Porter-Cable 7538 Instruction Manual

7500 SERIES 3-1/4
Instruction manual
DEFINITIONS - SAFETY GUIDELINES
indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
indicates a potentially haz ard ous situation which, if not
avoided, may result in minor or mod er ate injury.
used without the safety alert symbol indicates potentially
hazardous situation which, if not avoided, may result in property damage.

General Safety Rules

Read all instructions. Failure to follow all instructions listed below may result in electric
shock, fi re and/or serious injury. The term "power tool" in all of the warnings listed below refers to your
mains-operated (corded) power tool or battery-operated (cordless) power tool.
SAVE THESE INSTRUCTIONS
1) Work area safety
a) Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b) Do not operate power tools in explosive atmospheres, such as in the presence of
fl ammable liquids, gases or dust. Power tools create sparks which may ignite the dust or
fumes.
c) Keep children and bystanders away while operating a power tool. Distractions can
cause you to lose control.
2) Electrical safety
a) Power tool plugs must match the outlet. Never modify the plug in any way. Do not use
anyadapter plugs with earthed (grounded) power tools. Unmodifi ed plugs and matching
outlets will reduce risk of electric shock.
b) Avoid body contact with earthed or grounded surfaces such as pipes, radiators, rang-
es and refrigerators. There is an increased risk of electric shock if your body is earthed or
grounded.
c) Do not expose power tools to rain or wet conditions. Water entering a power tool will
increase the risk of electric shock.
d) Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the
power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or
entangled cords increase the risk of electric shock. Use only 3-wire extension cords that
have 3-prong grounding-type plugs and 3-pole receptacles that accept the tool's plug.
e) When operating a power tool outdoors, use an extension cord suitable for outdoor
use. If an extension cord is to be used outdoors, it must be marked with the suffi x W-A or
W following the cord type designation. Use of a cord suitable for outdoor use reduces the
risk of electric shock. When using an extension cord, be sure to use one heavy enough to
carry the current your product will draw. An undersized cord will cause a drop in line voltage
resulting in loss of power and overheating. The following table shows the correct size to use
depending on cord length and nameplate ampere rating. If in doubt, use the next heavier
gauge. The smaller the gauge number, the heavier the cord.
Minimum Gauge for Cord Sets
Volts Total Length of Cord in Feet
120V 0-25
220V 0-50
Ampere Rating Gauge of wire in AWG units
From 12 to 16 amps
3) Personal safety
a) Stay alert, watch what you are doing and use common sense when operating a power
tool. Do not use a power tool while you are tired or under the infl uence of drugs, al-
cohol or medication. A moment of inattention while operating power tools may result in
serious personal injury.
b) Use safety equipment. Always wear eye protection. Safety equipment such as dust
mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate condi-
tions will reduce personal injuries.
c) Avoid accidental starting. Be sure the switch is in the off-position before plugging in.
Carrying power tools with your fi nger on the switch or plugging in power tools that have the
switch on invites accidents.
d) Remove any adjusting key or wrench before turning the power tool on. A wrench or a
key left attached to a rotating part of the power tool may result in personal injury.
e) Do not overreach. Keep proper footing and balance at all times. This enables better
control of the power tool in unexpected situations.
f) Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and
gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in mov-
ing parts. Air vents often cover moving parts and should also be avoided.
g) If devices are provided for the connection of dust extraction and collection facilities,
ensure these are connected and properly used. Use of these devices can reduce dust-
related hazards.
4) Power tool use and care
a) Do not force the power tool. Use the correct power tool for your application. The cor-
rect power tool will do the job better and safer at the rate for which it was designed.
b) Do not use the power tool if the switch does not turn it on and off. Any power tool that
cannot be controlled with the switch is dangerous and must be repaired.
c) Disconnect the plug from the power source before making any adjustments, chang-
ing accessories, or storing power tools. Such preventive safety measures reduce the risk
