Porter-Cable SPEEDTRONIC 520 User manual

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