Ironton 30091 User manual

ELECTRIC METAL CUTTING
SHEAR
OWNER’S MANUAL
WARNING:
Read carefully and understand all ASSEMBLY AND OPERATION
INSTRUCTIONS before operating. Failure to follow the safety rules and other
basic safety precautions may result in serious personal injury.
Item# 30091

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Thank you very much for choosing an Ironton product! For future reference, please complete the
owner’s record below:
Model: _______________ Purchase Date: _______________
Save the receipt, warranty and these instructions. It is important that you read the entire manual
to become familiar with this product before you begin using it.
This machine is designed for certain applications only. The distributor cannot be responsible for
issues arising from modification. We strongly recommend this machine not be modified and/or
used for any application other than that for which it was designed. If you have any questions
relative to a particular application, DO NOT use the machine until you have first contacted the
distributor to determine if it can or should be performed on the product.
For technical questions please call 1-800-222-5381.
INTENDED USE
For auto body work or any other metal cutting project, this metal shear makes smooth and clean
cuts in aluminum, plastic or sheet metal as thick as 14 gauge. This 120 Volt powered metal
shear features tungsten carbide blades for durability and long life. It is designed for any shop,
garage or hobbyist requiring precision metal cutting.
TECHNICAL SPECIFICATIONS
Voltage: 120V, 60Hz, 3.5Amps
Arbor Reciprocating Frequency: 1800 RPM
Max Shear Thickness: 14 gauge
GENERAL SAFETY RULES
WARNING: Read and understand all instructions. Failure to follow all instructions listed
below may result in serious injury.
CAUTION: Do not allow persons to operate or assemble this Metal Shear until they
have read this manual and have developed a thorough understanding of how the Metal Shear
works.
WARNING: The warnings, cautions, and instructions discussed in this instruction
manual cannot cover all possible conditions or situations that could occur. It must be
understood by the operator that common sense and caution are factors which cannot be built into
this product, but must be supplied by the operator.
SAVE THESE INSTRUCTIONS

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IMPORTANT SAFETY CONSIDERATIONS
Safety Warnings and Precautions
WARNING: When using tool, basic safety precautions should always be followed to reduce
the risk of personal injury and damage to equipment. Read all instructions before using this tool!
Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents.
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.
Keep bystanders, children, and visitors away while operating a power tool. Distractions can
cause you to lose control. Protect others in the work area from debris such as chips and
sparks. Provide carriers or shields as needed.
Grounded tools must be plugged into an outlet properly installed and grounded in
accordance with all codes and ordinances. Never remove the grounding prong or modify the
plug in any way. Do not use any adapter plugs. Check with a qualified electrician if you are in
doubt whether the outlet is properly grounded. If the tool should electrically malfunction or
break down, grounding provides a low resistance path to carry electricity away from the user.
Double insulated tools are equipped with a polarized plug (one blade is wider than the other).
This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet,
reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized
outlet. Do not change the plug in any way. Double insulation eliminates the need for the
three wire grounded power cord and grounded power supply system.
Avoid body contact with grounded surfaces such as pipes, radiators, ranges, and
refrigerator. There is an increased risk of electric shock if your body is grounded.
Do not expose power tools to rain or wet conditions. Water entering a power tool will increase
the risk of electric shock.
Do not abuse the power cord. Never use the power cord to carry the tool or pull the plug from
an outlet. Keep the power cord away from heat, oil, sharp edges, or moving parts. Replace
damaged power cords immediately. Damaged power cords increase the risk of electric
shock.
When operating a power tool outside, use an outdoor extension cord marked “W-A” or “W”.
These extension cords are rated for outdoor use, and reduce the risk of electric shock.
Personal Safety
Stay alert. Watch what you are doing, and use common sense when operating a power tool.
Do not use a power tool while tired or under the influence of drugs, alcohol, or medication. A
moment of inattention while operating power tools may result in serious personal injury.
Dress properly. Do not wear loose clothing or jewelry. Tie back long hair. Keep your hair,
clothing, and gloves away from moving parts. Loose clothing, jewelry, or long hair can be
caught in moving parts.
Avoid accidental starting. Be sure the power switch is off before plugging in. Carrying power
tools with your finger on the power switch, or plugging in power tools with the power switch
on, invites accidents.

