Ironton 45967 User manual

PORTABLE BAND SAW
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#
45967

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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 Portable Band Saw features a needle bearing mounted spindle and 3 bearing blade guides
for smooth, accurate cuts. Light weight for easy transport to the job site.
TECHNICAL SPECIFICATIONS
ITEM DESCRIPTION
Voltage 120V / 60Hz
Power Input 660W
Blade Speed 230 FPM (feet per minute)
Max. Cutting Capacity Round Pipe : 4-17/32"
Square Pipe : 4-17/32" x 4-17/32"
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 Portable Band Saw until
they have read this manual and have developed a thorough understanding of how the
Portable Band Saw 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
IMPORTANT SAFETY CONSIDERATIONS
Metalworking can be dangerous if safe and proper operation procedures are not followed. As with
all machinery, there are certain hazards involved with the operation of the product. Using the
machine with respect and caution will considerably lessen the possibility of personal injury.
However, if normal safety precautions are overlooked or ignored, personal injury to the operator
may result. Safety equipment such as guards, push sticks, hold–downs feather boards, goggles,
dust masks and hearing protection can reduce your potential for injury. But even the best guard
won't make up for poor judgment, carelessness or inattention. Always use common sense and
exercise caution in the workshop. If a procedure feels dangerous, don't try it. Figure out an alternate
procedure that is safe REMEMBER: Your personal safety is your responsibility.
This machine was designed for certain applications only. We strongly recommend that 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 seller to determine if it can or should be performed by the product.
WARNING: FAILURE TO FOLLOW THESE RULES MAY RESULT IN SERIOUS
PERSONAL INJURY. SAVE THESE INSTRUCTIONS.
1. FOR YOUR OWN SAFETY, READ THIS INSTRUCTION MANUAL BEFORE OPERATING
THE TOOL. Learn the tool applications and limitations as well as the specific hazards
particular to it.
2. KEEP GUARDS IN PLACE and in working order.
3. ALWAYS WEAR EYE PROTECTION.
4. REMOVE ADJUSTING KEYS AND WRENCHES. Make a habit of checking to see that all
adjusting tools are removed from the tool before turning it on.
5. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents.
6. DON'T USE IN DANGEROUS ENVIRONMENT. Don't use power tools in damp or wet
locations, or expose them to rain. Keep work area dry.
7. KEEP CHILDREN AND VISITORS AWAY. All children and visitors should be kept a safe
distance from the work area.
8. MAKE WORKSHOP CHILDPROOF. Use padlocks, master switches, or by removing starter
keys.
9. DON'T FORCE TOOL. It will do the job better and be safer at the rate for which it was
designed.
10. USE CORRECT TOOL. Don't force tool or attachment to do a job for which it was not
designed.
11. WEAR PROPER APPAREL. No loose clothing, gloves, neckties, rings, bracelets, or other
jewelry to get caught in moving parts. Nonskid foot wear is recommended. Wear protective
hair covering to contain long hair.
12. ALWAYS USE SAFETY GLASSES. Wear safety glasses (must comply with ANSIZ87.1)
Everyday eyeglasses are not impact resistant. Also use face or dust mask if cutting
operation is dusty.
13. SECURE WORK. Use clamps or a vise to hold work, when practical use both hands to

