Porter-Cable SPEEDTRONIC 520 User manual

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1

Table of contents

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FOREDOM

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Heawf

Duty

Routers

Instruction

manual

MODEL

520

Consisting

of

Model

5202

Motor

Model

5201

Base

SPEEDTRONIC

MODEL

518

Consisting

of

Model

5182

Motor

Mode!

5181

Base

IMPORTANT

Please

make

certain

that

the

person

who

is

to

use

this

equipment

carefully

reads

and

understands

these

instructions

before

starting

operations.

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.

Serial

No.

SAFETY

INSTRUCTIONS

GROUNDING

INSTRUCTIONS

This

tool

should

be

grounded

while

in

use

to

protect

the

operator

from

electric

shock.

The

tool

is

equipped

with

an

approved

three-conductor

cord

and

three-prong

grounding

type

plug

to

fit

the

proper

grounding

type

receptacle.

The

green

(or

green

and

yellow)

conductor

in

the

cord

is

the

grounding

wire.

Never

connect

the

green

(or

green

and

yellow)

wire

to

a

live

terminal.

__

If

your

unit

is

for

use

on

less

than

150

Volts,

the

power

cord

is

equipped

with

a

plug

that

has

two

flat,

parallel

current-carrying

prongs

and

one

longer,

round

or

“U”-

shaped,

ground

prong

which

requires

a

mating

3-conductor

grounded

type

receptacle,

as

shown

in

Fig.

1.

An

adapter,

shown

in

Fig.

2,

is

available

for

connecting

3-prong

grounding

type

plugs

that

are

used

on

units

less

than

150

Volts

to

2-

prong

receptacles.

THIS

ADAPTER

IS

NOT

ALLOWED

IN

CANADA.

The

green

colored

rigid

ear,

lug,

etc.,

must

be

connected

to

a

per¬

manent

ground

such

as

a

properly

grounded

outlet

box,

as

shown

in

Fig.

2.

If

your

unit

is

for

use

on

150

to

250

Volts,

the

power

cord

is

equipped

with

a

plug

that

has

two

flat

current-

carrying

prongs

in

tandem,

and

one

round

or

“U”

-

shaped,

longer

ground

prong,

as

shown

in

Fig.

3.

This

plug

is

used

only

with

the

proper

mating

3-conductor

ground¬

ing

type

receptacle,

as

shown

in

Fig.

3.

No

adapter

is

available

for

this

type

plug.

IN

ALL

CASES,

MAKE

SURE

THE

RECEPTACLE

IN

QUESTION

IS

PROPERLY

GROUNDED.

NEVER

REMOVE

GROUNDING

PRONG

FROM

POWER

PLUG.

EXTENSION

CORDS

Use

only

three-wire

extension

cords

which

have

three

prong

grounding-

type

plugs

and

three-pole

receptacle

which

accept

the

tool’s

plug.

Replace

or

repair

damaged

or

worn

cord

immediately.

DO

NOT

ATTEMPT

TO

REPAIR

POWER

CORD.

2

IMPORTANT

SAFETY

INSTRUCTIONS

WARNING:

When

using

electric

tools,

basic

safety

precautions

should

always

be

followed

to

reduce

the

risk

of

fire,

electric

shock

and

personal

injury,

including

the

following:

READ

AND

FOLLOW

ALL

INSTRUCTIONS.

There

are

certain

applications

for

which

this

tool

was

designed.

Porter-

Cable

strongly

recommends

that

this

tool

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

tool

until

you

have

written

Porter-Cable

and

we

have

advised

you.

Manager

of

Product

Engineering

Porter-Cable

Corporation

Youngs

Crossing

at

Highway

45

P.O.

Box

2468

Jackson,

TN

38302-2468

1.

KEEP

WORK

AREA

CLEAN.

Cluttered

areas

and

benches

invite

injuries.

2.

AVOID

DANGEROUS

ENVIRONMENT.

Don’t

expose

power

tools

to

rain.

Don’t

use

power

tools

in

damp

or

wet

locations.

Keep

area

well

lit.

Avoid

chemical

or

corrosive

environment.

Do

not

use

tool

in

presence

of

flammable

liquids

or

gases.

THIS

SYMBOL

DENOTES

DO

NOT

EXPOSE

TO

RAIN

OR

USE

IN

DAMP

LOCATIONS

CE

SIGNE

EST

VINDICATION

DE

NE

PAS

EXPOSER

A

LA

PLUIE

ET

NE

PAS

UTILISER

DANS

LES

EMPLACEMENTS

HUMIDES

3.

