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
Copyright © 2005 PORTER-CABLE Corporation

2
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

3
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

4
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

5
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

6
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!

7
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!

8
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

9
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.
6.
DISCONNECT TOOL FROM POWER SOURCE.
Fig. 1
Fig. 2 Fig. 3
A
B
ASSEMBLY TOOLS REQUIRED - None
ASSEMBLY TIME ESTIMATE - 15-30 minutes

10
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.
6.
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
A
B
C
OPERATION