Ironton 61458 User manual

READ & SAVE THESE INSTRUCTIONS
8 Inch Benchtop 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 #61458

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Thank you very much for choosing an Ironton™product!
For future reference, please complete the owner’s record below:
Serial Number/Lot Date Code: ________________________________
Purchase Date: ____________________________________________
Save the receipt, warranty, and this manual. It is important that you read
the entire manual to become familiar with this product before you begin
using it.
This benchtop grinder is designed for certain applications only. Northern
Tool and Equipment is not responsible for issues arising from
modification or improper use of this product such as an application for
which it was not designed. We strongly recommend that this product not
be modified and/or used for any application other than that for which it
was designed.
For technical questions, please call 1-800-222-5381.

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Table of Contents
Intended Use..........................................................................................................................................4
Packaging Contents..............................................................................................................................4
Technical Specifications......................................................................................................................4
Important Safety Information...............................................................................................................4
Specific Operation Warnings...............................................................................................................6
Grounding..............................................................................................................................................6
Extension Cords....................................................................................................................................8
Main Parts of Benchtop Grinder..........................................................................................................9
Assembly Instructions..........................................................................................................................9
Before Each Use..................................................................................................................................12
Operating Instructions........................................................................................................................12
After Each Use.....................................................................................................................................14
Maintenance ........................................................................................................................................14
Troubleshooting..................................................................................................................................15
Parts Diagram......................................................................................................................................17
Parts List..............................................................................................................................................18
Replacement Parts..............................................................................................................................18
Limited Warranty.................................................................................................................................19

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Intended Use
The Ironton 8 Inch Benchtop Grinder is designed for general metal grinding and sharpening. It’s
powered by its 1/2 HP, 120V motor operating at 3560 RPM. It comes with two aluminum oxide
wheels, each with an adjustable tool rest with eye shields for safety.
Packaging Contents
Benchtop Grinder
2 Eye Shields
2 Tool Rests
Owner’s Manual
Hardware Bag
Technical Specifications
Property
Specification
Rate
110V / 60Hz
Motor
1/2 HP
Speed
3560 RPM
Wheel Size
8 x 3/4in.
Arbor
5/8in.
Important Safety Information
⚠WARNING
Read and understand all instructions. Failure to follow all instructions may result in serious injury
or property damage.
The warnings, cautions, and instructions in this manual cannot cover all possible conditions or
situations that could occur. Exercise common sense and caution when using this tool. Always be
aware of the environment and ensure that the tool is used in a safe and responsible manner.
Do not allow persons to operate or assemble the product until they have read this manual and
have developed a thorough understanding of how it works.
Do not modify this product in any way. Unauthorized modification may impair the function and/or
safety and could affect the life of the product. There are specific applications for which the product
was designed.
Use the right tool for the job. DO NOT attempt to force small equipment to do the work of larger
industrial equipment. There are certain applications for which this equipment was designed. This
product will be safer and do a better job at the capacity for which it was intended. DO NOT use
this equipment for a purpose for which it was not intended.
Industrial or commercial applications must follow OSHA requirements.

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⚠WARNING
WORK AREA SAFETY
Inspect the work area before each use. Keep work area clean, dry, free of clutter, and well-lit.
Cluttered, wet, or dark work areas can result in injury. Using the product in confined work areas
may put you dangerously close to cutting tools and rotating parts.
Do not use the product where there is a risk of causing a fire or an explosion; e.g., in the presence
of flammable liquids, gases, or dust. The product can create sparks, which may ignite the
flammable liquids, gases, or dust.
Do not allow the product to come into contact with an electrical source. The tool is not insulated
and contact will cause electrical shock.
Keep children and bystanders away from the work area while operating the tool. Do not allow
children to handle the product.
Be aware of all power lines, electrical circuits, water pipes, and other mechanical hazards in your
work area. Some of these hazards may be hidden from your view and may cause personal injury
and/or property damage if contacted.
⚠WARNING
PERSONAL SAFETY
Stay alert, watch what you are doing, and use common sense when operating the tool. Do not use
the tool while you are tired or under the influence of drugs, alcohol, or medication. A moment of
inattention while operating the tool 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 on the tool often cover moving parts and should be avoided.
Wear the proper personal protective equipment when necessary. Use ANSI Z87.1 compliant safety
goggles (not safety glasses) with side shields, or when needed, a face shield. Use a dust mask in
dusty work conditions. Also use non-skid safety shoes, hardhat, gloves, dust collection systems,
and hearing protection when appropriate. This applies to all persons in the work area.
Do not overreach. Keep proper footing and balance at all times.
Remove keys or wrenches before connecting the tool to an air supply, power supply, or turning on
the tool. A wrench or key that is left attached to a rotating part of the tool may cause personal
injury.
⚠CAUTION
BENCHTOP GRINDER USE AND CARE
Do not force the benchtop grinder. Products are safer and do a better job when used in the
manner for which they are designed. Plan your work, and use the correct product for the job.
Check for damaged parts before each use. Carefully check that the product will operate properly
and perform its intended function. Replace damaged or worn parts immediately. Never operate the

