Porter-Cable 7538 Instruction Manual page 2

Fig. 1
B
A
J
K
L
H
M
Fig. 5
P
O
T
Fig. 9
Do not allow the wrenches to contact the columns (A) Fig. 3. If the columns are
damaged, the plunge action will be restricted.
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.
Avoid possible damage to the collet. Never tighten the collet without a bit.
1. Place the router upside down on its motor cap (see Fig. 3).
2. Clean and insert the shank of the bit into the collet at least 3/4". If the shank "bottoms"
in the router, back it out approximately 1/16" to allow for proper tightening.
3. Place one wrench on the flats on the chuck and one wrench on the collet nut (see Fig.
3). Tighten firmly.
4. To remove the bit, reverse the procedure. If the bit is difficult to remove easily, tap the
collet nut with the wrench.
INSTALLING THE MOTOR (7518 / 7519)
To reduce the risk of injury, turn unit off and disconnect it from power
source before installing and removing accessories, before adjusting or when
making repairs. An accidental start-up can cause injury.
1. Loosen the clamp screw (A), Fig. 1, to allow the power unit to be set in the base unit.
2. Insert motor unit into base aligning lower pin (B) with groove in base.
3. Rotate motor unit CLOCKWISE into base until upper guide pins are rigidly set in the
groove of the base.
4. Tighten clamp screw firmly.
ADJUSTING THE DEPTH OF CUT (7518 / 7519)
To reduce the risk of injury, turn unit off and disconnect it from power
source before installing and removing accessories, before adjusting or when
making repairs. An accidental start-up can cause injury.
1. Loosen clamp screw (A) Fig. 4.
2. While holding base (E), turn motor unit (F), COUNTERCLOCKWISE until the tip of the
bit is above bottom surface of base.
3. Set router on flat wood surface.
4. Turn motor unit (F) CLOCKWISE until bit touches the wood surface.
5. Tighten clamp screw (A).
6. Rotate depth adjusting ring (B) until the zero-line (C) is opposite the index line (D) on the
housing.
7. Loosen clamp screw (A).
8. Tip the router so bit is clear of the wood surface. Tur n motor unit (F),
CLOCKWISE until the index line (D) on the motor housing reaches the desired depth indicated
on the ring.
9. Tighten clamp screw (A) firmly.
NOTE: Setting the index line to 1/4" on the ring means the cutting edge of the bit is exposed 1/4"
below the base.
ADJUSTING PLUNGE DEPTH (7538 / 7539)
To reduce the risk of injury, turn unit off and disconnect it from power source
before installing and removing accessories, before adjusting or when making repairs. An
accidental start-up can cause injury.
Laceration hazard. Do not change the turret stop while the router is running. This will
place your hands too near the cutter head.
1. Loosen the depth rod locking knob (K) Fig. 5, and the depth indicator knob (J), allowing the
depth rod (L) to contact one of the turret stops (M). Normally, the deepest desired cut is set
with the depth rod resting on the shortest turret stop (see Fig. 7). The other two fixed stops
(S) Fig. 9 provide reduced cutting depths of 1/4" and 1/2" respectively. You can position the
three adjustable stops (R) Fig. 7 to any height and can use any combination of fixed and/or
adjustable stops to achieve the desired depths required.
2. Release the plunge mechanism by pulling the locking lever (C) Fig. 6 to the left, and lower the
plunge mechanism until the router bit touches the work surface. Release the lever and push it
to the right to lock the mechanism in position.
3. Tighten the depth-rod locking knob (K) Fig. 5.
4. Position the depth indicator (H) Fig. 5 at the "O" position and tighten the knob (J).
5. Loosen the depth rod locking knob (K) Fig. 5, and raise the depth rod until the indicator aligns
with the graduation representing the desired depth of plunge. Tighten the depth rod locking
knob (K).
6. To limit the upward travel of the plunge mechanism: (1) release the plunge lock by moving the
plunge locking lever (C) Fig. 6 to the left, and move the motor to the desired maximum height;
(2) release and push the locking lever (C) to the right to secure the motor in this position; (3) use
two 9/16" open-end wrenches (not furnished) to move the travel-limiting nuts (O) Fig. 9 against
the top of the motor housing boss (T) Fig. 9. "Jam" the nuts together to lock.
