Porter-Cable Model 543 User manual

Double Insulated

Bayonet Saw

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.

Part No. 900471- 01-14-05

ESPAÑOL: PÁGINA 17

FRANÇAISE : PAGE 33

To learn more about Porter-Cable

visit our website at:

http://www.porter-cable.com

MODEL 543 with

Keyless Quik-Change™

Blade Clamp

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 . . . . . . . . . . . . . . . . . . . . . . . .7

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

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

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

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

ESPAÑOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

FRANÇAISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

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

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.

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.

GENERAL SAFETY RULES

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 jewelry. Keep your

hair, clothing and gloves away from moving parts. Loose clothes,

jewelry 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.

GENERAL SAFETY RULES continued

SYMBOL DEFINITION

V ........................ volts

A ........................ amperes

Hz ........................ hertz

W ........................ watts

kW ........................ kilowatts

F ........................ farads

µF ........................ microfarads

l ........................ litres

g ........................ grams

kg ........................ kilograms

bar ........................ bars

Pa ........................ pascals

h ........................ hours

min ........................ minutes

s ........................ seconds

n0........................ no-load speed

…/min or …min-1......... Revolutions or reciprocations per minute

or d.c. ............... direct current

or a.c. ................ alternating current

2........................ two-phase alternating current

2N ........................ two-phase alternating current with neutral

3........................ three-phase alternating current

3N ........................ 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

IPXX ........................ IP symbol

SAVE THESE INSTRUCTIONS!

1. Hold power tool 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. Keep blades sharp. Sharp blades will do the job better and safer.

4. Keep hands away from cutting area. When sawing never reach underneath

or behind the material being cut for any reason.

5. When you have finished a cut be careful not to come into contact with

the blade. Turn off the motor immediately.

6. Exercise extreme caution when blind cutting. Be certain

that there are no foreign objects such as electrical wire, conduit, plumbing

pipes, etc., that may come into contact with the blade.

7. 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.

8. 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

SAVE THESE INSTRUCTIONS!

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 cord is to be used outdoors, it must be marked with the suffix W-

A or W 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

Length of Cord in Feet

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.

0-2181818161614141212

2-3181816141412121010

3-418181614121210108

4-5 18 18 14 12 12 10 10 8 8

5-6 18 16 14 12 10 10 8 8 6

6-8 18 16 12 10 10 8 6 6 6

8-10 18 14 12 10 8 8 6 6 4

10-12 16 14 10 8 8 6 6 4 4

12-14 16 12 10 8 6 6 6 4 2

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

Nameplate Ampere Rating

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.

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.

* Bayonet saw

* Blade

* Non-marring base

* Anti-splinter base insert

* Carrying case

CARTON CONTENTS

SAVE THESE INSTRUCTIONS!

FOREWORD

Model 543 Bayonet Saw is designed for cutting materials of the following

MAXIMUM thickness: wood 41/3", plastic and fiberglass 11/4", aluminum and

nonferrous metals 13/16", mild steel 3/8", and stainless steel 1/8". The saw is also

equipped with the Keyless Quik-Change™ Blade Clamp for ease of blade

installation and removal.

FUNCTIONAL DESCRIPTION

ASSEMBLY

ANTI-SPLINTER BASE INSERT INSTALLATION

The anti-splinter base insert is used to

reduce chipping and splintering of the

top fibers of plywood, paneling, and

other splinter prone materials. When this

insert is used it is not necessary to have

the good or finished side of the work

down during the cutting operation.

Install the insert as shown in Fig. 1.

NOTE: When using the anti-splinter

insert, the base should be set to the

forward most position, Fig. 9.

ANTI-MAR PLASTIC SUB-BASE INSTALLATION

DISCONNECT TOOL FROM POWER SOURCE.

The anti-mar plastic sub-base is used when cutting on finished surfaces to

prevent the normal metal base from scratching, gouging, or otherwise

marring the surface of the material to be cut.

To install the plastic sub-base, remove the six screws from the bottom of the

base, remove the metal sub-base, place the plastic sub-base on the saw, and

reinstall the six screws. Be sure to save the metal sub-base for reuse.

BLADE INSTALLATION

1. Remove anti-splinter insert if installed.

2. Gently squeeze the switch trigger until the blade shaft moves slowly and

stop the motor when the blade shaft is at or near the bottom of its stroke, Fig.

DISCONNECT TOOL FROM POWER SOURCE.

Fig. 1

Fig. 2 Fig. 3

ASSEMBLY TOOLS REQUIRED - None

ASSEMBLY TIME ESTIMATE - 15-30 minutes

3. Open the Keyless Quik-Change™ Blade

Clamp by rotating the movable lever (B),

Fig. 2, towards the stationary lever (A), Fig.

2, as far as it will go and hold.

4. While holding the blade clamp open;

move lever (A) as far forward as it will go,

(see Figs. 2 & 3), and hold.

NOTE: Steps 3 and 4 should be done

in one motion.

5. With the teeth of the blade toward the

front of the saw, insert the blade through

the blade guide into the blade holder as far

as it will go and release the levers. See Fig. 4.

6. Pull up on the blade until it locks in place. The blade is properly installed

when the levers are aligned as shown in Fig. 4.

BLADE REMOVAL

1. Remove the anti-splinter insert if installed.

2. Gently squeeze the switch trigger until the blade shaft moves slowly and

stop the motor when the blade shaft is at or near the bottom of its stroke, Fig.

DISCONNECT TOOL FROM POWER SOURCE.

3. Open the blade clamp by rotating the movable lever (B), Fig. 2, towards

the stationary lever (A), Fig. 2, as far as it will go.

4. Move the blade shaft forward until the blade is clear of the blade guide.

5. Grasp the tip of the blade, move it towards the blade holder lever/right

hand side of saw and pull the blade out of the clamp.

TO START AND STOP SAW

Make sure power circuit voltage

is the same as shown on the

specification plate on the saw,

and that saw switch is OFF.

Connect saw to power circuit.

1. Squeeze trigger switch (A),

Fig. 5, to start motor. Release

trigger to stop motor.

2. Lock Button – A lock button

(B), Fig. 5, is provided to keep the

saw running without holding the

switch trigger “ON”. To lock the

switch trigger “ON”, squeeze the trigger as far as it will go and push in the lock

button and release trigger.

To UNLOCK the lock, squeeze trigger allowing lock button to spring out, and

release trigger.

Fig. 4

Fig. 5

OPERATION

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