Porter-Cable 7538 User's Manual
Contents
1. Fax 909 390 5554 San Diego 92111 7638 Clairemont Blvd Phone 858 277 9595 Fax 858 277 9696 San Leandro 94577 Oakland 3039 Teagarden Street Phone 510 357 9762 Fax 510 357 7939 COLORADO Arvada 80003 Denver 8175 Sheridan Blvd Unit S Phone 303 487 1809 Fax 303 487 1868 FLORIDA Davie 33314 Miami 4343 South State Rd 7 441 Unit 107 Phone 954 321 6635 Fax 954 321 6638 Tampa 33609 4538 W Kennedy Boulevard Phone 813 877 9585 Fax 813 289 7948 GEORGIA Forest Park 30297 Atlanta 5442 Frontage Road Suite 112 Phone 404 608 0006 Fax 404 608 1123 ILLINOIS Addison 60101 Chicago 400 South Rohlwing Rd Phone 630 424 8805 Fax 630 424 8895 Woodridge 60517 Chicago 2033 West 75th Street Phone 630 910 9200 Fax 630 910 0360 MARYLAND Elkridge 21075 Baltimore 7397 102 Washington Blvd Phone 410 799 9394 Fax 410 799 9398 MASSACHUSETTS Franklin 02038 Boston Franklin Industrial Park 101E Constitution Blvd Phone 508 520 8802 Fax 508 528 8089 MICHIGAN Madison Heights 48071 Detroit 30475 Stephenson Highway Phone 248 597 5000 Fax 248 597 5004 MINNESOTA Minneapolis 55429 5522 Lakeland Avenue North Phone 763 561 9080 Fax 763 561 0653 MISSOURI North Kansas City 64116 1141 Swift Avenue Phone 816 221 2070 Fax 816 221 2897 St Louis 63119 7574 Watson Road Phone 314 968 8950 Fax 314 962. TWIN LITE UNIGUARD Unifence UNIFEEDER Unihead Uniplane Unirip Unisaw Univise Versa Feeder VERSA PLANE WHISPER SERIES WOODWORKER S CHOICE Trademarks noted with and are registered in the United States Patent and Trademark Office and may also be registered in other countries Las Marcas Registradas con el signo de y son registradas por la Oficina de Registros y Patentes de los Estados Unidos y tambi n pueden estar registradas en otros paises Marques d pos es indiqu es par la lettre et sont d pos es au Bureau des brevets d invention et marques d pos es aux Etats Unis et pourraient tre d pos es aux autres pays 7 2 PTG F 1
3. Using The Router section in this manual Climb cutting increases the chance for loss of control resulting in possible personal injury 18 DO NOT HAND HOLD THE ROUTER IN AN UPSIDE DOWN OR HORI ZONTAL POSITION The motor can separate from the base if not properly attached according to the instructions 19 Wear eye and hearing protection Always use safety glasses Everyday eyeglasses are NOT safety glasses USE CERTIFIED SAFETY EQUIPMENT Eye protection equipment should comply with ANSI Z87 1 standards Hearing equipment should comply with ANSI S3 19 standards 20 Use of this tool can generate and disburse dust or other airborne particles including wood dust crystalline silica dust and asbestos dust Direct particles away from face and body Always operate tool in well ventilated area and provide for proper dust removal Use dust collection system wherever possible Exposure to the dust may cause serious and permanent respiratory or other injury including silicosis a serious lung disease cancer and death Avoid breathing the dust and avoid prolonged contact with dust Allowing dust to get into your mouth or eyes or lay on your skin may promote absorption of harmful material Always use properly fitting NIOSH OSHA approved respiratory protection appropriate for the dust exposure and wash exposed areas with soap and water DEFINITION amperes kilowatts microfarads litres kilograms bars pascals hours minutes
4. brush inspection and replacement on this tool should ONLY be performed by an AUTHORIZED PORTER CABLE SERVICE STATION or a PORTER CABLE DELTA FACTORY SERVICE CENTER At approximately 100 hours of use take or send your tool to your nearest authorized Porter Cable Service Station 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 SERVICE REPLACEMENT PARTS When servicing use only identical replacement parts For a service parts list or to learn more about Porter Cable visit our website at www porter cable com SERVICE AND REPAIRS All quality tools will eventually require servicing or replacement of parts due to wear from normal use For assistance with your tool visit our website at www porter cable com for a list of service centers or call the Customer Care Department at 1 800 487 8665 All repairs made by our service centers are fully guaranteed against defective material and workmanship We cannot guarantee repairs made or attempted by others Should you have any questions about your tool feel free to write us at any time In any communications pleas