of starting the power tool accidentally.
d) Store idle power tools out of the reach of children and do not allow persons unfamiliar
with the power tool or these instructions to operate the power tool. Power tools are
dangerous in the hands of untrained users.
e) Maintain power tools. Check for misalignment or binding of moving parts, breakage
of parts and any other condition that may affect the power tools operation. If dam-
PEAK HP ROUTERS
7518/ 7519
7538/7539
26-50 51-100
51-100 101-200
14 12 Not recommended
aged, have the power tool repaired before use. Many accidents are caused by poorly
maintained power tools.
f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting
edges are less likely to bind and are easier to control.
g) Use the power tool, accessories and tool bits etc., in accordance with these instruc-
tions and in the manner intended for the particular type of power tool, taking into ac-
count the working conditions and the work to be performed. Use of the power tool for
operations different from those intended could result in a hazardous situation.
5) Service
a) Have your power tool serviced by a qualifi ed repair person using only identical re-
placement parts. This will ensure that the safety of the power tool is maintained.
• Hold power tools by insulated gripping surfaces when performing an operation where the
cutting tool may contact hidden wiring or its own cord. Contact with a "live" wire will make
exposed metal parts of the tool "live" and shock the operator.
• Use clamps or another practical way to secure and support the workpiece to a stable plat-
form. Holding the work by hand or against your body leaves it unstable and may lead to loss of
control.
• Metal cutting with router: If using router for metal cutting, clean out tool often. Metal dust
and chips often accumulate on interior surfaces and could create a risk of serious injury, electrical
shock or death.
• Keep handles dry, clean, and free from oil and grease. This will enable better control of the
tool.
• Maintain firm grip with both hands on router to resist starting torque.
• Keep hands away from cutting area. Never reach under the workpiece for any reason. Keep the
router base firmly in contact with the workpiece when cutting. Hold the router only by the handles.
These precautions will reduce the risk of personal injury.
• Do not hand-hold the router in an upside-down or horizontal position. The motor can sepa-
rate from the base if not properly attached according to the instructions.
• Never run the motor unit when it is not inserted in one of the router bases. The motor is not
designed to be handheld.
• Keep cutting pressure constant. Do not overload motor.
• Check to see that the cord will not snag or impede the routing operation.
• Use sharp cutters. Dull cutters may cause the router to swerve or stall under pressure.
• Be sure that the motor has stopped completely before you lay the router down. If the cutter
head is still spinning when the tool is laid down, it could cause injury or damage.
• Be sure that the router bit is clear of the workpiece before starting the motor. If the bit is in
contact with the workpiece when the motor starts it could make the router jump, causing damage
or injury.
• ALWAYS disconnect tool from power source before making adjustments or changing bits.
• Keep hands clear of bit when motor is running to prevent personal injury.
• NEVER touch the bit immediately after use. It may be extremely hot.
• Provide clearance under workpiece for router bit when through-cutting.
• Tighten collet nut securely to prevent the bit from slipping.
• Never tighten collet nut without a bit.
• Do not use router bits with a diameter in excess of 2-1/2" at RPM above 13,000. Router bits
up to 3-1/2" in diameter can be used when speed control is set for 13,000 RPM or less.
• Avoid Climb-Cutting (cutting in direction opposite that shown in Fig. 16). Climb-Cutting
increases the chance for loss of control resulting in possible injury. When "Climb-Cutting" is
required (backing around a corner), exercise extreme caution to maintain control of router. Make
smaller cuts and remove minimal material with each pass.
• Always keep chip shield clean and in place.
ALWAYS USE SAFETY GLASSES.(ANSI Z87.1) and (CAN/CSA Z94.3) Everyday eye-
glasses are NOT safety glasses. Also use face or dust mask if cutting operation is dusty. ALWAYS
WEAR CERTIFIED SAFETY EQUIPMENT:
• ANSI Z87.1 eye protection (CAN/CSA Z94.3)
• ANSI S12.6 (S3.19) hearing protection
• NIOSH/OSHA/MSHA respiratory protection
Some dust created by power sanding, sawing, grinding, drilling, and other construction
activities contains chemicals known to cause cancer, birth defects or other reproductive harm. Some
