Ironton 45964 User manual

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BENCH GRINDER
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#s 45964, 45965, 45966

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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
This bench grinder is designed for general metal grinding and sharpening.
TECHNICAL SPECIFICATIONS
Item# Description Voltage/
Frequency Power Rated Running Speed Wheel Size
45964 6in. bench grinder with work
lamp 120V / 60Hz 1/2 HP 3560 RPM 6in. x 13/16in. x
1/2in.
45965 6in. bench
grinder 120V / 60Hz 1/2 HP 3560 RPM 6in. x 13/16in. x
1/2in
45966 8in. bench
grinder 120V / 60Hz 1/2 HP 3560RPM 8in. x 13/16in. x
5/8in.
GENERAL SAFETY RULES
WARNING: Read and understand all instructions. Failure to follow all instructions listed
below may result in electric shock, fire and/or serious injury.
CAUTION: Do not allow persons to operate or assemble this Bench Grinder until
they have read this manual and have developed a thorough understanding of how the
Bench Grinder 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 that cannot be built into
this product, but must be supplied by the operator.
SAVE THESE INSTRUCTIONS

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IMPORTANT SAFETY CONSIDERATIONS
BENCH GRINDER USE AND CARE
•Do not modify the Bench Grinder 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 Bench Grinder was designed.
•Always check of damaged or worn out parts before using the Bench Grinder. Broken
parts will affect the Bench Grinder operation. Replace or repair damaged or worn parts
immediately.
•Store idle Bench Grinder. When Bench Grinder 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.
WORK AREA
•Keep work area clean, free of clutter and well lit. Cluttered and dark work areas can cause
accidents.
•Do not use your tool where there is a risk of causing a fire or an explosion; e.g. in the
presence of flammable liquids, gases, or dust. Power tools create sparks, which may ignite the
dust or fumes.
•Keep children and bystanders away while operating a power tool. Distractions can cause
you to lose control, so visitors should remain at a safe distance from the work area.
•Be aware of all power lines, electrical circuits, water pipes and other mechanical
hazards in your work area, particularly those hazards below the work surface hidden from the
operator's view that may be unintentionally contacted and may cause personal harm or
property damage.
•Be alert of your surroundings. Using power tools in confined work areas may put you
dangerously close to cutting tools and rotating parts.
ELECTRICAL SAFETY
WARNING! Always check to ensure the power supply corresponds to the voltage on the
plate.
•Do not abuse the cord. Never carry a portable tool by its power cord, or yank tool or
extension cords from the receptacle. Keep power and extension cords away from heat, oil,
sharp edges or moving parts. Replace damaged cords immediately. Damaged cords may
cause a fire and increase the risk of electric shock.
•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 as to whether the outlet is properly grounded.
•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 doesn't fit, contact a qualified electrician to install a polarized
outlet. Do not change the plug in any way.
•Avoid body contact with grounded surfaces such as pipes, radiators, ranges, and
refrigerators. There is an increase risk of electric shock if your body is grounded.
•When operating a power tool outside, use an outdoor extension cord marked “W-A” or
“W.” These cords are rated for outdoor use and reduce the risk of electric shock.
•Extension Cord Use:
A. Use only 'Listed' extension cords. If used outdoors, they must be marked “For Outdoor
Use.” Those cords having 3-prong grounding type plugs and mating receptacles are to be
used with grounded tools.
B. Replace damaged or worn cords immediately.
Check the nameplate rating of your tool. Use of improper size or gauge of extension cord may
cause unsafe or inefficient operation of your tool. Be sure your extension cord is rated to allow