5. 505 Southgate Drive 1447 Begin Burnaby B C Guelph Ontario St Laurent Mtl P Q V5A 4T8 N1H 6M7 H4R 1V8 Phone 604 420 0102 Phone 519 767 4132 Phone 514 336 8772 Fax 604 420 3522 519 Fax 514 336 3505 The following are trademarks of PORTER CABLE e DELTA Las siguientes son marcas registradas de PORTER CABLE e DELTA S A Les marques suivantes sont des marques de fabriquant de la PORTER CABLE e DELTA Auto Set BAMMER B 0O S S Builder s Saw Contractor s Saw Contractor s Saw II Delta DELTACRAFT DELTAGRAM Delta Series 2000 DURATRONIC Emc2 FLEX Flying Chips FRAME SAW Grip Vac Homecraft INNOVATION THAT WORKS Jet Lock JETSTREAM kickstand LASERLOC MICRO SET Micro Set MIDI LATHE MORTEN NETWORK OMNIJIG POCKET CUTTER PORTA BAND PORTA PLANE PORTER CABLE amp design PORTER CABLE PROFESSIONAL POWER TOOLS PORTER CABLE REDEFINING PERFORMANCE Posi Matic Q 3 amp design QUICKSAND amp design QUICKSET QUICKSET II QUICKSET PLUS RIPTIDE amp design SAFE GUARD II SAFE LOC Sanding Center SANDTRAP amp design SAW BOSS Sawbuck Sidekick SPEED BLOC SPEEDMATIC SPEEDTRONIC STAIR EASE The American Woodshop amp design The Lumber Company amp design THE PROFESSIONAL EDGE THE PROFESSIONAL SELECT THIN LINE TIGER TIGER CUB TIGER SAW TORQBUSTER TORQ BUSTER TRU MATCH
6. 7538 Fig 10 located in the top of the motor This circuit breaker will shut the motor OFF if the overload is prolonged If the circuit breaker trips switch the motor OFF and 1 release the trigger switch A Fig 9 2 determine cause of the i overload i e dull bit low voltage excessive feed rate etc and correct 3 allow the router to cool for three minutes ACAUTION Confirm that the trigger switch is OFF before resetting the circuit breaker to avoid accidental start up 4 reset the circuit breaker by pressing the ON end of circuit breaker 5 restart the router using the instructions found in the section TO START AND STOP ROUTER MODEL 7539 is equipped with an internal overload protector that will shut motor OFF if the overload is prolonged If the motor stops during use 1 release the trigger switch A Fig 9 2 determine the cause of the overload i e dull bit low voltage excessive feed rate etc and correct 3 allow the router to cool for three minutes 4 restart the router using the instructions found in the section TO START AND STOP ROUTER SOFT START MODELS 7538 and 7539 have a Soft Start feature designed to minimize startup reaction torque SPEED CONTROL Model 7539 only Five operating speeds from 10 000 RPM to 21 000 RPM are available MODEL 7539 by moving the speed selector knob 21 000 ELEC F Fig 11 Set the spee
7. opposite that shown in Fig 12 Climb Cutting increases the chance for loss of control resulting in possible personal injury When Climb Cutting is required backing around a corner exercise extreme caution to maintain control of router The speed and depth of cut will depend largely on the type of material being worked upon Keep the cutting pressure constant but do not crowd the router so that the motor speed slows excessively More than one pass may be necessary on exceptionally hard woods or problem materials to get the desired depth of cut When making cuts on all four edges of the workpiece make the first cut on the end of the piece across the grain Thus if chipping of wood occurs at the end of a cut it can be removed when making the next cut parallel with the grain 14 THE EDGE GUIDE An accessory edge guide is available to aid in straight edge planing parallel grooving dado or slotting operations To attach insert the grooved end of the guide rods W Fig 13 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 Fig 13 on the rods and adjust to the desired position Secure with the two thumb screws 2 ROUTER BASE TEMPLATE GUIDES XX p gt i EXXX AN A I I I I AAS f ars 3E P xX an i j SUB BASE TEMPLATE GUIDE ea ROUTER BIT A wide variety of template guides is available for use in pa