examples of these chemicals are:
• lead from lead-based paint.
• crystalline silica from bricks and cement and other masonry products.
• arsenic and chromium from chemically-treated lumber (CCA).
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your
exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment,
such as those dust masks that are specially designed to filter out microscopic particles.
Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling, and
other construction activities. Wear protective clothing and wash exposed areas with soap and water.
Allowing dust to get into your mouth, eyes, or lay on the skin may promote absorption of harmful
chemicals.
permanent respiratory or other injury. Always use NIOSH/OSHA approved respiratory protection
appropriate for the dust exposure. Direct particles away from face and body.
ALWAYS use eye protection. All users and bystanders must wear eye protection that
conforms to ANSI Z87.1.
Wear appropriate hearing protection during use [ANSI S12.6 (S3.19)]. Under some con-
ditions and duration of use, noise from this product may contribute to hearing loss.
SYMBOLS
The label on your tool may include the following symbols. The symbols and their definitions are as
follows:
V....................... volts
Hz .................... hertz
min .................. minutes
............... direct current
.................... Class I Construction
..................... Class II Construction
BPM ..............beats per minute
SAVE THESE INSTRUCTIONS
MOTOR
Do not operate tools rated A.C. only on D.C. current. To do so may seriously damage the tool.
FAMILIARIZATION
Model 7518/7539 Porter-Cable routers incorporate a speed control that provides operating speeds
from 10,000 RPM to 21,000 RPM.
Model 7519/7538 Porter-Cable Routers are designed for opearations at 21,000 RPM.
SELECTING THE BIT (ALL UNITS)
To reduce the risk of personal injury, always disconnect tool from power source before
preparing the router for use, before making adjustments, and when router is not in use.
For the 7519 and 7538, DON'T USE router bits with a cutting diameter in excess of
101-150
2-1/2".
201-300
For the variable speed units (7518 and 7539), bits larger than 2-1/2" can be used when
running the router at lower speeds. If the bit is between 2-1/2" and 3", you can only use the 10,000
or 13,000 RPM speed settings. If the bit is between 3" and 3-1/2", you can only use the 10,000 RPM
speed setting.
All 7500 Series routers accommodate bits with 1/2" diameter shanks that are installed directly into
the power unit collet. Collets are available that will allow the use of bits having 1/4" or 3/8" diameter
shanks.
INSTALLING AND REMOVING THE BIT (7518 / 7519)
before installing and removing accessories, before adjusting or when making repairs. An
accidental start-up can cause injury.
For the 7519 and 7538, DON'T USE router bits with a cutting diameter in excess of
2-1/2".
Avoid possible damage to the collet. Never tighten the collet without a bit.
1. To remove motor unit from base unit:
(a) Open the clamp (A) Fig. 1.
(b) While holding base, turn motor unit COUNTERCLOCKWISE until lower pin (B) in motor
housing is disengaged from groove in base.
(c) Lift power unit free from base unit.
2. Clean and insert shank of bit into collet at least 3/4". If shank "bottoms" in router, then back it
out approximately 1/16" to allow proper tightening.
3. Lay the power unit on its side on a bench with the collet pointing AWAY from you.
4. Place one wrench on flats on chuck with the opposite end of the wrench resting on the bench
to your left, Fig. 2.
5. Place other wrench on collet and tighten COUNTERCLOCKWISE as shown in Fig. 2. TIGHTEN
SECURELY.
6. To remove the bit, reverse the above procedure. If bit does not remove easily, tap the collet nut
with wrench to release.
INSTALLING AND REMOVING THE BIT (7538 / 7539)
before installing and removing accessories, before adjusting or when making repairs. An
accidental start-up can cause injury.

ADDITIONAL SPECIFIC SAFETY RULES

Use of this tool can generate and/or disburse dust, which may cause serious and
(grounded)
(double insulated)
Do not operate your tool on a current on which the voltage is not within correct limits.
OPERATION
To reduce the risk of injury, turn unit off and disconnect it from power source
To reduce the risk of injury, turn unit off and disconnect it from power source
A...........................amperes
W .........................watts
.......................alternating current
n o .........................no load speed
.........................earthing terminal
........................safety alert symbol
.../min .................revolutions or reciprocations
per minute