Porter-Cable BAYONET SAWS 7648 User's Manual
Contents
1. 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 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 LOCATION2. 8 L 01 z S Buiqn pue sieeus 19818 DI 011 ejbuy oluL EL O0 ZE S SIRAN 188 SR sno1194 UoN pue jeddoo ezuoig sseig Dunn og vL 8 S 8 1 2 LeezL OL OL LEEZL l Dunn gien 133LS Q33dS H5IH Bulyind pooM e48uetc pue 18jSe d yOOY 199us 18S sonseid ai weydsy ssejBieqiy Buying z I 9 c L Z 4 06 2L Anm Buryynd IEUaIEW w jqoid dIiL 3diguvo 181se d sonse d el 1 Weydsy yo0Y 1eeus 18S pooMA d 0 pepuog ssejD1eqi4 ssejD1eqi4 Bunning gg 9 GE v c LO ZL OL OL LOEZL T Dumn2 ssejBueqi4 1331S Q33dS HDIH 1 deL 8 90 2L 00L 00L 90EZL y poom Bumm yBnoy gg 9 St 90 2L OL OL 90EZL l wingjoury Jeqqny ssejBixejd seyeunue dade go9ezt 00L 001 09 2L p onseid pue jedeg seqi4 Bunino pooM jejeueo ae OL CIE O9EZL OL OL 09 Z1 SUOISPLIIXZ uinuiun y 10S l sonseid eyuose pooM d p00M UIID PIOS 1ede 899 2L 00L 00L 99EZL SE Bunno anung eBje pue iuDreng jejeue g c 0L 8 S 8 1 2 99 2L OL 0L 99 2L SOlSe d 911uOSe N jede p00M UIBID pios Dun Jeno pue 0499 sey Z I 9 c t O8ezt ol OL OSEZL EEEE 13 PORTER CABLE LIMITED ONE YEAR WARRANTY Porter Cable warrants its Professional Power Tools for a period of one year from the date of original purchase We will repair or replace at our option any part or parts of the product and accessories covered under this warranty which examin
3. 414 774 3653 Authorized Service Stations are located in many large cities For the one nearest you see the classified section in your phone book under Tools Electric ALBERTA MANITOBA 10 6320 11th Street S E 1699 Dublin Avenue Calgary Alberta Winnipeg Manitoba T2H 217 R3H 0H2 Phone 403 255 3530 Fax 403 258 0767 10632 169th Street Edmonton Alberta T5P 3X6 Phone 403 489 5587 Fax 403 489 0465 BRITISH COLUMBIA 45 West 7th Avenue Vancouver B C V5Y 1L4 Phone 604 879 8622 Fax 604 879 4594 PORTER CABLES Phone 204 633 9259 Fax 204 632 1976 ONTARIO 644 Imperial Road Guelph Ontario N1H 6M7 Phone 519 836 2840 Fax 519 836 9352 6463 Northam Drive Mississauga Ontario LAN 1J2 Phone 416 677 5330 416 677 5332 Fax 416 677 3728 851 Richmond Road Ottawa Ontario K2A 3X2 Phone 613 728 1124 613 728 4535 Fax 613 728 9208 CENTRES D ENTRETIEN DELTA QU BEC 523 Rue Deslauriers St Laurent Montr al P Q HAN 1W2 l Phone 514 336 8772 Fax 514 336 3505 Suite 202 2022 Rue Lavoisier Ste Foy Qu bec Qu bec G1N 4L5 Phone 418 681 7305 Fax 418 681 1695 Authorized Service Stations are located in many large cities For the one nearest you see the classified section in your phone book under Tools Electric OMNIJIGS PORTA BAND PORTA PLANE SAW BOSS SPEED BLOC SPEEDMATIC SPEEDTRON
4. 0653 MISSOURI North Kansas City 64116 1141 Swift Avenue P O Box 12393 Phone 816 221 2070 Fax 816 221 2897 St Louis 63119 7574 Watson Road Phone 314 968 8950 Fax 314 968 2790 NEW JERSEY Union 07083 945 Ball Avenue Phone 201 964 1730 Fax 201 688 6679 NEW YORK Flushing 11365 1595 NYC 175 25 Horace Harding Expwy Phone 718 225 2040 Fax 718 423 9619 NORTH CAROLINA Charlotte 28209 4303 B South Boulevard Phone 704 525 4410 Fax 704 525 0618 OHIO Columbus 43214 4560 Indianola Avenue Phone 614 263 0929 Fax 614 263 1238 Cleveland 44125 8001 Sweet Valley Drive Unit 18 Phone 216 447 9030 Fax 216 447 3097 PENNSYLVANIA Philadelphia 19154 12285 McNulty Road Phone 215 677 7800 Fax 215 677 9908 RHODE ISLAND East Providence 02914 1009 Waterman Avenue Phone 401 434 3620 Fax 401 431 9277 TEXAS Dallas 75220 10714 N Stemmons Freeway Phone 214 353 2996 Fax 214 350 3943 Houston 77092 5201 Mitchelldale B 9 Phone 713 682 0334 Fax 713 682 4867 UTAH Salt Lake City 84115 2990 Southwest Temple Phone 801 487 4953 Fax 801 484 5637 VIRGINIA Richmond 23230 1705 Dabney Road Phone 804 257 7348 Fax 804 257 5919 WASHINGTON Renton 98055 Seattle 268 Southwest 43rd Street Phone 206 251 6680 Fax 206 251 9337 WISCONSIN Milwaukee 53222 10700 W Burleigh Street Phone 414 774 3650 Fax
5. 6 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 H 7548 Fig 8 7648 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 surfa
6. IC VERSA PLANE STAIR EASE STUB RITE DURATRONIC HAMMER HEAD MICRO SET MORTEN TIGER SAW TIGER CUB TRU MATCH are trademarks of Porter Cable Corporation Copyright 1989 Porter Cable Corporation Printed in U S A
7. 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 7546 MODEL 7648 Top of Handle Rear of Motor Housing Fig 4 The control knob A Fig 4 is numbered 1 through 6 with 1 being the slowest speed approximately 500 SPM and 6 bei ng the fastest speed approximately 3200 SPM The speed control may be adjusted with or without the motor running Achart 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
8. S CE SIGNE EST L INDICATION 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 E 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 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 gondie 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 EC Keep cord from heat oil and sharp edges _ Have damage