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product with a damaged part.
Do not use a product with a malfunctioning switch. Any power tool that cannot be controlled with
the power switch is dangerous and must be repaired by an authorized service representative
before using.
Disconnect the power/air supply from the product and place the switch in the locked or off position
before making any adjustments, changing accessories, or storing the tool. Such preventive safety
measures reduce the risk of starting the tool accidentally.
Store the benchtop grinder when it is not in use. Store it in a dry, secure place out of the reach of
children. Inspect the tool for good working condition prior to storage and before re-use.
Use only accessories that are recommended by the manufacturer for use with your product.
Accessories that may be suitable for one product may create a risk of injury when used with
another tool. Never use an accessory that has a lower operating speed or operating pressure than
the tool itself.
Keep guards in place and in working order. Never operate the product without the guards in place.
Do not leave the tool running unattended.
Specific Operation Warnings
⚠WARNING
Always wear eye protection.
Only use accessories rated at least equal to the maximum speed marked on the tool.
Do not modify the tool in any way.
Do not wear gloves, jewelry, or loose clothing.
Do not use a cracked or chipped grinding wheel.
Bolt down the benchtop grinder before using.
Do not use in the rain or in a damp location.
Never reach to pick up a workpiece, a piece of scrap, or anything else that is in or near the
grinding path of the wheel.
Never stand, or have any part of your body in line with the path of the wheel.
Do not over tighten wheel nut. Excessive tightening can cause the wheel to crack during
operation.
Always use the grinder’s wheel guards and safety shields.
Grounding
⚠WARNING
This machine must be grounded while in use to protect the operator from electrical shock. This
unit is equipped with an electrical cord that has an equipment grounding conductor and a
grounding plug. The plug MUST be plugged into a matching receptacle that is properly installed

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and grounded in accordance with ALL local codes and ordinances.
DO NOT MODIFY THE PROVIDED PLUG. If it will not fit the receptacle, have the proper
receptacle installed by a qualified electrician.
CHECK with a qualified electrician or service person if you do not completely understand the
grounding instructions, or if you are not sure the tool is properly grounded.
Grounded Tools: Tools with 3-Prong Plugs
Tools marked with Grounding Required have a 3-wire cord and 3-prong grounding plug. The plug
must be connected to a properly grounded outlet. If the tool should electrically malfunction or break
down, grounding provides a low resistance path to carry electricity away from the user, reducing the
risk of electric shock. (See Figure A.)
The grounding prong in the plug is connected through the green wire inside the cord to the grounding
system in the tool. The green wire in the cord must be the only wire connected to the tool’s grounding
system and must never be attached to an electrically live terminal.
Your tool must be plugged into an appropriate outlet, properly installed and grounded in accordance
with all codes and ordinances. The plug and outlet should look like those in the following illustration.
Double Insulated Tools: Tools with Two-Prong Plugs
Tools marked Double Insulated do not require grounding. They have a special double insulation
system which satisfies OSHA requirements and complies with the applicable standards of
Underwriters Laboratories, Inc., the Canadian Standard Association, and the National Electrical Code.
(See Figure B.)
Double insulated tools may be used in either of the 120 volt outlets shown in the following illustration.

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Extension Cords
⚠WARNING
USE A PROPER EXTENSION CORD. Make sure your extension cord is in good condition. When
using an extension cord, be sure to use one heavy enough to carry the current your product will
draw. An undersized cord will cause a drop in line voltage, resulting in loss of power and cause
overheating.
Be sure your extension cord is properly wired and in good condition. Always replace a damaged
extension cord or have it repaired by a qualified person before using it. Protect your extension
cords from sharp objects, excessive heat and damp or wet areas.
Grounded tools require a 3-wire extension cord. Double Insulated tools can use either a 2- or 3-
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.
The smaller the wire’s gauge number, the greater the capacity of the cord. For example, a 14-
gauge cord can carry a higher current than a 16-gauge cord. Minimum extension cord wire size is
shown in the following table:
Minimum Wire Size Of Extension Cords
Nameplate AMPS
Cord Length
25'
50'
100'
150'
0-6
18 AWG
16 AWG
16 AWG
14 AWG
6-10
18 AWG
16 AWG
14 AWG
12 AWG
10-12
16 AWG
16 AWG
14 AWG
12 AWG
12-16
14 AWG
12 AWG
NOT RECOMMENDED
When using more than one extension cord to make up the total length, make sure each cord
contains at least the minimum wire size required.
If you are using one 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 (Win
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.