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operate the tool.
14. DON'T OVERREACH. Keep proper footing and balance at all times.
15. MAINTAIN TOOLS IN TOP CONDITION. Keep tools sharp and clean for best and safest
performance. Follow instructions for lubricating and changing accessories.
16. DISCONNECT TOOLS before servicing and when changing accessories such as blades,
bite cutters, etc.
17. USE RECOMMENDED ACCESSORIES. The use of accessories or attachments not
recommended by the seller may cause hazards or risk of injury.
18. REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure switch is in "OFF"
position before plugging in power cord.
19. NEVER STAND ON TOOL. Serious injury could occur if the tool is tipped or if the cutting
tool is accidentally contacted.
20. CHECK DAMAGED PARTS. Before further use of the tool, a guard or other part that is
damaged should be carefully checked to ensure that it will operate properly and perform its
intended function. Check for alignment of moving parts, mounting, and any other condition
that may affect its operation. A guard or other part that is damaged should be properly
repaired of replaced.
21. DIRECTION OF FEED. Feed work into a blade or cutter against the direction of rotation of
the blade or cutter only.
22. NEVER LEAVE TOOL RUNNING UNATTENDED. TURN POWER OFF. Don't leave tool
until it comes to a complete stop.
23. DRUGS, ALCOHOL MEDICATION. Do not operate tool while under the influence of drugs,
alcohol or any medication.
24. MAKE SURE TOOL IS DISCONNECTED FROM POWER SUPPLY. While motor is being
mounted, connected or reconnected.
25. WARNING: The fragments generated by certain metal and metal products can be
injurious to your health. Always operate machinery in well-ventilated areas and provide for
proper removal of fragments.
ADDITIONAL SAFETY RULES FOR PORTABLE BAND SAW
•Do not operate your portable band saw until it is completely assembled and installed according
to the instructions.
•If you are not thoroughly familiar with the operation of portable band saws, obtain advice from
your supervisor, instructor or other qualified person.
•Firm grip and proper balance must be maintained during operation.
•The Portable Band Saw cannot be used in wet conditions.
•Make sure blade is properly tensioned before operating saw.
•To avoid blade breakage, always adjust blade tension correctly.
•Make sure the blade turns in correct direction before use.
•Do not cut material that is too small to be safely supported.
•Avoid awkward hand positions where a sudden slip could cause a hand to move into the blade.
•Always keep hands and fingers away from blade
•Do not use dull or bent blades
•Do not attempt to cut material that is not securely fastened or clamped.
•Do not attempt to cut material too fast while cutting.
•Never start the portable band saw with the stock pressed against the blade.
•When cutting a large work-piece make sure the material is in a safe cutting position.

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•Never perform layout, assembly or set-up work on the table while the saw is operating.
•Should any part of your portable band saw be missing or damaged, or fail in any way or to
perform properly, shut off switch and remove plug from power supply outlet. Replace missing,
damaged or failed parts before resuming operation.
PORTABLE BAND SAW USE AND CARE
•Do not modify the Portable Band Saw 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 Portable Band Saw was designed.
•Always check of damaged or worn out parts before using the Portable Band Saw. Broken parts
will affect the Portable Band Saw operation. Replace or repair damaged or worn parts
immediately.
•Store idle Portable Band Saw. When the Portable Band Saw 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.
READ ALL INSTRUCTIONS BEFORE USING THIS PRODUCT!
WORK AREA
To avoid risk of personal injury, equipment damage, fire and shock, make sure your WORK AREA
is:
•Free of damp, wet or rainy conditions.
•Free of flammable gases or liquids.
•Childproof: use padlocks and master switches when not in use.
•Clean and uncluttered.
•Well ventilated and well lit.
THE OPERATOR
1. COMMON SENSE AND CAUTION ARE FACTORS WHICH CANNOT BE BUILT INTO ANY
PRODUCT.THESE FACTORS MUST BE SUPPLIED BY THE OPERATOR.
2. Prevent body contact with grounded surfaces such as pipes or radiators.
3. Stay alert; never operate equipment if you are tired.
4. Do not operate the product if under the influence of alcohol or drugs. Read warning labels on
prescriptions to determine if your judgment/reflexes might be impaired.
5. Do not wear loose clothing or jewelry as they can be caught in moving parts.
6. Non-skid footwear is recommended.
7. Wear restrictive hair covering to contain long hair.
8. Use eye and ear protection. Always wear:
•ANSI approved dust mask or respirator when working around metal, wood and chemical
dusts and mists.
•A full face shield if you are producing metal or wood filings
•Ear protectors
9. Maintain proper footing and balance at all times.
10. Do not reach over or across running machines.