GUARD

AGAINST

ELECTRIC

SHOCK.

Prevent

body

contact

with

grounded

surfaces.

For

example:

pipes,

radiators,

ranges,

refrigerator

enclosures.

4.

KEEP

CHILDREN

AWAY.

Do

not

let

visitors

contact

tool

or

extension

cord.

All

visitors

should

be

kept

away

from

work

area.

5.

STORE

IDLE

TOOLS.

When

not

in

use,

tools

should

be

stored

in

dry,

and

high

or

locked-up

place

—

out

of

the

reach

of

children.

6.

DON’T

FORCE

TOOL.

It

will

do

the

job

better

and

safer

at

the

rate

for

which

it

was

intended.

7.

USE

RIGHT

TOOL.

Don’t

force

small

tool

or

attachment

to

do

the

job

of

a

heavy

duty

tool.

Don’t

use

tool

for

purpose

not

intended—

for

example—do

not

use

a

circular

saw

for

cutting

tree

limbs

or

logs.

8.

DRESS

PROPERLY.

Do

not

wear

loose

clothing

or

jewelry.

Loose

clothing,

draw

strings

and

jewelry

can

be

caught

in

moving

parts.

Rubber

gloves

and

non-skid

footwear

are

recommended

when

working.

Wear

protective

hair

covering

to

contain

long

hair.

9.

USE

SAFETY

GLASSES.

Wear

safety

glasses

or

goggles

while

operating

power

tools.

Also

face

or

dust

mask

if

operation

creates

dust.

All

persons

in

the

area

where

power

tools

are

being

operated

should

also

wear

safety

glasses

and

face

or

dust

mask.

10.

DON’T

ABUSE

CORD.

Never

carry

tool

by

cord

or

yank

it

to

disconnect

from

receptacle.

Keep

cord

from

heat,

oil,

and

sharp

edges.

3

Have

damaged

or

worn

power

cord

and

strain

reliever

replaced

immediately.

DO

NOT

ATTEMPT

TO

REPAIR

POWER

CORD.

11.

SECURE

WORK.

Use

clamps

or

a

vise

to

hold

work.

It’s

safer

than

using

your

hand

and

it

frees

both

hands

to

operate

tool.

12.

DON’T

OVERREACH.

Keep

proper

footing

and

balance

at

all

times.

13.

MAINTAIN

TOOLS

WITH

CARE.

Keep

tools

sharp

and

clean

for

better

and

safer

performance.

Follow

instructions

for

lubricating

and

changing

accessories.

Inspect

tool

cords

periodically

and

if

damaged,

have

repaired

by

authorized

service

facility.

Inspect

extension

cords

periodically

and

replace

if

damaged.

Have

all

worn,

broken

or

lost

parts

replaced

immediately.

Keep

handles

dry,

clean

and

free

from

oil

and

grease.

14.

DISCONNECT

TOOLS.

When

not

in

use,

before

servicing,

and

when

changing

accessories

such

as

blades,

bits,

cutters,

etc.

15.

REMOVE

ADJUSTING

KEYS

AND

WRENCHES.

Form

habit

of

checking

to

see

that

keys

and

adjusting

wrenches

are

removed

from

the

tool

before

turning

it

on.

16.

AVOID

UNINTENTIONAL

STARTING.

Do

not

carry

a

plugged-

in

tool

with

finger

on

switch.

Be

sure

switch

is

off

when

plugging

in.

Keep

hands,

body

and

clothing

clear

of

blades,

bits,

cutters,

etc.

when

plugging

in

the

tool.

17.

OUTDOOR

USE

EXTENSION

CORDS.

When

tool

is

used

outdoors,

use

only

extension

cords

marked

“Suitable

for

use

with

outdoor

appliances

-

store

indoors

when

not

in

use.”

18.

STAY

ALERT.

Watch

what

you

are

doing.

Use

common

sense.

Do

not

operate

tool

when

you

are

tired

or

while

under

the

influence

of

medication,

alcohol

or

drugs.

19.

CHECK

DAMAGED

PARTS.

Before

further

use

of

the

tool,

a

guard

or

other

part

that

is

damaged

should

be

carefully

checked

to

determine

that

it

will

operate

properly

and

perform

its

intended

function.

Check

for

alignment

of

moving

parts,

binding

of

moving

parts,

breakage

of

parts,

mounting,

and

any

other

conditions

that

may

affect

its

operation.