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Main Parts of Benchtop Grinder
Reference
Subassembly
1
Grinding Base
2
Power Switch
3
Rest
4
Grinding Wheel
5
Eye Shield
6
Guard
Assembly Instructions
⚠WARNING
Remove the benchtop grinder from the carton and examine it carefully. Do not dispose of carton or
any packaging material until all parts are examined.
To avoid injury, ALWAYS turn the tool off and disconnect the grinder from the power outlet before
installing or changing the grinding wheel.
Always make sure your benchtop grinder is securely mounted to a workbench. Failure to do so
could result in an accident or possibly serious personal injury.
Installing Tool Rests
Turn off and unplug the benchtop 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 Fig. 1.

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Installing the Spark Guard and Eye Shield Brackets
Install the spark guards to the wheel guards of your grinder as shown in Fig. 2. Adjust them to within
1/16 in. of the grinding wheel or other accessory being used.
Note:There is a left and right spark guard. Refer to Fig. 2 to ensure that you install them correctly.
Installing the Eye Shields
Note: There is a left and a right eye shield mounting rod.
Fig. 3 is for the right wheel guard as you face the front of the tool. Carefully examine Fig. 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 Fig. 4 and tighten the bolt securely.

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Tip: 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 Fig. 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.
Mounting the Grinder to the Workbench
Before attempting to use this grinder, it must be properly mounted to a workbench or grinding stand.
Note: Bench grinders vibrate. Grinder movement during high-speed rotation may cause injury to the
operator or damage to the workpiece. Mount the grinder securely to a sturdy workbench or grinding
stand.
1. Position the grinder on the workbench. Mark the workbench through the two mounting holes
located in the grinder base (see illustration below).
2. Drill holes in the workbench at the marks. Using two long bolts, washers, lock-washers, and nuts,
as shown (not supplied), secure the grinder to the workbench.

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Before Each Use
⚠WARNING
Always check for damaged or worn parts before using the benchtop grinder.
The benchtop grinder needs to be bolted to the work surface before operating.
Test the Grinding Wheel
1. Imagine a vertical line up the center of the wheel. With a hard plastic or wood object, tap the wheel
at 45 degrees on each side of the vertical line, 1” – 2” from the wheel’s edge.
2. Rotate the wheel 180 degrees and repeat the tapping test.
3. If the wheel rings with a clear tone, the wheel is safe and may be installed. If the wheel has a dead
thud at any of the points, it is damaged and cannot be used. Replace the wheel.
Tool Rest Adjustment
Adjust the tool rest to the desired grinding angle. Keep the tool rest approximately 1/16” away from
the surface of the grinding wheel in order to provide appropriate workpiece support.
Shield Adjustment
Place the workpiece on the tool rest and fold down the eye shield. Ensure that there is adequate
clearance for the workpiece and clear line of sight for operation through the shield.
Operating Instructions
⚠WARNING
Always wear eye protection.
Only use accessories rated at least equal to the maximum speed marked on the tool.
Do not modify the tool in any way.
Do not wear gloves, jewelry, or loose clothing.

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Do not use a cracked or chipped grinding wheel.
Bolt down benchtop grinder before using.
Do not use in the rain or in a damp location.
Never reach to pick up a workpiece, a piece of scrap, or anything else that is in or near the
grinding path of the wheel.
Never stand, or have any part of your body in line with the path of the wheel.
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.
Do not over tighten wheel nut. Excessive tightening can cause the wheel to crack during
operation.
Always use the grinder’s wheel guards and safety shields.
ADJUST DISTANCE BETWEEN WHEEL AND TOOL REST to maintain 1/16 in. or less separation
as the diameter of the wheel decreases with use. The value of separation used in the marking is to
be the separation recommended by the manufacturer but shall not be more than 1/8 inch.
When starting to grind, a harsh impact can break the wheel. Use light pressure when starting to
grind; too much pressure on a cold wheel can cause the wheel to crack.
Never start the grinder when the wheel is in contact with the workpiece.
Always hold workpiece firmly against the tool rest.
1. Turn on the benchtop grinder and allow it to come up to full speed before touching the wheel.
2. Bring the workpiece up to the wheel, gently and without jarring. Use the tool rest to support the
workpiece as you steadily move the workpiece to the wheel.
3. Keep the workpiece moving across the face of the wheel so that the grinding wheel wears evenly
from side to side.