9. Suite 105 Phone 205 942 6325 Fax 205 945 9615 CALIFORNIA City of Industry 91745 Los Angeles 1305 John Reed Court Phone 818 333 3566 Fax 818 330 5900 San Leandro 94577 Oakland 3039 Teagarden Street Phone 415 357 9762 Fax 415 357 7939 COLORADO Denver 80204 2561 West 8th Avenue Phone 303 892 6113 Fax 303 595 0358 FLORIDA Hialeah 33014 Miami 16373 75 NW 57th Ave Phone 305 624 2523 Fax 305 628 2654 Tampa 33609 4538 W Kennedy Boulevard Phone 813 877 9585 Fax 813 289 7948 Orlando 32803 1807 Winter Park Road Phone 407 644 8100 Fax 407 740 5956 GEORGIA Forest Park 30050 Atlanta 4017 Jonesboro Road Phone 404 363 8000 Fax 404 363 3129 DELTA SERVICE CENTRES ILLINOIS Addison 60101 Chicago 311 Laura Drive Phone 312 628 6100 Fax 312 628 0023 MARYLAND Baltimore 21205 4714 Erdman Avenue Phone 301 483 3100 Fax 301 325 6934 Hyattsville 20781 4811 Kenilworth Avenue Phone 301 779 8080 Fax 301 209 8421 MASSACHUSETTS Allston 02134 Boston 414 Cambridge Street Phone 617 782 1700 Fax 617 789 4232 MICHIGAN Grand Rapids 49508 Broadmoor Business Center 3755 G Broadmoor S E Phone 616 949 9040 Fax 616 949 3164 Southfield 48075 Detroit 18650 W Eight Mile Road Phone 313 569 4333 Fax 313 569 4337 MINNESOTA Minneapolis 55429 4315 68th Avenue North Phone 612 561 9080 Fax 612 561
10. ation proves to be defective in workmanship or material during the warranty period For repair or replacement return the complete tool or accessory transportation prepaid to your nearest Porter Cable Service Center or Authorized Service Station as listed under TOOLS ELECTRIC in the Yellow Pages of your telephone directory Proof of purchase may be required This warranty does not apply to repair or replacement required due to misuse abuse normal wear and tear or repairs attempted or made by other than our Service Centers or Authorized Service Stations To obtain information on warranty performance please write to PORTER CABLE CORPORATION 4825 Highway 45 North P O Box 2468 Jackson Tennessee 38302 2468 Attention Product Service The foregoing obligation is Porter Cable s sole liability under this or any implied warranty and under no circumstances shall Porter Cable be liable for any incidental or consequential damages Some states do not allow limitations on how long an implied warranty lasts on the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state 14 15 PORTER CABLE SERVICE CENTERS Parts and Repair Service for Porter Cable Power Tools are Available at These Locations ALABAMA Birmingham 35209 131 West Oxmoor Road
11. ce 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 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 ofthe 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 mE DO NOT FORCE LET THE SAW DO THE WORK Move the machine forward only rapidly enough to
12. d Or worn power cord and strain reliever replaced immediately E 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 E 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 316 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 whil
13. e 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 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 E When servicing use only identical replacement parts MOTOR bb Most Porter Cable tools will operate on either D C
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15. 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 lubricantitis 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
16. lade 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 Itis 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 IE 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 gt 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 goand push i in the lock button and release trigger To UNLOCK the lock squeeze trigger allowing lock button free to spring out and release trigger ECTRONIC Fig 2 Fig 3
17. 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 SES By anyone other than these agencies 10 Should you have any questions about your tool feel free to write us at any time In any communications please give all information shown on the nameplate of your tool model number type serial number etc ACCESSORIES The testing of this tool has been accomplished with the following accessories For safest operation it is recommended merous these accessories be used with this product WARNING Since accessories other than those listed T not been tested with this product use of such accessories could be hazardous 11 9nseld 901s ui p use pJeH puejog pooM aadel aS ejuosew Bumm
18. 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 100 Ft AA A A TE A TT TT Te FE 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 b
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