Ironton 46481 User manual

ULTIMATE CAR POLISHING KIT
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# 46481

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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:
The Ironton Ultimate Car Polishing Kit is used for polishing metal surfaces with included pad, It is
also able to smooth wood and metal finishes, and prepare a variety of surfaces for painting or
refinishing.
TECHNICAL SPECIFICATIONS:
Input: 120V AC, 11.0Amp
No-Load Speed: 600-3,000rpm.
Disc Size: 7 in.
Arbor Size:
Net Weight: 7.5 lbs.
Minimum Disc Rating: 3,000 rpm
Includes high-quality polishing pad, spanner wrench, rubber pad, hook-and-loop backer pad, 2
polyfoam pads, side handle, wax applicator bonnet, fake wool bonnet, 6 microfiber towels and
nylon bag.
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 anyone to operate or assemble this Car Polisher until they
have read this manual and have developed a thorough understanding of how the Car
Polisher 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.

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SAVE THESE INSTRUCTIONS
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, gasses, 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 rating 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.
•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 increased 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.
C. 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 sufficient current flow to the motor. For the proper wire gauge for your tool, see
chart.

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CHART FOR MINIMUM WIRE SIZE OF EXTENSION CORD:
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)
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 as 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. Do not carry the power tool with your finger on the switch. 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.
CAR POLISHER 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.
•Use only accessories that are recommended by the manufacturer for your model.
Accessories that are suitable for one tool may create an injury risk when used on another tool.
•Keep guards in place and in working order.
•Never leave tool running unattended.

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•Do not modify the Car Polisher 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 Car Polisher was designed.
•Always check of damaged or worn out parts before using the Car Polisher. Broken parts
will affect the Car Polisher operation. Replace or repair damaged or worn parts immediately.
•Store idle Car Polisher. When Car Polisher 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 reuse.
•DO NOT let comfort or familiarity with product (gained from repeated use) replace strict
adherence to sander/polisher safety rules. If you use this tool unsafely or incorrectly, you can
suffer serious personal injury.
•Use only accessories rated at, or above, the maximum speed as displayed on the tool’s
nameplate. Backing pads, discs, and other accessories running at speeds greater than their
rated maximum speed may fly apart and cause serious personal injury.
•Check the backing pad for cracks, damage or deformity before operation. Immediately replace
cracked, damaged, or deformed pads.
•Never use this tool with wood cutting blades or other saw blades. Using such blades on the
sander/polisher frequently kickback, causing loss of tool control resulting in personal injury.
•Hold the tool firmly using the rear handle and front mounted auxiliary handle.
•Keep hands away from rotating parts.
•Before starting the tool make sure the sanding disc or polishing bonnet is not contacting the
work piece.
•Check that the work piece is properly supported and secured in place.
•After switching off the tool the wheel will continue to rotate. Do not release your grip on the
tool until the wheel comes to a complete stop.
•Operate the tool only when it is hand held.
•This tool is not waterproof; do not use water on the work piece surface.
•Adequately ventilate your work area when performing sanding operations.
•Using this tool to sand some products, paints and woods may expose the user to dust
containing hazardous substances. Use adequate and appropriate respiratory protection.
ASSEMBLY
WARNING: ALWAYS BE SURE THE TOOL IS SWITCHED OFF AND UNPLUGGED
BEFORE ASSEMBLING PARTS, MAKING ADJUSTMENTS, ASSEMBLING OR REPLACING
SANDING DISCS OR BONNETS, OR CHECKING FUNCTION ON THE TOOL.
WARNING: TO AVOID ACCIDENTAL START, CHECK TO MAKE SURE LOCK-ON
BUTTON IS NOT ENGAGED PRIOR TO PLUGGING IN TOOL AND YOUR FINGER IS NOT
TOUCHING THE ON/OFF SWITCH.
CAUTION: For safe and reliable control, always be sure the auxiliary handle is installed
securely before operating the tool.