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Note:The workpiece will quickly become heated. Frequently submerge 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.
After Each Use
⚠WARNING
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.
Do not touch the benchtop grinder right after use, it will be very hot.
Maintain the Grinding Wheel
Check the surface of the grinding wheel for flatness. If the surface is uneven or grooved, dress the
wheel back to flatness.
Maintenance
⚠WARNING
Disconnect power from tool and place the switch in the locked or off position before servicing,
adjusting, installing accessories or attachments, or storing.
Use only accessories that are recommended by the manufacturer for your model.
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.
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.
Never sharpen or grind anything made of aluminum, brass, or copper.
Keep cutting tools sharp and clean.

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Maintain the benchtop grinder by adopting a program of conscientious repair and maintenance in
accordance with the following recommended procedures. It is recommended that the general
condition of any tool be examined before it is used. Keep your tool in good repair. Keep handles dry,
clean, and free from oil and grease. The following chart is based on a normal operation schedule.
Maintenance Interval
Maintenance Point
Daily before operating
1. Examine the general condition of the bench grinder.
2. Check the power cord.
3. Check the wheels for cracks.
4. Check moving parts for alignment and binding issues.
5. Adjust periodically to insure that the distance between the
stone/wire wheel and the bottom edge of the spark
arrestor is 1/16 in. clearance.
As needed
1. Dress the grinding wheels.
2. Replace grinding wheels.
3. Clean and vacuum dust from the motor housing and other
grinder parts.
Troubleshooting
Use the table below to troubleshoot problems before contacting service personnel or your local
dealer. If the problem continues after troubleshooting, call your local dealer for assistance.
Failure
Possible Cause
Corrective Action
Motor will not
start.
Low voltage.
Check power source for proper
voltage.
Open circuit in motor or loose
connections.
Have a qualified technician repair unit.
Blown fuse or breaker.
Have a qualified technician repair unit.
Motor will not
start because
fuses or circuit
breakers are
tripping or
blowing.
Short circuit in line, cord, or plug.
Inspect cord or plug for damaged
insulation and shorted wires.
Short circuit in motor or loose
connections.
Inspect all connections on motor for
loose or shorted terminals and/or worn
insulation.
Incorrect fuses or circuit breakers in
power line.
Have a qualified technician repair unit.
Motor overheats.
Motor overloaded.
Reduce load on motor.
Extension cord is too long and of
insufficient gauge (weight).
Use an extension cord of appropriate
gauge and length or plug tool directly
into outlet.
Motor stalls
(resulting in
blown fuses or
tripped circuit).
Short circuit in motor or loose
connections.
Have a qualified technician repair unit.
Low voltage.
Correct low voltage conditions (for
example: improper extension cord
length and/or gauge).
Incorrect fuses or circuit breakers in
power line.
Have a qualified technician repair unit.
Motor overload.
Reduce the load on the motor.

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Failure
Possible Cause
Corrective Action
Unit slows when
operating.
Feed rate is too great.
Reduce the rate at which the
workpiece is fed into the working area
of the tool (grinding wheel).
Wavy condition
on surface of
workpiece.
Machine vibrating.
Ensure machine is securely mounted
on a solid surface.
Workpiece not being held firmly.
Use a holding device to firmly retain
the workpiece.
Wheel face is uneven.
Dress the grinding wheel.
Wheel is too hard.
Use a softer wheel or reduce the feed
rate.
Lines on surface
of workpiece.
Impurity on surface of wheel.
Dress the grinding wheel.
Workpiece not being held tightly.
Use a holding device to more firmly
retain the workpiece.
Burning spots or
cracks in the
workpiece.
Improper type of grinding wheel.
Try wheels with a softer bond or
coarser grit.
Improper feed rate.
Slow down the rate at which the
workpiece is fed into the wheel.
Coolant required.
Add coolant.
Wheel dulls
quickly or grit
falls off.
Feed rate is too aggressive.
Decrease feed rate of workpiece into
grinding wheel.
Wheel is soft.
Select a grinding wheel with a harder
bond of material.
Bad wheel dressing.
Dress the wheel.
Defective wheel bonding.
DO NOT USE.
Wheel clogs and
workpiece shows
burn marks.
Wheel is too hard.
Select a grinding wheel with a softer
bond of material.
Feed rate is too slow.
Increase the feed rate of the
workpiece into the grinding wheel.
Bad wheel dressing.
Dress the wheel.
Coolant required.
Add coolant.

