Porter-Cable 7518 Instruction Manual page 2

FIG. 1
B
A
A
J
K
L
H
M
FIG. 5
P
O
T
FIG. 9
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)
Do not allow the wrenches to contact the columns (A) Fig. 3. If the columns are
damaged, the plunge action will be restricted.
Never tighten the collet without first installing a router bit in it. Tightening
an empty collet, even by hand, can damage the collet.
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" (19 mm). If the shank
"bottoms" in the router, back it out approximately 1/16" (1.6 mm) 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)
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)
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. Turn 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"
(6.4 mm) below the base.
ADJUSTING PLUNGE DEPTH (7538 / 7539)
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. 7 provide reduced cutting depths of 1/4" (6.4 mm) and 1/2" (13 mm) 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 rotating the plunge locking lever (C) Fig. 6 toward the
handle, and lower the plunge mechanism until the router bit touches the work surface. Firmly
rotate the locking lever (C) toward the motor 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 rotating
the plunge locking lever (C) Fig. 6 toward the handle, and move the mechanism to the
desired maximum height; (2) firmly rotate the locking lever (C) toward the motor to secure the
mechanism 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)
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 cross head 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 tool to power source, check to see that the switch is in the OFF
position. An accidental start-up can cause injury.
TO START AND STOP ROUTER (7518 / 7519)
Before starting the tool, clear the work area of all foreign objects. Check to see that
the cord will not snag or impede the routing operation. Also keep firm grip on tool to resist starting
torque.
The router is started and stopped by depressing the rocker switch (A), Fig. 12, into the "ON" or
"OFF" position.
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 tool, clear the work area of all foreign objects. Check to see that
the cord will not snag or impede the routing operation. Also keep firm grip on tool 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.
FIG. 2
C
FIG. 7
FIG. 6
V
FIG. 10
A
FIG. 3
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
1. BASE DE LA TOUPIE
2. SOUS-BASE
3. MÈCHE DE TOUPIE
4. GUIDE DE GABARIT
5. CONTRE-ÉCROU
1. BASE DEL
REBAJADORA
2. SUB-BASE
3. BROCA
4. GUIA DE PATRON
5. TUERCA
INAFLOJABLE
FIG. 19
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.
SOFT START (ALL UNITS)
The 7500 Router series units have a "Soft Start" feature designed to minimize startup reaction
torque.
SPEED CONTROL (7518 / 7539)
Always follow the bit manufacturer's speed recommendations as some bit
designs require specific speeds for safety or performance. If you are unsure of the proper
speed or are experiencing any type of problem, contact the bit manufacturer.
Do not operate tools rated "AC only" on a DC supply. Loss of speed control may
result, causing tool damage and possible hazard to the operator.
If the speed control ceases to operate, or is intermittent, stop using the tool
immediately. Take it to a PORTER-CABLE factory or authorized service facility for repair.
In low and medium speed operation, the speed control prevents the motor speed
from decreasing. If you expect to hear a speed change and continue to load the motor, you could
damage the motor by overheating. Reduce the depth of cut and/or slow the feed rate to prevent
tool damage.
The router is equipped with electronics to monitor and maintain the speed of the tool
NOTICE
while cutting. In low and medium speed operation, the speed control prevents the motor speed
from decreasing. If you expect to hear a speed change and continue to load the motor, you could
damage the motor by overheating. Reduce the depth of cut and/or slow the feed rate to prevent
tool damage.
The speed control is located as shown in Fig. 15. Five operating speeds from 10,000 RPM to
21,000 RPM are available by moving the speed selector knob (B), Fig. 15.
NOTE: The speeds listed are approximate and are for reference only. Your router may not exactly
produce the speed listed for the dial setting.
USING THE TOOL (ALL UNITS)
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 be sure the work is rigidly clamped or otherwise secured before making a
cut. Since the cutter rotates clockwise (when viewing router from top), move the router from left to
right as you stand facing the work. When working on the inside of a template, move the router in
a clockwise direction. When working on the outside of a template, move the router in a counter-
clockwise direction.
THE EDGE GUIDE
An edge guide is available as an accessory to aid in routing operations such as: straight edge
planing, parallel grooving, dado or slotting operations.
FIG. 4
B
A
R
MODEL 7518
S
MODEL 7519
B
A
FIG. 13
B
FIG. 15 FIG. 16
B
C
D
X
W
Y
7518/7519
5
3
4
7538/7539
5
4
3
F
D
C
E
A
FIG. 12
W
Z
FIG. 18
1
2
1
2