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Remove adjusting keys or wrenches before turning the power tool on. A wrench or a key that
is left attached to a rotating part of the power tool may result in personal injury.
Do not overreach. Keep proper footing and balance at all times. Proper footing and balance
enables better control of the power tool in unexpected situations.
Use safety equipment. Always wear eye protection. Dust mask, nonskid safety shoes, hard
hat, or hearing protection must be used for appropriate conditions.
Specific Safety Rules
Maintain label and name plate on the tool. These carry important information. If unreadable
or missing, contact the distributor for a replacement.
Always wear ANSI approved safety impact eye goggles and heavy leather work gloves when
using the tool. Using personal safety devices reduces the risk for injury.
Maintain a safe working environment. Keep the work area well lit. Make sure there is
adequate surrounding work space. Always keep the work area free of obstructions, grease,
oil, trash, and other debris. Do not use a power tool in areas near flammable chemicals, dust,
and vapors. Do not use this product in damp or wet locations.
When starting a handheld power tool, always maintain a firm grip on the tool with both hands
to resist starting torque.
Always keep the extension cord away from moving parts on the tool.
Avoid unintentional starting. Make sure you are prepared to begin work before turning on the
tool.
Do not force the tool. This tool will do the work better and safer at the speed and capacity for
which it was designed.
Never lay the tool down until the motor has come to a complete stop. The tool may create
unforeseen risk while the motor cycles down.
Never leave the tool unattended when it is plugged into an electrical outlet. Turn off the tool,
and unplug it from its electrical outlet before leaving.
Always unplug the tool from its electrical outlet before performing and inspection,
maintenance, or cleaning procedures.
WARNING: People with pacemakers should consult their physician(s) before using
this product. Operations of electrical equipment in close proximity to a heart pacemaker
could cause interference or failure of the pacemaker.
Extension Cords
Grounded tools require a three wire extension cord. Double insulated tools can use either a
two or three wire extension cord.
As the distance from the supply outlet increases, you must use a heavier gauge extension
cord. Using extension cords with inadequately sized wire causes a serious drop in voltage,
resulting in loss of power and possible tool damage. (See Figure A, below)
The smaller the gauge number of the wire, the greater the capacity of the cord. For example,
a 14 gauge cord can carry a higher current than a 16 gauge cord. (See Figure A)
When using more than one extension cord to make up the total length, make sure each cord

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contains at least the minimum wire size required. (See Figure A)
If you are using an extension cord for more than one tool, add the nameplate amperes and
use the sum to determine the required minimum cord size.
If you are using an extension cord outdoors, make sure it is marked with the suffix “W-A”(“W”
in Canada) to indicate it is acceptable for outdoor use.
Make sure your extension cord is properly wired and in good electrical condition. Always
replace a damaged extension cord or have it repaired by a qualified electrician before using
it.
Protect your extension cords from sharp objects, excessive heat and damp or wet areas.
(Figure A) Recommended Minimum Wire Gauge for 120 Volt Extension Cords
Nameplate
Amperes
(at full load)
Extension Cord Length
25 Feet
50 Feet
75 Feet
100 Feet
150 Feet
0-2.0
18
18
18
18
16
2.1-3.4
18
18
18
16
14
3.5-5.0
18
18
16
14
12
6.1-7.0
18
16
14
12
12
7.1-12.0
16
14
12
10
X
12.1-16.0
14
12
10
X
X
16.1-20.0
12
10
X
X
X
X – Not recommended for use with extension cord.
METAL SHEAR USE AND CARE
Do not modify the Metal Shear in any way. Unauthorized modification may impair the
function and/or safety and could affect the life of the equipment. There are specific
applications for which the Metal Shear was designed.
Always check of damaged or worn out parts before using the Metal Shear. Broken
parts will affect the Metal Shear operation. Replace or repair damaged or worn parts
immediately.
Store idle Metal Shear. When Metal Shear is not in use, store it in a secure place out of the
reach of children. Inspect it for good working condition prior to storage and before re-use.
TOOL USE AND CARE
Use clamps (not included) or other practical ways to secure and support the work piece to a
stable platform. Holding the work by hand or against your body is unstable and may lead to
loss of control.
Do not force the tool. Use the correct tool for your application. The correct tool will do the job
better and safer at the rate for which it is designed.
Do not use the power tool if the power switch does not turn it on or off. Any tool that cannot
be controlled with the power switch is dangerous and must be replaced.
Disconnect the power cord plug from the power source before making any adjustments,
changing accessories, or storing the tool. Such preventive safety measures reduce the risk of
starting the tool accidentally.
Store idle tools out of reach of children and other untrained persons. Tools are dangerous in
the hands of untrained users.

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Maintain tools with care. Keep Cutting tools maintained and clean. Properly maintained tools
are less likely to bind and are easier to control. Do not use a damaged tool. Tag damaged
tools <<Do not use >> until repaired.
Use only accessories that are recommended by the manufacturer for your model.
Accessories that may be suitable for one tool may become hazardous when used on another
tool.
OPERATION
Following all safety requirements already listed, plug the power cord into a circuit breaker
protected 120V, 60Hz power outlet.
WARNING: Do not turn on the tool until you have read this entire manual, and follow all
safety information, notes, cautions and warnings provided.
To turn on the tool, slide the power switch (38) forward to the ON position. The upper shear blade
(12) will begin to move up and down at high speed.
NOTE: It is a good idea to make a few practice cuts on scrap material before cutting your work
piece.
To cut material, fit the tool rest (1) over the edge of the material, and move the tool slowly forward
along the desired cut line of the material. As the upper shear blade (12) moves up and down
against the lower shear blade (2), the material will be cut.
WARNING: The edge of sheet metal is very sharp. Always wear protective gloves when
handling sheet metal.
CAUTION: Do not cut across a welded seam as this might damage the blades.
To stop cutting, slide the power switch (38) back to the OFF position. Unplug the tool.