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An auxiliary handle is included with your sander/polisher to ease tool handling and to help maintain
tool control during operation. The gear housing is designed to allow mounting of the auxiliary handle
on either side of the tool or on top of the tool.
To install the auxiliary handle, screw the handle securely into the threaded hole on the right of left,
of the gear housing as desired.
HOOK & LOOP BACKER PAD INSTALLATION/REMOVAL
1. Unplug the sander/polisher from the power source. Failure to unplug the sander/polisher
from the power source may result in accidental tool start-up, causing possible serious
personal injury.
2. Place the tool on a flat, stable surface, with the threaded spindle facing upwards and slide
the rubber backer pad over and down the spindle, flat face up. Screw on the backer pad by
rotating it in a clockwise direction.
3. Depress the shaft lock, and then rotate backer pad clockwise until the shaft lock engages
the spindle shaft so it will no longer rotate.
4. Maintain pressure on the shaft lock, preventing the spindle shaft from rotating. Tighten the
backer pad by hand rotating the pad until snug. DO NOT OVER TIGHTEN.
5. Release the shaft lock after the clamp nut has been securely tightened.
6. To remove the rubber backing back, be sure the tool is unplugged from the power source,
engage the shaft lock and perform the installation procedure in reverse order.
FOAM POLISHING PAD INSTALLATION/REMOVAL
1. Unplug the sander/polisher and install the rubber backer pad as explained previously.
2. Inspect the hook & loop backing pad and clean off any dirt or debris that is discovered.
3. Align the foam polishing pad over the backer pad. With the pad aligned, push down on the
foam polishing pad to engage the hook & loop system. Confirm that the polishing pad is
secured over the entire pad.
4. To remove the polishing pad, pull it off the backer pad.
CAUTION: Tuck away or trim any loose attachment strings or pieces of the pad.
Loose and spinning attachment strings can entangle your fingers or snag on the workpiece.
ABRASIVE DISC REMOVAL/INSTALLATION
1. Unplug the sander/polisher from the power source. Failure to unplug the sander/polisher
from the power source may result in accidental tool start-up, causing possible serious
personal injury.
2. Install the backer pad onto the stander/polisher threaded spindle as described earlier.
3. Center the desire hook & loop grit abrasive disc over the backer pad.
4. With the disc aligned, push down on the disc to engage the hook & loop system. Confirm
that the disc is secured over the entire pad.
5. To remove the disc, pull it off the backer pad.

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OPERATION:
WARNING: ALWAYS BE SURE THE TOOL IS SWITCHED OFF AND UNPLUGGED
BEFORE ASSEMBLING PARTS, MAKING ADJUSTMENTS, ASSEMBLING OR REPLACING
SANDING DISCS, BUFFER PADS, OR CHECKING FUNCTION ON THE TOOL.
SHAFT LOCK
Never depress the shaft lock when the spindle is moving.
The shaft lock is located on the top, forward portion of the gear housing. Depress the shaft lock to
prevent the spindle from rotating when installing or removing accessories.
SWITCH OPERATION
The tool can be locked on by depressing the lock-on button and the on/off switch at the same time,
then releasing pressure on the on/off switch. The lock-on feature is to relieve fatigue on the trigger
finger only. Grip tool firmly at all times while it is running, and keep both hands away from the
Sanding/Polishing wheel.
SPEED ADJUSTMENT DIAL
The speed adjustment dial is located on top of the rear handle. In this position slightly forward of the
switch trigger, the sander/polisher’s speed is easily adjusted by the operator’s thumb on the hand
grasping the tool on the rear handle.
With the switch trigger fully depressed and the tool running, tool speed can be changed by rotating
the speed adjustment dial to a numbered setting from 1 to 6. Tool speed increases as the dial is
moved in the direction of the number 6 and lower speed is obtained as the dial is turned towards the
number 1.
To ensure operator control, the tool should always be turned “ON” with the speed adjustment dial in
the number 1 position.
CAUTION: Continuous operation of the tool at low speeds for a long time will cause the motor to
become overheated, possibly resulting in malfunction or tool failure. To cool the motor, occasionally
run the tool at high RPM under no load for short periods of time allowing the tool’s fan to cool the
motor. Be careful not to obstruct the air vents located in the forward gear housing or in the rear
handle, near the switch trigger.
The speed adjustment dial can only be rotated as far back as the number 1 or forward to the
number 6. DO NOT attempt forcing the dial beyond the numbers 1 or 6, or the speed adjustment
dial will be damaged and no longer function.
POLISHING OPERATION
WARNING: Always wear safety glasses with side shields or a full face shield during tool
operation.