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sufficient current flow to the motor. For the proper wire gauge for your tool, see chart.
CHART FOR MINIMUM WIRE SIZE OF EXTENSION CORD:
If in doubt, use larger cord. Be sure to check voltage requirements of the tool to your incoming
power source.
•Do not expose power tools to rain or wet conditions. Water entering a power tool will increase
the risk of electric shock.
•Do not let your fingers touch the terminals of plug when installing to or removing from the
outlet.
•Ground fault circuit interrupters. If work area is not equipped with a permanently installed
Ground Fault Circuit Interrupter outlet (GFCI), use a plug-in GFCI between power tool or
extension cord and power receptacle.
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 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.
•Dress properly. Do not wear loose clothing, dangling objects, or jewelry. Keep your hair,
clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught
in moving parts. Air vents often cover moving parts and should be avoided.
•Use safety apparel and equipment. Use safety goggles or safety glasses with side shields
which comply with current national standards, or when needed, a face shield. Use a dust mask
in dusty work conditions. This applies to all persons in the work area. Also use non-skid safety
shoes, hardhat, gloves, dust collection systems, and hearing protection when appropriate.
•Avoid accidental starting. Ensure the switch is in the off position before plugging tool into
power outlet. In the event of a power failure, while a tool is being used, turn the switch off to
prevent surprise starting when power is restored.
•Do not overreach. Keep proper footing and balance at all times.
•Remove adjusting keys or wrenches before connecting to the power supply or turning
on the tool. A wrench or key that is left attached to a rotating part of the tool may result in
personal injury.
TOOL USE AND CARE
•Do not force the tool. Tools do a better and safer job when used in the manner for which they
are designed. Plan your work, and use the correct tool for the job.
•Never use a tool with a malfunctioning switch. Any power tool that cannot be controlled with
the switch is dangerous and must be repaired by an authorized service representative before
using.
•Disconnect power from tool and place the switch in the locked or off position before
servicing, adjusting, installing accessories or attachments, or storing. Such preventive
safety measures reduce the risk of starting the power tool accidentally.
•Secure work with clamps or a vise instead of your hand to hold work when practical.
This safety precaution allows for proper tool operation using both hands.
•Store idle tools. When tools are not is use, store them in a dry, secure place out of the reach
of children. Inspect tools for good working condition prior to storage and before re-use.
•Use only accessories that are recommended by the manufacturer for your model.
Accessories that may be suitable for one tool may create a risk of injury when used on another
tool.
•Keep guards in place and in working order.

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•Never leave tool running unattended.
UNPACKING
When unpacking the Bench Grinder, please check if any parts are missing or broken, please call
the distributor. Carefully remove the grinder and related hardware from the carton and examine it
thoroughly to insure it has not been damaged. This carton should contain the following items:
Description Qty
Bench Grinder . . . . . . . . . . . .. . . 1
Eye Shields . . . . . . . . . . . . . . . . . 2
Tool Rests . . . . . . . . . . . . . . . . . . 2
Spark Guards . . . . . . . . . . . . . . . .2
Manual . . . . . . . . . . . . . . . . . . . . ..1
Short bolts . . . . . . . . . . . . . . . . . . 4
Bolts . . . . . . . . . . . . . . . . . . . . . . . 2
Long bolts . . . . . . . . . . . . . . . . . . .2
Mounting Rods . . . . . . . . . . . . . . .2
Washers . . . . . . . . . . . . . . . . . … .2
Brackets . . . . . . . . . . . . . . . . …. . 2
Large Washers . . . . . . . . . . . . . . . 6
Work lamp (only for #24288) . . . ..1
ASSEMBLY
SWITCH
The switch is located on the front of the grinder near the bottom. To turn the tool ON, depress the
rocker switch at the top near the word ON. To turn the tool OFF, depress the bottom portion of the
rocker switch near the word OFF.
INSTALLING TOOL RESTS
Turn off and unplug the bench grinder. Remove the tool rests from the top portion
of the poly-foam carton liner and install them to the wheel guards as shown in the
figure. Use the bolts and washers from the plastic bag to secure them in place as
shown in Figure 1.
NOTE: There is a left and a right tool rest. Refer to Figure 1 to ensure that you
install them correctly. When in actual use, the tool rests should be adjusted to
within 1/4in. of the grinding wheel or other accessory being used.
INSTALLING THE SPARK GUARDS AND EYE SHIELD BRACKETS
Turn off and unplug the bench grinder. The spark guards are packed in
the plastic bag shipped with your grinder. Select from the bag, the two
spark guards and the two smaller bolts and washers. Install the spark
guards to the wheel guards of your grinder as shown in Figure 2. Adjust
them to within 1/16in. of the grinding wheel or other accessory being
used. NOTE: There is a left and right spark guard. Refer to Figure 2 to
ensure, that you install them correctly.