8. 8 2790 NEW YORK Flushing 11365 1595 N Y C 175 25 Horace Harding Expwy Phone 718 225 2040 Fax 718 423 9619 NORTH CAROLINA Charlotte 28270 9129 Monroe Road Suite 115 Phone 704 841 1176 Fax 704 708 4625 OHIO Columbus 43214 4560 Indianola Avenue Phone 614 263 0929 Fax 614 263 1238 Cleveland 44125 8001 Sweet Valley Drive Unit 19 Phone 216 447 9030 Fax 216 447 3097 OREGON Portland 97230 4916 NE 122 nd Ave Phone 503 252 0107 Fax 503 252 2123 PENNSYLVANIA Willow Grove 19090 Philadelphia 520 North York Road Phone 215 658 1430 Fax 215 658 1433 TEXAS Carrollton 75006 Dallas 1300 Interstate 35 N Suite 112 Phone 972 446 2996 Fax 972 446 8157 Houston 77043 4321 Sam Houston Parkway West Suite 180 Phone 713 983 9910 Fax 713 983 6645 WASHINGTON Auburn 98001 Seattle 3320 West Valley HWY North Building D Suite 111 Phone 253 333 8353 Fax 253 333 9613 Authorized Service Stations are located in many large cities Telephone 800 487 8665 or 731 541 6042 for assistance locating one Parts and accessories for Porter Cable e Delta products should be obtained by contacting any Porter Cable e Delta Distributor Authorized Service Center or Porter Cable e Delta Factory Service Center If you do not have access to any of these call 888 848 5175 and you will be directed to the nearest Porter Cable e Delta Factory Service Center Las Estacione
9. ESPA OL P GINA 19 FRANCAISE PAGE 35 Instruction Plunge Routers manual MODEL 7539 MODEL 7538 IMPORTANT To learn more about Porter Cable Please make certain that the person who is visit our website at to use this equipment carefully reads and E T E E con understands these instructions before i P A starting operations The Model and Serial No plate is located on the main housing of the tool Record these numbers in the PORTER COBLE spaces below and retain for future reference Model No PROFESSIONAL POWER TOOLS Copyright O 2004 Porter Cable Corporation Part No 899715 12 01 04 TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS SAFETY GUIDELINES GENERAL SAFETY RULES ADDITIONAL SPECIFIC SAFETY RULES CARTON CONTENTS FUNCTIONAL DESCRIPTION ASSEMBLY OPERATION TROUBLESHOOTING MAINTENANCE FRAN AISE SERVICE CENTER LOCATIONS IMPORTANT SAFETY INSTRUCTIONS PEA Read and understand all warnings and operating instructions before using any tool or equipment When using tools or equipment basic safety precautions should always be followed to reduce the risk of personal injury Improper operation maintenance or modification of tools or equipment could result in serious injury and property damage There are certain applications for which tools and equipment are designed Porter Cable strongly recommends that this product NOT be modified and or used for any application other than for which it was design
10. THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WILL LAST ONLY FOR ONE 1 YEAR FROM THE DATE OF PURCHASE To obtain information on warranty performance please write to PORTER CABLE CORPORATION 4825 Highway 45 North Jackson Tennessee 38305 Attention Product Service THE FOREGOING OBLIGATION IS PORTER CABLE S SOLE LIABILITY UNDER THIS OR ANY IMPLIED WARRANTY AND UNDER NO CIRCUMSTANCES SHALL PORTER CABLE BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state 18 PORTER CABLE DELTA SERVICE CENTERS CENTROS DE SERVICIO DE PORTER CABLE DELTA CENTRE DE SERVICE PORTER CABLE DELTA Parts and Repair Service for Porter Cable e Delta Power Tools are Available at These Locations Obtenga Refaccion de Partes o Servicio para su Herramienta en los Siguientes Centros de Porter Cable Delta Locations o vous trouverez les pi ces de rechange n cessaires ainsi qu un service d entretien ARIZONA Tempe 85282 Phoenix 2400 West Southern Avenue Suite 105 Phone 602 437 1200 Fax 602 437 2200 CALIFORNIA Ontario 91761 Los Angeles 3949A East Guasti Road Phone 909 390 5555
11. afety shoes hard hat or hearing protection used for appropriate conditions will reduce personal injuries c Avoid accidental starting Ensure the switch is in the off position before plugging in Carrying power tools with your finger on the switch or plugging in power tools that have the switch on invites accidents GENERAL SAFETY RULES continuea 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 jewelery Keep your hair clothing and gloves away from moving parts Loose clothes jewelery or long hair can be caught in moving parts 9 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 correct 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 be