To prevent loss of control ALWAYS tighten the travel-limiting nuts together. Inadvertant
movement could prevent full bit retraction.
To prevent loss of control, set the travel-limiting nuts so that bit can be retracted into the
base of the router, clear of the workpiece.
To reduce the risk of injury, NEVER adjust or remove the stop nut. Motor can disengage
resulting in loss of control.
ADJUSTING PLUNGE LOCKING LEVER (7538 / 7539)
To reduce the risk of injury, turn unit off and disconnect it from power source
before installing and removing accessories, before adjusting or when making repairs. An
accidental start-up can cause injury.
You can adjust the plunge locking mechanism to compensate for wear or to reposition lever (in
locked position). To adjust:
1. Hold the lever in the upright position (see Fig. 10). Use a phillips screwdriver to remove retaining
screw (V) Fig. 10. Continue to hold the lever through the remaining steps.
2. Insert a 1/8" hex wrench (not furnished) into the adjusting screw (see Fig. 11) and turn counter-
clockwise approximately 1/2 turn.
3. Move the lever to the desired position and tighten the adjusting screw.
4. Remove the hex wrench and replace the retaining screw.
CONNECTING TO POWER SOURCE (ALL UNITS)
Before connecting router to power source ALWAYS MAKE SURE SWITCH IS IN THE
"OFF" POSITION. Also check that the power circuit is the same as that shown on specification plate
of the router.
TO START AND STOP ROUTER (7518 / 7519)
Before starting the router make sure bit is clear of workpiece and foreign objects. Also
keep firm grip on router to resist starting torque.
The router is started and stopped by depressing the rocker switch (A), Fig. 12, into the "ON" or
"OFF" position.
Fig. 2
C
Fig. 7
Fig. 6
V
Fig. 10
A
A
Fig. 11
MODEL 7538
G
Fig. 14
B
D
Fig. 17
A
1. ROUTER BASE
2. SUB-BASE
3. ROUTER BIT
4. TEMPLET GUIDE
5. LOCKNUT
Fig. 19
To avoid personal injury or damage to finished work always allow the motor to come to
a COMPLETE STOP before setting it down.
TO START AND STOP ROUTER (7538 / 7539)
Before starting the router, make sure bit is clear of workpiece and foreign objects. Also
keep a firm grip on the router to resist starting torque.
To avoid injury or damage to finished work, allow the motor to come to a COMPLETE
STOP before putting it down.
1. Squeeze the trigger switch (A) Fig. 13 to start the motor. Release the trigger switch to stop the
motor.
2. To allow the motor to run continuously, press the trigger switch (A), push the lock button (B) Fig.
13, and release the trigger switch.
3. To release the lock button, squeeze the trigger switch and release.
OVERLOAD PROTECTION (ALL UNITS)
To avoid accidental start-up, confirm that the switch is OFF and tool is disconnected
from the power source before resetting the circuit breaker.
The 7500 series routers are equipped with overload protection that will shut the motor off if
prolonged overload conditions are encountered. If the motor stops during use, follow these steps:
7518/7519
1. Turn rocker switch (A), Fig. 12, to the "OFF" position.
2. Determine cause of overload (i.e. dull bit, low voltage, excessive feed rate, etc.) and correct
before continuing.
3. Restart router following the instructions in "TO START AND STOP ROUTER."
7538
1. Release the trigger switch (A) Fig. 13 and then turn rocker switch (G) Fig. 14 on router cap to
the "OFF" position.
2. Determine cause of overload (i.e. dull bit, low voltage, excessive feed rate, etc.) and correct
before continuing.
3. Turn rocker switch (G) Fig. 14 to the "ON" position.
4. Restart router following the instructions in "TO START AND STOP ROUTER."
7539
1. Release the trigger switch (A) Fig. 13.
2. Determine cause of overload (i.e. dull bit, low voltage, excessive feed rate, etc.) and correct
before continuing.
3. Turn rocker switch (G) Fig. 14 to the "ON" position.
4. Restart router following the instructions in "TO START AND STOP ROUTER."
Fig. 4
B
Fig. 3
A
R
MODEL 7518
S
MODEL 7519
B
A
Fig. 13
B
Fig. 16
Fig. 15
B
C
D
X W
Y
7518/7519
5
3
7538/7539
5
4
3
F
D
C
E
A
Fig. 12
W
Z
Fig. 18
1
2
4
1
2