Porter-Cable 7538 User Manual

Instruction

manual

The Model and Serial No. plate is located on the main housing of the tool. Record these numbers in the spaces below and retain for future reference.

Model No. ______________________________________

Type ___________________________________________

Serial No. _______________________________________

IMPORTANT

Please make certain that the person who is to use this equipment carefully reads and understands these instructions before starting operations.

ESPAÑOL: PÁGINA 19 FRANÇAISE : PAGE 35

To learn more about Porter-Cable

visit our website at:

http://www.porter-cable.com

Part No. 899715 - 12-01-04

Plunge Routers

MODEL 7539

MODEL 7538

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 designed.

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!

IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . .2

SAFETY GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

ADDITIONAL SPECIFIC SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . .6

CARTON CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

ESPAÑOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

FRANÇAISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

SERVICE CENTER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . .back cover

TABLE OF CONTENTS

IMPORTANT SAFETY INSTRUCTIONS

Some dust created by power sanding, sawing, grinding, drilling,

and other construction activities contains chemicals known (to the State of California) to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

● lead from lead-based paints

● 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.

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 hazardous situation which, if not avoided,may result in minor or moderate injury.

used without the safety alert symbol indicates potentially hazardous situation which, if not avoided, may result in property damage.

CALIFORNIA PROPOSITION 65

It is important for you to read and understand this manual. The information it contains relates to protecting YOUR SAFETY and PREVENTING PROBLEMS. The symbols below are used to help you recognize this information.

SAFETY GUIDELINES - DEFINITIONS

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 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 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 safety 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.

Read all instructions. Failure to follow all instructions listed below may result in electric shock, fire 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.

GENERAL SAFETY RULES

continued

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.

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 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 before 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.

1. 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.

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 adjustments 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 throughcutting.

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 “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 HORIZONTAL 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.

ADDITIONAL SPECIFIC SAFETY RULES

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