12. completely assembled No assembly time or tools are required 1 Trigger Switch 2 Switch Locking Button 3 Plunge Locking Lever 4 Collet Nut 5 Chuck 10 Depth Rod Locking Knob 6 Speed Selector Knob 7539 only 11 Depth Rod 7 Circuit Breaker 7538 only 12 Depth Stop Turret 8 Depth Indicator 13 Travel Limiting Nuts 9 Depth Indicator Knob 14 Stop Nut SELECTING THE BIT Models 7538 and 7539 accommodate bits with 1 2 diameter shanks that install directly into the power unit collet Collets are available that will allow the use of bits having 1 4 or 3 8 diameter shanks DO NOT USE router bits with a diameter in excess of 2 1 2 except when using Model 7539 set for either 10 000 or 13 000 RPM Router bits with a diameter up to 3 may be used with the 7539 motor operating in the 10 000 or 13 000 RPM speeds While preparing the router for use while making adjustments and when router is not in use ALWAYS DISCONNECT IT FROM THE POWER SOURCE INSTALLING AND REMOVING THE BIT Nez ale E Confirm that the power switch is in the OFF position and that the tool is disconnected from the power source to avoid accidental starting which could result in injury h Place the router upside down on its motor cap see Fig 1 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 w
13. d prior to engaging the router bit into work 19 000 VARIABI To change the speed after work 16 000 has begun stop the router remove a the router from the workpiece and 13 000 E adjust the speed setting MADE 10 000 13 USING THE TOOL Periodically wipe the columns clean with a dry cloth DO NOT lubricate columns IMPORTANT Before using your router consider the kind and total amount of material to be removed Depending on the material it may be necessary to make more than one cut to avoid overloading the motor Before beginning the cut on the actual workpiece make a sample cut on a piece of scrap lumber This will show exactly how the cut will look as well as enable you to check dimensions ACAUTION When through cutting be sure the router bit has enough clearance under workpiece ACAUTION Firmly clamp or otherwise secure the workpiece before making a cut Generally speaking when working on a bench hold the workpiece on the bench by wood clamps When routing edges hold the router firmly down and against the work by both handles Since the cutter rotates clockwise when viewing router from top you can cut more efficiently if the router is moved from left to right as you stand facing the work When working on the inside of a templet move the router in a clockwise direction When working on the outside of a templet move the router in a counter clock wise direction Avoid Climb Cutting cutting in direction
14. dicates potentiall CAUTION hazardous situation ON If o avoided may resi in property damage CALIFORNIA PROPOSITION 65 Some dust created by power sanding sawing grinding drilling ANORNING and other construction activities contains hemieaie known to the State of California to cause cancer birth defects or other reproductive harm Some examples of these chemicals are O lead from lead based paints O crystalline silica from bricks and cement and other masonry products arsenic and chromium from chemically treated lumber 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 always wear NIOSH OSHA approved properly fitting face mask or respirator when using such tools GENERAL SAFETY RULES _AWARNING Read all instructions Failure to follow all instructions listed below may result in electric shock fire and or serious ues The term power tool in all of the warnings listed below refers to your mains operated corded power tool or battery operated corde 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 flammable liquids gases or dust Power tools create sparks which may ignite the dust or fu
15. e give all information shown on the nameplate of your tool model number type serial number etc ACCESSORIES A complete line of accessories is available from your Porter CableeDelta Supplier Porter CableeDelta Factory Service Centers and Porter Cable Authorized Service Stations Please visit our Web Site www porter cable com for a catalog or for the name of your nearest supplier Since accessories other than those offered by Porter CableeDelta have not been tested with this product use of such accessories could be hazardous For safest operation only Porter CableeDelta recommended accessories should be used with this product 17 WARRANTY PORTER CABLE LIMITED ONE YEAR WARRANTY Porter Cable warrants its Professional Power Tools for a period of one year from the date of original purchase We will repair or replace at our option any part or parts of the product and accessories covered under this warranty which after examination proves to be defective in workmanship or material during the warranty period For repair or replacement return the complete tool or accessory transportation prepaid to your nearest Porter Cable Service Center or Authorized Service Station Proof of purchase may be required This warranty does not apply to repair or replacement required due to misuse abuse normal wear and tear or repairs attempted or made by other than our Service Centers or Authorized Service Stations ANY IMPLIED WARRANTY INCLUDING