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11. Always check that adjusting keys and wrenches are removed from the tool or machine work
surface before plugging it in.
BEFORE OPERATING
1. Know the machine. Learn its applications and limitations, as well as the specific potential
hazards.
2. Check for damage; if part of the machine is damaged, it should be carefully inspected to ensure
that it can perform its intended function correctly. If in doubt, the part should be replaced.
3. Be sure the switch is OFF before plugging in the tool.
4. Make sure tool has been cleaned and properly lubricated.
5. Check for damaged parts. Before using any tool, any part that appears damaged should be
carefully checked to determine that it will operate properly and perform its intended function.
6. Check for alignment and binding of all moving parts, broken parts or mounting fixtures and any
other condition that may affect proper operation. Any part that is damaged should be properly
repaired or replaced by a qualified technician.
7. Do not use the tool if any switch does not turn off and on properly.
OPERATION
1. Never force the tool or attachment to do the work of a larger industrial tool. It is designed to do
the job at the rate for which it was intended.
2. Always unplug the cord by the plug. Never yank the cord out of the wall.
3. Always turn off the machine before unplugging. With normal use, the motor housing may get hot.
4. Make all adjustments to the machine with the power OFF.
5. Never leave the band saw unattended while it is running.
6. When turning off the machine, never leave the band saw until it has come to a complete stop.
7. Make every effort to prevent snagging by exercising special care when working corners, sharp
edges, ragged welds, etc.
8. Do not use a blade that is not in accordance with specified sizes.
9. Never carry the tool by the cord.
10. Don't pour water or coolant on blade when cutting.
11. Make sure to secure material so it does not move during operation.
12. Cutting material can get extremely hot during operation.
IF THERE IS ANY QUESTION ABOUT A CONDITION BEING SAFE OR UNSAFE, DO NOT
OPERATE THE TOOL
How to Cut (See Figures A&B)
1. Apply saw blade to Work piece at a right angle.
(See Figures A)
2. Apply guide bar to work piece before switching on.
3. When you start to cut, tilt the unit so the blade is vertical.
(See Figures B)
4. When the switch is turned on, the blade will begin to turn counter
clockwise and cutting begins.
5. While cutting, it is not necessary to force the cut or lean on band saw.
Figure B

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Fi
g
ures E
Cut the material with the weight of the unit only (twisting the blade during cutting could result in
damage to the blade or the tool.)
6. When the cutting operation is close to ending, finish the cutting by slightly raising the unit.
Switch Operation (See Figure C)
1. Before plugging in, turn the switch to the on position to
confirm that the switch returns to its original position when
released.
2. When the trigger is pulled the switch is on. When the
trigger is released, the switch is off.
3. When the trigger is pulled and the switch is on,
pushing the lock button will cause the motor to continuously
run.
4. To disengage the lock button, pull the trigger again and release the lock button. The switch will
turn off and the motor will stop.
How to Change Saw Blade
CAUTION: Before removing or installing blade, unplug and switch off the tool, installing the Blade
1. Wipe-off oil and debris on saw blade with clean cloth.
2. Turn tension lever to "LOOSE" position.
3. Turn over the unit and install the blade from the "1" position shown in Figure E.
4. Insert the blade into one blade guide over one end of the frame.
5. Insert the blade into the other blade guide until it reaches the bearing that supports the back of
the blade
6. While holding the blade so that it does not fall off the guide, put the blades on as shown in 2&3
in Figure E.
7. Turn tension lever completely to "TIGHT" position until the blade is taut.
8. Plug in and switch on. Follow arrow from blade and then run the machine for a few seconds to
ensure that the blade steadily runs around the wheels.
9. Eye protection should be worn at all times.
To Remove the Blade
1. Wipe off any oil or debris on saw blade with a clean cloth.
2. Turn tension lever to "LOOSE" position.
3. Turn over the unit and remove the blade from the position shown in Figure E.
4. Remove the blade by completing steps 4-7 of above "How to change Saw Blade" in reverse
order.