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INSTALLING THE EYE SHIELDS
Turn off and unplug the bench grinder. Remove all remaining parts from the plastic bag.
NOTE: There is a left and a right eye shield mounting rod. Examine the figure closely to ensure
that you are installing them correctly. The one pictured in Figure 3 is for the right wheel guard as
you face the front of the tool. Carefully examine Figure 3 and assemble one rod, one bracket, one
bolt and one flat washer as shown. When it has been assembled as shown in the figure, install it to
the wheel guard of the grinder.
Position it with the arm high, as shown in Figure 4. and tighten the bolt securely.
NOTE: The eye shields are identical and will fit properly on either side of the grinder. However it
may be necessary to loosen the center hex nut in order to slip the shield over the mounting rod.
After you have assembled and installed each eye shield
mounting rod to the grinder, attach the eye shields to the rods
as shown in Figure 5.
Install them in such a way that the three hex nuts on each
eye shield are on the back side, away from the operator,
when the tool is in use.
Tighten the center hex nut so that the shield can be moved,
but will be tight enough to stay in place.
Always position the eye shields between your eyes and the
grinding wheel or other accessory being used.
OPERATION
Note: The bench grinder needs to be bolted to the work surface before you start to use the tool.
Use2/5in. (10mm) bolts or screws to fix the bench grinder on your work surface.
GENERAL OPERATION
Step 1: Obtain a tray that is large enough for the workpiece to fit into, fill it with water and place it
near the Bench Grinder.
Step 2: Turn the Bench Grinder on.
Step 3: Once the GRINDING WHEEL has reached full speed, bring the workpiece up to the Wheel,
gently and without jarring.
Step 4: Use the TOOL REST to steady the workpiece.
Step 5: The workpiece will quickly become heated. Frequently quench the workpiece in water. If
the metal becomes heated so much that it gets blue-colored, it will be too soft to be useful. You
must grind off the part that is colored, cool the workpiece and start again.
SWITCH
WARNING! Be safe! Protect your eyes and wear safety goggles at all times while operating
grinder.
The switch is located on the front of the base of this grinder. Move ON/OFF switch to the ON
position to activate.
NOTE: ALWAYS turn grinder OFF via the switch in the event of a disruption in the electrical power
supply. This will safeguard operator against possible injury when power is restored.
EYESHIELDS
WARNING! Never operate grinder with eyeshields removed. Position the eyeshields so that

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manipulation of the work piece to the grinding stone is not obstructed by the shield and that the
piece of work is between the stone and the eyeshields.
SPARK DEFLECTORS
zAdjust periodically to insure that the distance between O.D. of the stone/wire wheel and the
bottom edge of the spark deflector is 1/16in. clearance.
zInsure screws are securely tightened.
TOOL RESTS
zKeep tool rests adjusted to 1/16in. clearance between O.D. of stone/wire wheel and the inside
edge of tool rests.
zAdjust the tool rests to insure the work piece to be ground will contact the wheel slightly above
center line of the shaft.
zPeriodically check adjustment to insure proper clearance is maintained.
GRINDING STONE
zTo replace grinding wheel, remove outer guard by removing 3 screws (Fig 5)
zRemove hex nut (Fig. 5) using appropriate wrench.
zRemove and replace stone with a proper size stone of choice insuring that the speed rating of
the stone is equal to or greater than the machine nameplate.
zAssemble as shown in Fig. 5. The nut should be tightened to a recommended 55 in.-lbs. of
torque. Note the orientation of the flanged washers whereby the large diameter of washer
should bear against the wheel. Under no condition should the washers be reversed.
Caution: The grinding wheels must always be checked for cracks of imperfections. This is
done with the “ring test.” Tap the wheel gently near the outer rim with the handle of a screwdriver;
you should hear a clear bell-like ringing. If a dull thud occurs do not use the wheel! This means the
wheel has been damaged and will, most likely, come apart during normal operations.
MAINTENANCE
WARNING! Make sure this tool is disconnected from its power source before attempting
any maintenance, cleaning, or inspection.
zMaintain your tools. It is recommended that the general condition of any tool be examined
before it is used. Keep your tools in good repair by adopting a program of conscientious repair
and maintenance in accordance with the recommended procedures found in this manual. If
any abnormal vibrations or noise occurs, turn the tool off immediately and have the problem
corrected before further use. Have necessary repairs made by qualified service personnel.
zKeep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting
edges are less likely to bind and are easier to control. Keep handles dry, clean, and free from
oil and grease.
zCleaning. Use only soap and a damp cloth to clean your tools. Many household cleaners are
harmful to plastics and other insulation. Never let liquid get inside a tool.

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DIAGRAM & PART LIST
For Item# 45964, the lamp illustration is below:

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Item#s 45964, 45965, and 45966 share the same parts drawing as below:

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Parts List

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WARRANTY
One-year limited warranty.
For warranty questions, call 1-800-222-5381
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 55306-6936
NorthernTool.com
Made in China