Porter-Cable 7538 Instruction Manual page 3

SOFT START (ALL UNITS)
The 7500 Router series units have a "Soft Start" feature designed to minimize startup reaction
torque.
SPEED CONTROL (7518 / 7539)
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. It is recommended that the speed
be set prior to engaging the router bit into work. Should it be necessary to change the speed after work
has begun, stop router, remove router clear of work, and adjust speed setting.
USING THE TOOL (ALL UNITS)
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.
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.
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.
To assemble:
7518/7519: Insert guide rods (A) in holes in base, Fig. 17, and secure with screws (B). The guide (C)
is adjusted on the rods and secured in desired position with thumb screws (D).
7538/7539: Insert the grooved end of the guide rods (W) Fig. 18, in holes in base and secure with
two screws (X). (NOTE: These screws should engage the groove in the guide rod.) Slide the guide
(Y) on the rods, and adjust to the desired position. Secure with the two thumb screws (Z).
TEMPLATE GUIDES
A wide variety of template guides are available for use in pattern and templet routing operations. Fig.
19 shows a typical combination bit, templet guide, and locknut for the 7500 Router Series bases.
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.
To install, insert templet guide in center hole in router base and secure in place with the locknut.
NOTE: Before connecting the router to the power source, install, the bit, adjust depth of cut, and
rotate the router chuck by hand to be sure the bit or the collet do not contact the templet guide.
ROUTER TABLES
Your router is designed for use with the Porter Cable router table. Refer to the router table manual
for complete, detailed set-up instructions.
For your own safety, always read the router instruction manual and accessory
instructions before using any accessory. Failure to heed these warnings may result in personal
injury and serious damage to the router and the accessory. When servicing this tool, use only
identical replacement parts.
MAINTENANCE
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.
CLEANING
Periodically blowing dust and chips out of the motor housing using clean, dry com-
pressed air is a suggested maintenance procedure. To reduce the risk of serious personal injury,
ALWAYS wear ANSI Z87.1 safety glasses while using compressed air.
When cleaning, use only mild soap and a damp cloth on plastic parts. Many house-
hold cleaners contain chemicals which could seriously damage plastic. Also, do not use gasoline,
turpentine, lacquer or paint thinner, dry cleaning fluids or similar products which may seriously dam-
age plastic parts. NEVER let any liquid get inside the tool; NEVER immerse any part of the tool into
a liquid.
NOTE FOR PLUNGE BASE ONLY: Use only a DRY cloth to wipe the plunge rods. These rods require
no lubrication. Lubricants attract dust, reducing the performance of your tool.
FAILURE TO START
Should your tool fail to start, check to make sure the prongs on the cord plug are making good contact
in the outlet. Also, check for blown fuses or open circuit breakers in the line.
LUBRICATION
This tool has been lubricated with a suffi cient amount of high grade lubricant for the life of the unit under
normal operating conditions. No further lubrication is necessary.
BRUSH INSPECTION (If applicable)
For your continued safety and electrical protection, brush inspection and replacement on this tool should
ONLY be performed by a PORTER-CABLE FACTORY SERVICE CENTER OR PORTER-CABLE AUTHO-
RIZED WARRANTY SERVICE CENTER.
At approximately 100 hours of use, take or send your tool to your nearest Porter-Cable Factory Service
center or Porter-Cable Authorized Warranty Service Center to be thoroughly cleaned and inspected.
Have worn parts replaced and lubricated with fresh lubricant. Have new brushes installed, and test the
tool for performance.
Any loss of power before the above maintenance check may indicate the need for immediate servicing
of your tool. DO NOT CONTINUE TO OPERATE TOOL UNDER THIS CONDITION. If proper operating
voltage is present, return your tool to the service station for immediate service.