A

guard

or

other

part

that

is

damaged

should

be

properly

repaired

or

replaced

by

an

authorized

service

center

unless

otherwise

indicated

elsewhere

in

this

instruction

manual.

Have

defective

switches

replaced

by

authorized

service

center.

Do

not

use

tool

if

switch

does

not

turn

it

on

and

off.

20.

WEAR

EAR

PROTECTION

to

safeguard

against

possible

hearing

loss.

SAVE

THESE

INSTRUCTIONS

ADDITIONAL

SAFETY

RULES

FOR

ROUTERS

1.

NEVER

adjust

depth

of

cut

while

motor

is

running.

A

slip

at

this

time

may

cause

personal

injury,

or

damage

to

cutter

or

workpiece.

2.

BE

SURE

cord

set

is

free

and

will

not

“hang

up”

during

routing

operations.

3.

KEEP

HANDS

CLEAR

of

cutter

when

motor

is

running

to

prevent

personal

injury.

4.

MAINTAIN

FIRM

GRIP

on

router

when

starting

motor

to

resist

starting

torque.

4

5.

STAY

ALERT

and

keep

cutter

clear

of

all

foreign

objects

while

motor

is

running.

6.

BE

SURE

motor

has

completely

stopped

before

setting

machine

down

between

operations.

7.

DO

NOT

USE

router

bits

with

a

diameter

in

excess

of

2Vz",

except

when

using

Model

5182

Motor

set

for

either

10,000

or

13,000

R.P.M.

Router

bits

with

a

diameter

up

to

3"

may

be

used

with

the

5182

Motor

operating

in

the

10,000

or

13,000

R.P.M.

speeds.

8.

DO

NOT

use

router

hand-held

in

an

upside-down

or

a

horizontal

position.

Motor

can

fall

from

base

if

not

properly

attached

according

to

instructions.

(See

page

7)

9.

AVOID

“CLIMB-CUTTING”

(See

page

10).

“Climb-Cutting”

in¬

creases

the

chance

for

loss

of

control

resulting

in

possible

personal

injury.

REPLACEMENT

PARTS

When

servicing

use

only

identical

replacement

parts.

MOTOR

Models

518

and

5182

will

operate

on

single

phase,

60

cycle,

A.C.

current

and

voltage

within

plus

or

minus

5

percent

of

that

shown

on

the

specification

plate

on

the

tool.

Model

520

and

5202

will

operate

on

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.

CAUTION:

Do

not

operate

your

tool

on

current

or

voltage

other

than

that

specified.

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

below.

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

cord

is

to

be

used

outdoors

it

must

be

marked

with

the

suffix

W-A

following

the

cord

type

designation.

For

example

—

SJTW-A

to

indicate

it

is

acceptable

for

outdoor

use.

RECOMMENDED

EXTENSION

CORD

SIZES

FOR

USE

WITH

PORTABLE

ELECTRIC

TOOLS

Lent

3

th

of

Cord

in

Feet

1

115V

25

Ft.

50

Ft.

100

Ft.

150

Ft.

200

Ft.

250

Ft.

300

Ft.

400

Ft.

500

Ft.

230V

50

Ft.

100

Ft.

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

o>

c

3-4

18

18

16

14

12

12

10

10

8

"ca

CE

4-5

18

18

14

12

12

10

10

8

8

©

5-6

18

16

14

12

10

10

8

8

6

©

Q.

6-8

18

16

12

10

10

8

6

6

6

E

<

8-10

18

14

12

10

8

8

6

6

4

©

c3

10-12

16

14

10

8

8

6

6

4

4

Q.

©

12-14

16

12

10

8

6

6

6

4

2

E

CCS

14-16

16

12

10

8

6

6

4

4

2

z

16-18

14

12

8

8

6

4

4

2

18-20

14

12

8

6

6

4

4

2

2

5

OPERATING

INSTRUCTIONS

FOREWORD

Model

518

Porter-Cable

Speedtronic

Router

incorporates

a

microprocessor

based

speed

control

that

maintains

a

no-load

and

cutting

load

speed

from

10,000

RPM

to

22,000

RPM,

in

3000

RPM

increments,

to

handle

the

most

demanding

router

applications

in

various

materials.

Model

520

PORTER-CABLE

Router

is

designed

for

continuous,

rugged

operations

to

handle

the

most

demanding

routing

applications.

SELECTING

THE

BIT

Models

518

and

520

accommodate

bits

with

1/2"

diameter

shanks

that

are

installed

directly

into

the

power

unit

collet.