16. ed If you have any questions relative to its application DO NOT use the product until you have written Porter Cable and we have advised you Online contact form at www porter cable com Postal Mail Technical Service Manager Porter Cable Corporation 4825 Highway 45 North Jackson TN 38305 Information regarding the safe and proper operation of this tool is available from the following sources Power Tool Institute 1300 Sumner Avenue Cleveland OH 44115 2851 www powertoolinstitute org National Safety Council 1121 Spring Lake Drive Itasca IL 60143 3201 American National Standards Institute 25 West 43rd Street 4 floor New York NY 10036 www ansi org ANSI 01 1Safety Requirements for Woodworking Machines and the U S Department of Labor regulations www osha gov SAVE THESE INSTRUCTIONS 2 SAFETY GUIDELINES DEFINITIONS It is important for you to read and understand this manual The W information it contains relates to protecting YOUR SAFETY and PREVENTING PROBLEMS The symbols below are used to help you recognize this information indicates an imminently hazardous situation which if not A DANGER avoided will result in death or serious injury indicates a potentially hazardous situation which if not A WARNING avoided could result if death or serious injury indicates a potentially hazardous situation which if not CNOA avoided may result in minor or moderate injury used without the safety alert symbol in
17. ert a 1 8 hex wrench not furnished into the adjusting screw see Fig 8 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 we ae y Lad 4 e r iN jo aay fe r AAA OS PORTE ERA j re j Fant tn ot oval CA A Pe 7 y2 Tae La 2 a LOAN te E 7 i A i pier DIA d j eset io yeas ot q i A 4 i ADE 1 lt a J Y AO OPERATION CONNECTING TO POWER SOURCE NTN Confirm that the switch is OFF and the power circuit voltage is the same as the voltage shown on the specification plate Connect the machine to a power circuit STARTING AND STOPPING THE MOTOR A CAUTION 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 1 Squeeze the trigger switch A Fig 9 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 9 and release the trigger switch 3 To release the lock button squeeze the trigger switch and release 12 NANI le To avoid injury or damage to finished work allow the motor to come to a COMPLETE STOP before putting it down OVERLOAD PROTECTION MODEL 7538 is equipped with a 3 thermal type circuit breaker G MODEL
18. fore making any adjustments changing 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 damaged 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 instructions and in the manner intended for the particular type of power tool taking into account 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 qualified repair person using only identical replacement parts This will ensure that the safety of the power tool is maintained ADDITIONAL SPECIFIC SAFETY RULES 1 Hold power tools by insulated gripping surfaces when performing an operation where the cutting too
19. knob K Fig 3 and raise the depth rod until the indicator aligns with the graduation representing the desired depth of plunge The example in Fig 5 shows setting for 1 plunge Tighten the depth rod locking knob 6 To limit the upward travel of the plunge mechanism 1 release the plunge lock by moving the plunge locking lever C Fig 2 to the left and move the motor to the desired maximum height 2 release and push the locking lever to the right to secure the motor in this position 8 use two 9 16 open end wrenches not furnished to move the travel limiting nuts O Fig 6 against the top of the motor housing boss T Fig 6 Jam the nuts together to lock A CAUTION Set the travel limiting nuts so that bit can be retracted into base of router clear of work A CAUTION Jam the travel limiting nuts together to prevent movement caused by vibration which could prevent full bit retraction DO NOT attempt to increase plunge travel by readjusting the stop nut P Fig 6 Increasing the travel beyond 3 can Cause mechanism to jam 11 ADJUSTING PLUNGE LOCKING LEVER You can adjust the plunge locking mechanism to compensate for wear or to reposition lever in locked position To adjust DISCONNECT TOOL FROM POWER SOURCE 1 Hold the lever in the upright position see Fig 7 Use a phillips screwdriver to remove retaining screw V Fig 7 Continue to hold the lever through the remaining steps 2 Ins
