Porter-Cable 7548 User manual

Instruction
manual
Bayonet Saws
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_
Type -
Serial No. _
L —_ _
Part No. 693946-092

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
4825 Highway 45 North
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.
o

Have damaged or worn power cord and strain reliever replaced
immediately.
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
CSlflSf . Do not USO tool If switch does not turn it on and oft.
20. WEAR EAR PROTECTION to safeguard against possible hearing
loss.
SAVE THESE INSTRUCTIONS
ADDITIONAL SAFETY RULES FOR PORTABLE BAYONET SAWS
1. KEEP BLADES SHARP.
2. KEEP HANDS AWAY FROM CUTTING AREA. When sawing never
reach underneath or behind the material being cut for any reasons.
3. WHEN YOU HAVE FINISHED A CUT be careful not to come into
contact with the blade. Turn off the motor immediately.

4. WARNING: EXERCISE EXTREME CAUTION WHEN BLIND
CUTTING TO BE CERTAIN THAT THERE ARE NOT FOREIGN
OBJECTS SUCH AS ELECTRICAL WIRE, CONDUIT, PLUMBING
PIPES, ETC., THAT MAY COME INTO CONTACT WITH THE
BLADE.
REPLACEMENT PARTS
When servicing use only identical replacement parts.
MOTOR
Most 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 specifica¬
tion plate on your tool for proper voltage and current rating.
CAUTION: 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 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

OPERATING INSTRUCTIONS
FOREWORD
Model 7548 and 7648 Bayonet Saws are designed for cutting
materials of the following MAXIMUM thickness: Wood 2-1/2";
Aluminum 3/4"; Steel 1/4".
SELECTING THE BLADE
To obtain best results with your Porter-Cable bayonet saw, it is
important that you use the right blade for the job. You will not only get
better performance, but your blades will last longer and a smoother
cut will result. A wide assortment of Porter-Cable blades is listed in
the back of this manual. It is strongly recommended that you obtain a
full assortment so you will always have the correct blade at hand for
any job you might choose to do.
Fig. 1
INSTALLING THE BLADE
CAUTION: Disconnect the saw from the power source.
Using the wrench furnished with your saw, loosen the blade screw
(C) Fig. 1. Insert the blade (A) Fig. 1, up into the blade clamp (B) Fig.
1, as far as it will go. While holding the blade to the front of the blade
clamp, lightly tighten blade screw (C) Fig. 1. Loosen blade screw (C)
Fig. 1,1/4 turn and pull down on the blade. The blade should not pull
out. Firmly tighten the blade screw.

TO START AND STOP SAW
Make sure power circuit voltage is the same as shown on the specifi¬
cation plate on the saw. Connect saw to power circuit.
Model 7546
1. Squeeze trigger switch (A) Fig. 2, to start motor. Release trigger
to stop motor.
2. Lock Button—A lock button (B) Fig. 2 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 free to
spring out, and release trigger.
Fig. 2 Fig. 3
Model 7648
1. Slide switch button (A) Fig. 3 forward to start motor. Slide switch
button rearward to stop motor.
VARIABLE SPEED
The 7548 and 7648 are equipped with adjustable variable speed
controls. The speed is adjusted by turning the control knob (A) Fig. 4.
MODEL 7648
(Rear of Motor Housing)
MODEL 7546
(Top of Handle)
Fig.

The control knob (A) Fig. 4, is numbered “1" through “6” with “1”
being the slowest speed (approximately 500 SPM) and “6” being the
fastest speed (approximately 3200 SPM). The speed control may be
adjusted with or without the motor running.
A Chart Of recommended speed settings for cutting various materials
is located on the front of the saw.
BLADE ORBIT
The blade orbit may be varied by turning knob (A) Fig. 5, to any of
four positions indicated by the numbers “0” through “3”, with “0”
producing no orbit and “3” producing maximum orbit. The orbit may
be adjusted with or without the motor running. Turn knob (A) Fig. 5,
to align the number producing the desired orbit with the index mark
(B) Fig. 5.
A chart of recommended orbit settings for cutting various materials
is on the front of the saw.
Fig. 5
CHIP BLOWER
These saws are equipped with a chip blower to keep the cutting area
free of chips. This blower may be switched “ON” or “OFF” by moving
lever (A) Fig. 6, to the “OPEN” position (blower “ON”) or to the
“CLOSED” position (blower “OFF”).