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Parts Diagram

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Parts List
Reference
Part Description
Quantity
1
Screw
1
2
Left Cover
1
3
Nut
1
4a
Outer Flange
1
4b
Inner Flange
1
5
Grinding Wheel
1
6
Screw
1
7
Left Wheel Guard
1
8
Screw
1
9
Motor End Bell
1
10
Ball Bearing
1
11
Nut
1
12
Motor Stator
1
13
Motor Case
1
14
Motor Rotor
1
15
Washer
1
16
Bolt
1
17
Left Spark Guard
1
18
Right Spark Guard
1
19
Eye Shield
1
20
Washer
1
21
Bolt
1
22
Left Adjustable Rest
1
23
Wire
1
24
Strain Relief
1
25
Plate
1
26
Terminals
1
27
Right Wheel Guard
1
28
Right Cover
1
29
Base Plate
1
30
Condenser
1
31
Screw
1
32
Pad
1
33
Base
1
34
Switch
1
35
Right Adjustable Rest
1
36
Screw
1
37
Mounting Plate
1
Replacement Parts
For replacement parts and technical questions, please call Customer Service at 1-800-222-5381.
Not all product components are available for replacement. The illustrations provided are a
convenient reference to the location and position of parts in the assembly sequence.
When ordering parts, the following information will be required: item description, item model
number, item serial number/item lot date code, and the replacement part reference number.
The distributor reserves the rights to make design changes and improvements to product lines
and manuals without notice.

Page 19 of 20
Limited Warranty
Northern Tool and Equipment Company, Inc. ("We'' or ''Us'') warrants to the original purchaser only
(''You'' or ''Your'') that the Ironton product purchased will be free from material defects in both
materials and workmanship, normal wear and tear excepted, for a period of one year from date of
purchase. The foregoing warranty is valid only if the installation and use of the product is strictly in
accordance with product instructions. There are no other warranties, express or implied, including the
warranty of merchantability or fitness for a particular purpose. If the product does not comply with this
limited warranty, Your sole and exclusive remedy is that We will, at our sole option and within a
commercially reasonable time, either replace the product or product component without charge to You
or refund the purchase price (less shipping). This limited warranty is not transferable.
Limitations on the Warranty
This limited warranty does not cover: (a) normal wear and tear; (b) damage through abuse, neglect,
misuse, or as a result of any accident or in any other manner; (c) damage from misapplication,
overloading, or improper installation; (d) improper maintenance and repair; and (e) product alteration
in any manner by anyone other than Us, with the sole exception of alterations made pursuant to
product instructions and in a workmanlike manner.
Obligations of Purchaser
You must retain Your product purchase receipt to verify date of purchase and that You are the original
purchaser. To make a warranty claim, contact Us at 1-800-222-5381, identify the product by make
and model number, and follow the claim instructions that will be provided. The product and the
purchase receipt must be provided to Us in order to process Your warranty claim. Any returned
product that is replaced or refunded by Us becomes our property. You will be responsible for return
shipping costs or costs related to Your return visit to a retail store.
Remedy Limits
Product replacement or a refund of the purchase price is Your sole remedy under this limited warranty
or any other warranty related to the product. We shall not be liable for: service or labor charges or
damage to Your property incurred in removing or replacing the product; any damages, including,
without limitation, damages to tangible personal property or personal injury, related to Your improper
use, installation, or maintenance of the product or product component; or any indirect, incidental or
consequential damages of any kind for any reason.
Assumption of Risk
You acknowledge and agree that any use of the product for any purpose other than the specified
use(s) stated in the product instructions is at Your own risk.
Governing Law
This limited warranty gives You specific legal rights, and You also may have other rights which vary
from state to state. Some states do not allow limitations or exclusions on implied warranties or
incidental or consequential damages, so the above limitations may not apply to You. This limited
warranty is governed by the laws of the State of Minnesota, without regard to rules pertaining to
conflicts of law. The state courts located in Dakota County, Minnesota shall have exclusive jurisdiction
for any disputes relating to this warranty.

Page 20 of 20
Distributed by:
Northern Tool & Equipment Company, Inc.
Burnsville, Minnesota 55306
www.northerntool.com
Made in China