20. l 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 2 Use clamps or other practical way to secure and support the workpiece to a stable platform Holding the work by hand or against your body is unstable and may lead to loss of control 3 DISCONNECT TOOL FROM POWER SOURCE before making ad justments or changing bits 4 TIGHTEN COLLET NUT securely to prevent the bit from slipping 5 USE A CLAMP or some other device to hold the workpiece rigidly in position and clear the path of the tool of obstructions 6 PROVIDE CLEARANCE under workpiece for router bit when through cutting 7 CHECK TO SEE THAT THE CORD will not hang up during routing operation 8 CLEAR THE ROUTER BIT AREA before starting motor 9 MAINTAIN FIRM GRIP on router to resist starting torque 10 KEEP HANDS CLEAR OF BIT when motor is running to prevent personal injury 11 KEEP CUTTING PRESSURE CONSTANT Do not overload motor 12 LET THE MOTOR COME TO A COMPLETE STOP before putting the tool down 13 NEVER TOUCH router bits after use They may be extremely hot 14 NEVER TIGHTEN COLLET NUT without a bit 15 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 16 ALWAYS KEEP CHIP SHIELD clean and in place 17 AVOID CLIMB CUTTING see
21. mes 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 any adapter plugs with earthed grounded power tools Unmodified plugs and matching outlets will reduce risk of electric shock b Avoid body contact with earthed or grounded surfaces such as pipes radiators ranges 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 e When operating a power tool outdoors use an extension cord suitable for outdoor use Use of a cord suitable for outdoor use reduces the risk of electric shock 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 influence of drugs alcohol 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 s
22. ord is to be used outdoors it must be marked with the suffix W A or W following the cord type designation For example SUTW A to indicate it is acceptable for outdoor use RECOMMENDED EXTENSION CORD SIZES FOR USE WITH PORTABLE ELECTRIC TOOLS Length of Cord in Feet 115V 25Ft 50Ft 100Ft 150Ft 200 Ft 250 Ft 300 Ft 400 Ft 500 Ft 230V 50Ft 100Ft 200 Ft 300 Ft 400 Ft 500 Ft 600 Ft 800 Ft 1000 Ft 0 2 18 18 18 16 16 14 14 12 12 2 3 18 18 16 14 14 12 12 10 10 E 3 4 18 18 16 14 12 12 10 10 8 4 5 18 18 14 12 12 10 10 8 8 S 5 6 18 16 14 12 10 10 8 8 6 e 6 8 18 16 12 10 10 8 6 6 6 E 8 10 18 14 12 10 8 8 6 6 4 t 10 12 16 14 10 8 8 6 6 4 4 J 12 14 16 12 10 8 6 6 6 4 2 S 14 16 16 12 10 8 6 6 4 4 2 16 18 14 12 8 8 6 4 4 2 2 18 20 14 12 8 6 6 4 4 2 2 SAVE THESE INSTRUCTIONS CARTON CONTENTS The contents of the shipping carton include the router two open end wrenches an instruction manual and a parts list FUNCTIONAL DESCRIPTION FOREWORD MODEL 7539 Porter Cable Router incorporates a speed control that provides operating speeds from 10 000 RPM to 21 000 RPM to handle the most demanding router applications in various materials MODEL 7538 Porter Cable Router is designed for continuous rugged operation to handle the most demanding routing applications ASSEMBLY NOTE This tool is shipped
23. rench on the flats on the chuck and one wrench on the collet nut See Fig 1 Tighten firmly 4 Toremove the bit reverse the procedure If the bit is difficult to remove easily tap the collet nut with the wrench 9 CAUTION Do not allow the wrenches to contact the columns A Fig 1 If the columns are damaged the plunge action will be restricted CAUTION Do not tighten the collet nut without a bit inserted to prevent collet damage ADJUSTING PLUNGE DEPTH DISCONNECT TOOL FROM POWER SOURCE i Loosen the depth rod locking knob K Fig 3 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 4 The other two fixed stops S Fig 6 provide reduced cutting depths of 1 4 and 1 2 respectively You can position the three adjustable stops R Fig 4 to any height and can use any combination of fixed and or adjustable stops to achieve the desired depths required Release the plunge mechanism by pulling the locking lever C Fig 2 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 Tighten the depth rod locking knob K Fig 3 10 4 Position the depth indicator H Fig 3 at the O position and tighten the knob 5 Loosen the depth rod locking