Collets

are

available

that

will

allow

the

use

of

bits

having

1

/4"

or

3/8"

diameter

shanks.

CAUTION:

DO

NOT

USE

router

bits

with

a

diameter

in

excess

of

except

when

using

Model

5182

Motor

set

for

either

10,000

or

13,000

R.P.M.

Router

bits

with

a

diameter

up

to

3"

may

be

used

with

the

5182

Motor

operating

in

the

10,000

or

13,000

R.P.M.

speeds.

CAUTION:

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

1.

CAUTION:

DISCONNECT

machine

from

power

source.

2.

Remove

Motor

Unit

from

Base

Unit

as

follows:

a)

Loosen

Clamp

Screw

(A)

Fig.

1.

b)

While

holding

base,

turn

motor

unit

COUNTERCLOCKWISE

until

lower

Pin

(B)

in

motor

housing

is

disengaging

from

groove

in

base.

c)

Lift

Motor

Unit

free

from

Base

Unit.

Fig.

1

6

3.

Clean

and

insert

shank

of

bit

into

collet

until

shank

bottoms.

Then

back

it

out

approximately

1

/16".

4.

Lay

Motor

Unit

on

bench

with

the

collet

pointing

AWAY

from

you.

5.

Place

one

wrench

on

flats

on

Chuck

and

allow

opposite

end

of

wrench

to

rest

on

the

bench

to

your

LEFT.

6.

Place

other

wrench

on

Collet

nut

and

turn

counterclockwise

to

tighten.

TIGHTEN

FIRMLY.

7.

To

remove

the

bit,

reverse

the

foregoing

procedure.

NEVER

TIGHTEN

COLLET

WITHOUT

BIT

INSERTED.

TO

DO

SO,

MAY

CAUSE

DAMAGE

TO

COLLET.

ASSEMBLING

THE

MOTOR

INTO

THE

ROUTER

BASE

1.

CAUTION:

DISCONNECT

motor

from

power

source.

2.

Loosen

the

Clamp

Screw

(A)

Fig.

1,

only

enough

so

Power

Unit

can

be

inserted

in

Base

Unit.

3.

Insert

Motor

Unit

into

base

aligning

lower

pins

(B)

with

grooves

in

base.

4.

Rotate

Motor

Unit

Clockwise

into

base.

5.

Tighten

clamp

screw

firmly.

ADJUSTING

DEPTH

OF

CUT

1.

CAUTION:

DISCONNECT

motor

from

power

source.

2.

Loosen

Clamp

Screw

(A)

Fig.

2.

Fig.

2

3.

W

h

il

e

holding

base,

turn

Motor

Unit

COUNTERCLOCKWISE

until

the

tip

of

the

bit

is

above

bottom

surface

of

base.

7

4.

Set

router

on

a

flat

wooded

surface.

5.

Turn

Motor

Unit

CLOCKWISE

until

bit

just

touches

the

wood

surface.

6.

Tighten

clamp

screw.

7.

Rotate

Depth

Adjusting

Ring

(B)

until

the

graduation

line

marked

j

zero

(C)

is

opposite

the

index

line

(D)

on

the

motor

housing.

8.

Loosen

clamp

screw.

f

9.

Tip

the

router

so

bit

is

clear

of

the

wood

surface

and

turn

motor

unit

CLOCKWISE

until

the

index

line

on

the

motor

housing

reaches

the

desired

depth

indicated

on

the

ring.

10.

Tighten

clamp

screw

firmly.

NOTE:

Setting

the

index

line

to

1/4"

on

the

ring

means

the

cutting

edge

of

the

bit

is

exposed

1

1

4

"

below

the

base.

CONNECTING

TO

POWER

SOURCE

TO

START

AND

STOP

ROUTER

CAUTION:

Before

starting

the

router

make

sure

bit

is

clear

of

work

piece

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.

3,

into

the

ON

or

OFF

position.

CAUTION:

T

o

avoid

personal

injury

or

damage

to

finished

work

always

allow

the

motor

to

come

to

a

COMPLETE

STOP

before

setting

it

down.

CIRCUIT

BREAKER

A

thermal

type

circuit

breaker

is

incorporated

into

the

ON/OFF

rocker

switch

(A)

Fig.

3.

This

circuit

breaker

will

turn

the

switch

OFF

if

prolonged

overload

conditions

are

encountered.

