Year Limited Warranty.
For warranty claims, technical support, or to order replacement parts, please contact General International customer service. Refer to the official product packaging or the General International website for current contact information.
Note: Online forums suggest that replacement parts for saws manufactured after 2017 might be affected by manufacturer changes. Always verify part availability with official customer support.