24. s de Servicio Autorizadas estan ubicadas en muchas grandes ciudades Llame al 800 487 8665 al 731 541 6042 para obtener asistencia a fin de localizar una Las piezas y los accesorios para los productos Porter Cable e Delta deben obtenerse poni ndose en contacto con cualquier distribuidor Porter Cable e Delta Centro de Servicio Autorizado o Centro de Servicio de Fabrica Porter Cable e Delta Si no tiene acceso a ninguna de estas opciones llame al 888 848 5175 y le dirigir n al Centro de Servicio de F brica Porter Cable e Delta m s cercano Des centres de service agr s sont situ s dans beaucoup de grandes villes Appelez au 800 487 8665 ou au 731 541 6042 pour obtenir de l aide pour en rep rer un Pour obtenir des pi ces et accessoires pour les produits Porter Cable e Delta s adresser a tout distributeur Porter Cable e Delta centre de service agr ou centre de service d usine Porter Cable e Delta Si vous n avez acces a aucun de ces centres appeler le 888 848 5175 et on vous dirigera vers le centre de service d usine Porter Cable e Delta le plus proche CANADIAN PORTER CABLE DELTA SERVICE CENTERS ALBERTA MANITOBA QUEBEC Bay 6 2520 23rd St N E 1699 Dublin Avenue 1515 Ave Calgary Alberta Winnipeg Manitoba St Jean Baptiste Suite 160 T2E 8L2 R3H 0H2 Qu bec P Q Phone 403 735 6166 Phone 204 633 9259 G2E 5E2 Fax 403 735 6144 Fax 204 632 1976 Phone 418 877 7112 BRITISH COLUMBIA ONTARIO e LS 8520 Baxter Place
25. seconds no load speed min or min Revolutions or reciprocations per minute o OOO as direct current ag OV A C cccnnnnnnnnnnnno alternating current two phase alternating current two phase alternating current with neutral three phase alternating current three phase alternating current with neutral rated current of the appropriate fuse link in amperes time lag miniature fuse link where X is the symbol for the time current characteristic as given in IEC 60127 protective earth class II tool IP symbol MOTOR Many Porter Cable tools will operate on either D C or single phase 25 to 60 cycle A C current and voltage within plus or minus 5 percent of that shown on the specification plate on the tool Several models however are designed for A C current only Refer to the specification plate on your tool for proper voltage and current rating SUL Do not operate your tool on a current on which the voltage is not within correct limits Do not operate tools rated A C only on D C current To do so may seriously damage the tool EXTENSION CORD SELECTION If an extension cord is used make sure the conductor size is large enough to prevent excessive voltage drop which will cause loss of power and possible motor damage A table of recommended extension cord sizes will be found in this section This table is based on limiting line voltage drop to 5 volts 10 volts for 230 volts at 150 of rated amperes If an extension c
26. ttern and templet routing operations A typical combination bit template guide and locknut are illustrated in Fig 14 NUI ANNE DISCONNECT TOOL FROM POWER SOURCE To install insert the template guide in the center hole of the router base and secure with the locknut Before connecting the router to the power source install the bit adjust the depth of cut and rotate the chuck by hand to confirm that the bit or collet will not contact the template guide 15 TROUBLESHOOTING GUIDE For assistance with your tool visit our website at www porter cable com for a list of service centers or call the Porter Cable help line at 1 800 487 8665 MAINTENANCE KEEP TOOL CLEAN Periodically blow out all air passages with dry compressed air All plastic parts should be cleaned with a soft damp cloth NEVER use solvents to clean plastic parts They could possibly dissolve or otherwise damage the material PAGODE Wear ANSI Z87 1 safety glasses while using compressed air 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 sufficient 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
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