If

the

circuit

breaker

“trips”,

switching

the

motor

OFF:

(1)

determine

cause

of

the

overload

(I.E.

dull

bit,

low

voltage,

excessive

feed

rate,

etc.)

and

correct

before

continuing,

(2)

allow

router

to

cool

for

three

minutes,

and

(3)

restart

router

following

the

instructions

in

TO

START

AND

STOP

ROUTER.

Fig.

3

Fig.

4

8

MICROPROCESSOR

SPEED

CONTROL

(MODEL

518

ONLY)

The

microprocessor

based

speed

control

is

located

as

shown

in

Fig.

4.

Five

operating

speeds

from

10,000

RPM

to

22,000

RPM,

in

3000

RPM

increments,

are

available

by

moving

the

Speed

Selector

Knob

A

(Fig.

4).

When

the

Speed

Selector

Knob

is

moved

to

the

left,

the

cutter

speed

increases

and

when

moved

to

the

right,

the

speed

decreases.

The

location

of

the

Speed

Selector

Knob

is

marked

A,

B,

C,

D,

and

E

corresponding

to

the

following

speeds:

A

=

22,000

RPM,

B

=

19,000

RPM,

C

=

16,000

RPM,

D

=

13,000

RPM

and

E

=

10,000

RPM.

The

set

speed

will

appear

in

the

readout

display.

The

desired

speed

may

be

set

prior

to

turning

the

router

“ON”

or

any

time

while

the

router

is

running.

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,

remove

router

clear

of

work,

maintain

a

firm

grip

on

the

router

and

adjust

speed

setting.

NOTE:

Model

518

Router

has

a

“Soft

Start”

feature

designed

to

minimize

startup

reaction

torque.

This

feature

will

also

prevent

the

router

from

starting

(especially

in

the

E

or

10,000

RPM

setting)

if:

(1)

the

bit

is

against

the

work,

(2)

if

a

low

voltage

situation

exists,

or

(3)

if

long

and/or

light

duty

extension

cords

are

used.

If

starting

problems

arise

from

the

above

situations,

start

the

router

with

the

control

in

the

mid-range

or

high

speed

setting.

The

following

chart

contains

suggested

speeds

for

various

cutter

diameters

and

material.

This

chart

is

also

on

the

router

base

for

easy

reference.

Experience

will

indicate

the

most

satisfactory

speed

to

use

for

any

particular

application

depending

on

desired

finish

and

feed

rate.

Cutter

Dia.

CONTROL

SETTING

Soft

Wood

Hard

Wood

Plastics

Aluminum

1/8-

1/4

A

B

C

D

5/16

-

7/16

B

C

D

D

1/2-5/8

C

D

D

E

3/4

-

UP

D

E

E

E

USING

THE

ROUTER

IMPORTANT:

Before

using

your

router,

consider

the

kind

and

total

amount

of

material

to

be

removed.

Depending

on

the

material,

if

may

be

necessary

to

make

more

than

one

cut

to

avoid

overloading

the

motor.

Before

beginning

the

cut

on

the

actual

workpiece,

it

is

advisable

to

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.

CAUTION:

Always

be

sure

the

work

is

rigidly

clamped

or

otherwise

secured

before

making

a

cut.

9

Generally

speaking,

when

working

on

a

bench,

the

workpiece

should

be

held

on

the

bench

by

wood

clamps.

When

routing

edges,

the

router

should

be

held

firmly

down

and

against

the

work

by

both

guiding

knobs.

Since

the

cutter

rotates

clockwise

(when

viewing

router

from

top),

more

efficient

cutting

will

be

obtained

if

the

router

is

moved

from

left

to

right

as

you

stand

facing

the

work.

When

working

on

the

inside

of

a

templet,

move

router

in

clockwise

direction.

When

working

on

the

outside

of

a

templet,

move

the

router

in

the

counterclockwise

direction.

WARNING:

Avoid

“Climb-Cutting”

(cutting

in

direction

opposite

that

shown

in

Fig.

5),

“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

the

motor

speed

slows

excessively.

If

may

be

necessary

on

exceptionally

hard

woods

or

problem

materials

to

make

more

than

one

pass

at

various

settings

to

get

the

desired

depth

of

cut.

When

making

cuts

on

all

four

edges

of

the

workpiece,

it

is

advisable

to

have

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

will

be

removed

when

making

the

next

cut

parallel

with

the

grain.

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,

insert

Guide

Rods

(A)

in

holes

in

base,

Fig.

6

and

secure

with

screws

(B).

The

Guide

(C)

is

adjusted

on

the

rods

and

secured

in

desired

position

with

Thumb

Screws

(D).

to