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MAINTENANCE
•MAINTAIN YOUR PORTABLE BAND SAW. It is recommended that the general condition of
any Portable Band Saw be examined before it is used. Keep your Portable Band Saw in good
repair by adopting a program of conscientious repair and maintenance. Have necessary repairs
made by qualified service personnel.
•CLEANING: Regularly clean the work surface with a dry brush or clean cloth. Wipe any oil or
debris off saw blade. Always keep the motor area clean of debris.
•MOTOR LUBRICATION: No lubrication is required. All of the bearings in this tool are lubricated
with a sufficient amount of high grade lubricant for the life of the machine under normal
operating conditions.
•POWER CORD: Inspect the power cord periodically and if damaged, have it repaired by an
authorized technician.
•REPLACEMENT PARTS: Replace saw blades at the first sign of slippage or dulling. When
servicing, use only identical replacement parts. Use of any other parts will void the warranty.
•STORAGE: When the tool is out of use for a long period of time, remove the saw blade.
KEEP OUT OF REACH OF CHILDREN

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DIAGRAM

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PARTS LIST
No. Name qty No. Name qty
1 Cross Pan head Screw M4x10 4 35 Carbon Brush Cap 2
Elastic Washer D4 4 Brush Spring 2
Flat Washer D4 4 Carbon Brush 2
2 Cover 1 36 Carbon Brush Holder 2
3 Saw Blade 1140x13x0.5mm 1 Holder Copper 2
4 Cross Sunk Head Screw 2 37 Brush Cap 2
5 Cross Pan Head Screw M5x12 1 38 Cross Pan Head Screw ST3.9×16 2
5+1 Saw Blade Guard 1 39 Switch 1
6 Cross Pan Head Screw M5x16 4 40 Cross Pan Head Screw M5×25 3
Elastic Washer D5 4 Elastic Washer D5 3
Flat Washer D5 4 Flast Washer D5 3
7 Collar 4 41 Upper Handle Housing 1
8 Fitting Plate 1 42 Cross Pan Head Screw ST3.9×12 2
9 Spring 2 43 Fixing Plate 1
10 Yoke 1 44 Lower Handle Housing 1
11 Right Blade Guide 1 45 Hex Nut M5 3
12 Frame 1 46 Cross Pan Head Screw M5×16 2
13 Instruction Sign 1 Elastic Washer D5 2
14 Bushing II 1 Flat Washer D5 2
15 Flat Washer 1 47 Power Supply Cord 1
16 Tension Handle 1 48 Cord Guard 1
Tension Handle Embedding Part 1 49 Stator Assembly 1
17 Cross Sunk Head Screw M6x30 1 50 Cross Screw 4x55 2
18 Grip Handle 1 51 Rubber Bearing Holder 1
19 Allen Head Bolt M6×30 2 52 Bearing 608 Φ8×Φ22×7 1
Elastic Washer 2 53 Rotor Assembly 1
Flat Washer 2 54 Bearing 629 Φ9×Φ26×8 1
20 Guide Bar 1 55 Baffle 1
21 Cross Pan Head Screw M5x20 2 56 Front Bracket 1
Elastic Washer 2 57 Rubber Ring Gear Assembly 2
Flat Washer 2 Rubber Ring Gear 2
22 Z5 Gear Shaft 1 58 Bushing I 2
23 Z4 Gear 1 59 Embedding Assembly 1
24 Bearing 6201 Φ12×Φ32×10 1 60 Bearing 619/6 φ6×φ15×5 3
25 Stop Ring 1 61 Left Blade Guide 1
26 Bushing III 1 62 Pin B6x16 2
27 Bearing 629 Φ9×Φ26×8 1 Cross Pan Head Screw M5x25 4
28 Pin 2 Elastic Washer D5 4
29 Z2 Gear 1 63 Flat Washer D5 4
30 Needle Bearing HK0810 Φ8×Φ12×10 1 64 Bearing φ6×φ15×10 4
31 Z3 Gear Shaft 1 65 Fixing Screw 4
32 Bearing 608 Φ8×Φ22×7 1 66 Square 1
33 Motor Housing 1 67 Hex key M6 1
34 Allen Head Bolt M6x50 4
Elastic Washer D6 4
Flast Washer D6 4
For replacement parts and technical questions, please call 1-800-222-5381.
WARRANTY
1-year limited warranty
Distributed by
Northern Tool + Equipment Co., Inc.
Burnsville, Minnesota 55306
NorthernTool.com
Made in China