Fig. 7
BASE INSERT
A base insert #48367 (A) Fig. 7, is furnished with your bayonet saw.
This base insert will reduce splintering top fibers of plywood.
To install insert, remove saw blade from Bayonet Saw and locate
insert in the throat of the saw base with the slot forward and the
beveled side of the slot up. Install appropriate blade as outlined in
section INSTALLING THE BLADE with the blade body in the slot of
the insert.
PLUNGE CUTTING
WARNING: When cutting into a wall avoid contact with all exposed
metal on the tool to prevent electrical shock hazard resulting from
accidentally cutting into a live wire. HOLD SAW AS ILLUSTRATED
IN FIG. 8.
One of the distinctive and important features of the Porter-Cable
bayonet saw is the ability to start the cut (in wood only) within an area
without making drilled holes first. This is especially important when
making cut-outs for electrical outlets in finished walls, openings in
cabinet tops for sinks and openings for plumbing fixtures.
NOTE: When plunge cutting, it is recommended the orbit knob be set
to position “3”.
7548
Fig. 8
7648
8

First, measure the area to be cut out and mark it clearly with a pencil
chalk or scriber. Choose a convenient starting point and hold the
bayonet saw over the point and inside the line of waste. Tip the
machine forward until the front edge of the base rests firmly on the
surface of the material with the tip of the blade clear of the work
surface, as shown in Fig. 9. Turn motor “on” and slowly lower the
back of the machine allowing blade to bite into surface of work. Do
not move the machine forward until the base is fully seated on the
surface of the work. Now, guide the cutting along the inside of the
marked area. If sharp corners are desired cut right up to the corner of
the marked edge. Stop and back up just a bit, start the turn and cut
along the side. Do the same at each corner until you end up where
you started. Then, go back and cut into each corner from the oppo¬
site direction. The base of the machine is wide enough so you will
have a solid guiding surface on either side of the cut.
Fig. 9
USING THE SAW
First, secure the material in a bench vise or with clamps to the work
table. This is especially important when sawing small pieces or thin
material. As the work progresses in scroll or curved cut-out pieces,
the material can be readjusted to accommodate the movement of the
saw. If the work is large enough it can be held by hand across saw
horses. The saw cuts freely with only light forward feed pressure on
the tool. Forcing the saw will not make it cut faster.
To start the cut, secure the work, mark the line of cut clearly, place the
forward edge of the saw base firmly on the edge of the material, start
the motor and move the blade into the work. Notice how rapidly and
easily it cuts.
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DO NOT FORCE, LET THE SAW DO THE WORK. Move the machine
forward only rapidly enough to keep the blade cutting.
You will find that the open throat and clear forward edge of the saw
base make it easy to follow the line and cut closely to the pattern. You
need not cut oversize for hand finishing or sanding on most
materials. The smoothness of cut will often make further sanding
unnecessary.
MAINTENANCE
KEEP TOOL CLEAN
Periodically blow out all air passages with compressed air. Remove
build up of grime resulting from working green or sappy wood. All
plastic parts should be cleaned with soft cloths. NEVER use solvents
when cleaning plastic parts.
CAUTION: Wear safety glasses when 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
Your machine is lubricated at the factory with sufficient lubricant to
last for approximately one year’s operation time. To add lubricant it is
necessary to dismantle the tool. This operation should always be
handled by the nearest Porter-Cable Authorized Service Center. All
repairs and servicing made by these centers are fully guaranteed
against defective materials and workmanship.
BRUSH INSPECTION
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; worn parts replaced, when necessary;
relubricated with fresh lubricant, if required; reassembled with new
brushes; and performance tested.
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 immedi¬
ate service.
SERVICE AND REPAIRS
All quality tools will eventually require servicing or replacement of
parts due to wear from normal use. These operations, including
brush inspection and replacement, should ONLY be performed by
either an AUTHORIZED PORTER-CABLE SERVICE STATION or a
PORTER-CABLE SERVICE CENTER. All repairs made by these
agencies are fully guaranteed against defective material and work¬
manship. We can not guarantee repairs made or attempted by
anyone other than these agencies.
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