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CAUTION: Never switch on the tool when it is contacting the work piece or possible
injury to the operator or damaging the work piece may occur.
Make sure the object being polished is free from burrs and other foreign matter which could
damage the polishing pads. Hold the tool firmly using both handles. With the speed adjustment
dial set at “1” turn the tool on and lightly apply the rotating foam pad to the work surface. Allow the
tool to operate freely using only the tool’s weight as pressure applied to the work surface.
Maintain the foam pad at an angle of about 15 degrees to the work surface. NEVER USE THE
POLISHING PAD FLAT TO THE WORK SURFACE. Use a long sweeping motion, back and forth,
while slowly advancing along the surface being polished. To avoid “burning” the surface or
causing finish swirls, use a low speed and do not hold the tool in one spot or use circular or spiral
like patterns. Work from the highest point on the surface downwards to avoid dust or polish from
being thrown onto the completed section.
Always follow the wax and polish manufacturer’s application and removal instructions for power
polishers. Dirty or clogged pads may be cleaned by washing in warm water with a mild detergent.
Allow the cleaned pad to dry completely before reuse.
SANDING OPERATION
WARNING: Always wear safety glasses with side shields or a full face shield during tool
operation.
The tool and sanding disc must completely stop rotating before setting the tool down after use
onto a workbench or other surface.
WARNING: Always maintain a firm grip on the tool with both hands at all times. Not
doing so may cause the operator to lose control of the tool and may lead to serious personal
injury.
Be sure the workpiece is firmly clamped or otherwise secured in place. Remove any objects that
may be struck and thrown by the rotating abrasive discs. If using an extension cord, be sure it is
held away from the work area to avoid contact with the rotating disc.
Hold the tool firmly using both handles. With the speed adjustment dial set at “1” turn the tool on
and lightly apply the abrasive disc to the work piece. Never use the sanding disc flat on the work
surface, keep the abrasive disc at an angle of about 15 degrees while working the work piece
surface.
Adjust the tool’s speed using the speed adjustment dial as you become more familiar with the
tool’s operation and the amount of work being performed by the chosen grit abrasive disc. Use
working motions as described in the earlier “Polishing” instructions. Do not allow the abrasive disc
to sand in one spot too long or an uneven or gouged surface may result.
When sanding operation is completed, remove the tool from the work surface before turning it off.

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WARNING: Use the proper size sanding disc paper only. Follow manufacturer’s
recommendations when selecting sanding paper. Larger sanding paper extending beyond the
sanding pad presents a laceration hazard and may cause snagging, tearing of the disc or kickback.
Procedures for using a lock-nut type sanding disc (with arbor hole):
1) Unplug the sander/polisher from the power source.
2) Place the tool on a flat, stable surface, with the threaded spindle facing upwards and slide
the rubber backing pad over and down the spindle, flat face up.
3) Center the sanding disc over the rubber backing pad.
4) Depress the shaft lock button located on back side of motor housing to prevent the threaded
spindle from rotating. Then place the enclosed lock nut through the center hole in the
sanding disc and onto threaded spindle and begin rotating the lock nut clockwise until finger
tight.
5) Securely tighten the lock nut with the provided spanner wrench.
6) After unplugging the tool from power source, reverse the installation procedure to remove
the sanding disc.
Procedures for using a self-adhesive sanding disc (no arbor hole):
1) Unplug the sander/polisher from the power source.
2) Place the tool on a flat, stable surface, with the threaded spindle facing upwards and slide
the rubber backing pad over and down the spindle, flat face up.
3) Depress the shaft lock button located on back side of motor housing to prevent the threaded
spindle from rotating. Then place the lock nut onto the threaded spindle and begin rotating
the lock nut counter clockwise until finger tight.
4) Securely tighten the lock nut with the provided spanner wrench.
5) Center sanding disc on rubber backing pad and press firmly.
6) After unplugging the tool from power source, reverse the installation procedure to remove
the sanding disc.
MAINTENANCE
It is recommended that the general condition of any Car Polisher be examined before it is used
Check for loose screws, misalignment or binding of moving parts, cracked or damaged parts and
discs, and damaged electrical wiring. Keep your Car Polisher in good repair by adopting a program
of conscientious repair and maintenance. Have necessary repairs made by qualified service
personnel.

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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