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Adjusting the cutting blades
If the tool is operating properly, but is not cutting satisfactorily, you may have to adjust
the blades.
1. Before attempting adjustment, turn off and unplug the tool.
2. Using a probe through the motor vents in the side of the
cover (48), turn the fan until the cutting blades are open
to the maximum amount. You can measure the gap
between the blades using an automotive feeler gauge
(not included).
3. To determine the best spacing, use the formula:
Distance in mm (L) =0.2x thickness of steel plate in mm.
(This is the same as the gap being equal to the material
thickness divided by 5.) For example, a thin steel plate which is 1 mm thick should be cut with
a shear blade setting of 0.2 mm. This assumes a hardness of the material at 390N/mm. For
softer material, reduce the gap. For harder
material, increase the gap.
4. Loosen the socket head screw (6) that
holds the upper shear blade (12) in place.
Adjust the upper shear blade until the space
between the upper and lower cutting edge
is between 0.1 mm and 0.6 mm. Then
tighten the socket head screw (6) to fix the
upper shear blade (12) in position.
MAINTENANCE
•Maintain your Metal Shear. It is recommended that the general condition of any Metal Shear be
examined before it is used. Keep your Metal Shear in good repair by adopting a program of
conscientious repair and maintenance. Have necessary repairs made by qualified service
personnel.
•Check the condition of this tool before each use.
1. Plug in the tool, and turn it on to run freely for one minute.
2. After the tool has run for one minute, turn it off and put 3-4
drops of light machine oil in the oil port on the head of the
tool. (See picture at right)
3. Also apply a small amount of oil into the space between
the arbor (13) and the shaft sleeve (15).
•To remove or replace the blades:
1. Unplug this tool before attempting any maintenance.
2. Remove the screw and washer (6,5,4) holding the upper shear
blade (12) & remove it as shown in the photo at right, using the
included hex key.
3. Remove the screw and washer (6,5,4) holding the lower shear
blade (2) & remove it as in photo below right.
4. To reinstall sharpened blades or new blades, first reinstall the
lower shear blade (2) and tighten it. Then install the upper

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shear blade (12) but leave it just loose enough to slide.
5. The upper shear blade (12) has an adjusting screw (8) and screw (6) that are used to adjust
the blade’s position. The screw (6) should be loosened with a wrench. Then the lock nut (7)
should be loosened and held using a box-end wrench (not included) and the adjusting screw
can be adjusted. The upper shear blade (12) should be adjusted for different material types
or thicknesses.
Adjusting the upper shear blade (12)
For sheet steel the formula is:
Gap = steel thickness divided by 5.
The gap will be slightly smaller for rubbery
or soft materials. The gap should be slightly
larger for hard materials.
When the two blades line up with the proper
gap, tighten and hold the adjusting screw (8)
while you tighten the lock nut (7). Then, tighten the screw (6).
6. Check that the blades will operate properly before use. The machine should always be tested
on scrap material before use on final work material.
7. If you sharpen the blades, maintain the original dimensions of a 12° angle on the upper shear
blade (12) with an 8° angle across its thickness. Maintain a 4° angle on the butt of the lower
shear blade (2) as shown in the illustration below.
REPLACING CARBON BRUSHES
After considerable use, your electric metal shear may not run as well as usual. If it starts or runs
slowly, makes a grinding noise or will not run at all, the problem may be worn carbon brushes.
1. Unplug your tool before beginning work.
2. To examine the condition of the brushes,
unscrew each brush cap (43) and remove each
brush (42).
NOTE: Record the position of each carbon brush
as you remove it, so you can replace them in
exactly the same way. Carbon brushes wear into
the armature. If they are replaced in a different
orientation, they will have to undergo additional
wear before they again fit properly.
3. If the carbon brushes (42) are severely worn
(less than 1/8” carbon remaining) they should be replaced. Also if either brush is cracked or
chipped both brushes must be replaced. If they are glazed, but more than 1/8” in length, the
glaze can be removed with a pencil eraser, and the brushes reused. If they are in good
condition and more than 1/8” remains, replace the original brushes in the exact configuration

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they were removed.
4. To replace a carbon brush (42), insert it into the brush holder (41) carbon end first, with the
spring end to the outside. Replace the brush cap (43) and tighten it by turning clock wise.
NOTE: When replacing carbon brushes (42) do not replace only one brush. Always replace
both carbon brushes at the same time.
5. After replacing the carbon brushes (42), let the tool run for 2 minutes before using it. This will
allow the carbon brushes (42) to wear into the armature.
Caution: During use, do not obstruct the motor vents in the Cover (48). Obstruction may
cause the motor to overheat during use, possibly damaging the tool.

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DIAGRAM & PARTS LIST

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For replacement parts and technical questions, please call 1-800-222-5381.

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WARNING
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, and
• 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,
such as those dust masks that are specially designed to filter out microscopic particles.
Distributed by
Northern Tool + Equipment Co., Inc.
Burnsville, Minnesota 55306
NorthernTool.com
Made in China