Ironton 46682 User manual

TOE-KICK 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# 46682

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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 6.8A 3-3/8 in. blade Toe-Kick saw will cut flush up to a wall or baseboard so you don’t have to
move cabinets to remove the flooring underneath. The saw has a dual handle to provide steady
control and features an automatic guard return. The blade is carbide tipped for easy and precise
cutting.
TECHNICAL SPECIFICATIONS
Electrical Rating
120VAC / 60Hz / 6.8A
No Load Speed
4500 RPM
Maximum Blade
Diameter
3-3/8in.
Arbor:
5/8in. round
Saw Blade Required
3-3/8in., rated for 4500 RPM
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 Toe-Kick Saw until they
have read this manual and have developed a thorough understanding of how the Toe-Kick
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
WARNING: Read all safety warnings and all instructions. Failure to follow the
warnings and instructions may result in electric shock, fire and/or serious injury. Save all
warnings and instructions for future reference. The term “power tool” in the warnings refers
to your corded power tool.
1. Work area safety
a. Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b. 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.
c. Keep children and bystanders away while operating a power tool. Distractions can cause you to
lose control.
2. Electrical safety
a. Power tool plugs must match the outlet. Never modify the plug in any way. Unmodified plugs
and matching outlets will reduce risk of electric shock.
b. Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and
refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
c. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase
the risk of electric shock.
d. Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool.
Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords
increase the risk of electric shock.
e. When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of
a cord suitable for outdoor use reduces the risk of electric shock.
f. If operating a power tool in a damp location is unavoidable, use a residual current device (RCD)
protected supply. Use of an RCD reduces the risk of electric shock.
3. Personal safety
a. 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.
b. Use personal protective equipment. Always wear eye protection. Protective equipment such as
dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions
will reduce personal injuries.
c. Prevent unintentional starting. Ensure the switch is in the off-position before connecting to
power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your
finger on the switch or energizing power tools that have the switch on invites accidents.
d. Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left
attached to a rotating part of the power tool may result in personal injury.

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e. Do not overreach. Keep proper footing and balance at all times. This enables better control of
the power tool in unexpected situations.
f. Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves away
from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
g. If devices are provided for the connection of dust extraction and collection facilities, ensure
these are connected and properly used. Use of dust collection can reduce dust-related hazards.
h. Not for use by children or people with reduced mental capacity.
4. Power tool use and care
a. Do not force the power tool. Use the correct power tool for your application. The correct power
tool will do the job better and safer at the rate for which it was designed.
b. Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot
be controlled with the switch is dangerous and must be repaired.
c. Disconnect the plug from the power source and/or the battery pack from the power tool before
making any adjustments, changing accessories, or storing power tools. Such preventive safety
measures reduce the risk of starting the power tool accidentally.
d. Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges
are less likely to bind and are easier to control.
e. Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking
into account the working conditions and the work to be performed. Use of the power tool for
operations different from those intended could result in a hazardous situation.
f. Inspect tool before each use. Do not use if any parts are missing or damaged.
5. Service
a. Have your power tool serviced by a qualified repair person using only identical replacement
parts. This will ensure that the safety of the power tool is maintained.
TOE-KICK SAW USE AND CARE
•Do not modify the Toe-Kick 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 Toe-Kick Saw was designed.
•Always check of damaged or worn out parts before using the Toe-Kick Saw. Broken parts
will affect the Toe-Kick Saw operation. Replace or repair damaged or worn parts immediately.
•Store idle Toe-Kick Saw. When Toe-Kick 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.
•DANGER: Keep hands away from cutting area and the blade. If both hands are holding the
saw, they cannot be cut by the blade.
•Do not reach underneath the workpiece. The guard cannot protect you from the blade below
the workpiece.
•Adjust the cutting depth to the thickness of the workpiece. Less than a full tooth of the
blade teeth should be visible below the workpiece.
•Never hold piece being cut in your hands or across your leg. Secure the workpiece to a
stable platform. It is important to support the work properly to minimize body exposure, blade
binding, or loss of control.

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•Hold power tool by insulated gripping surfaces when performing an operation where the
cutting tool may contact hidden wiring or its own cord. Contact with a ″live″wire will also
make exposed metal parts of the power tool ″live″and shock the operator.
•When ripping, always use a rip fence or straight edge guide. This improves the accuracy of
cut and reduces the chance of blade binding.
•Always use blades with correct size and shape (diamond versus round) of arbor holes.
This saw uses 3 3/8in. blades rated for 4500 RPM. Blades that do not match the mounting
hardware of the saw will run eccentrically, causing loss of control.
•Never use damaged or incorrect blade washers or bolt. The blade washers and bolt were
specially designed for your saw, for optimum performance and safety of operation. Contact the
manufacturer for replacement parts and service.
•Causes and Operator Prevention of Kickback:
Kickback is a sudden reaction to a pinched, bound or misaligned saw blade, causing an
uncontrolled saw to lift up and out of the workpiece toward the operator;
When the blade is pinched or bound tightly by the kerf closing down, the blade stalls and the
motor reaction drives the unit rapidly back toward the operator;
If the blade becomes twisted or misaligned in the cut, the teeth at the back edge of the blade
can dig into the top surface of the wood causing the blade to climb out of the kerf and jump
back toward the operator.
Kickback is the result of saw misuse and/or incorrect operating procedures or conditions and
can be avoided by taking proper precautions as given below:
a. Maintain a firm grip on the saw and position your arms to resist kickback forces.
Position your body to either side of the blade, but not in line with the blade. Kickback
could cause the saw to jump backwards, but kickback forces can be controlled by the operator,
if proper precautions are taken.
b. When blade is binding, or when interrupting a cut for any reason, release the Trigger
and hold the saw motionless in the material until the blade comes to a complete stop.
Never attempt to remove the saw from the work or pull the saw backward while the blade
is in motion or kickback may occur. Investigate and take corrective actions to eliminate the
cause of blade binding.
c. When restarting a saw in the workpiece, center the saw blade in the kerf and check
that saw teeth are not engaged into the material. If saw blade is binding, it may walk up or
kickback from the workpiece as the saw is restarted.
d. Support large panels to minimize the risk of blade pinching and kickback. Large panels
tend to sag under their own weight. Supports must be placed under the panel on both sides,
near the line of cut and near the edge of the panel.
e. Do not use dull or damaged blades. Unsharpened or improperly set blades produce
narrow kerf causing excessive friction, blade binding and kickback.
f. Blade depth and bevel adjusting locking levers must be tight and secure before making
cut. If blade adjustment shifts while cutting, it may cause binding and kickback.
g. Use extra caution when making a ″plunge cut″into existing walls or other blind areas.
The protruding blade may cut objects that can cause kickback.

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•Check guard for proper closing before each use. Do not operate the saw if guard does
not move freely and enclose the blade instantly. Never clamp or tie the guard with the
blade exposed. If saw is accidentally dropped, guard may be bent. Check to make sure that
guard moves freely and does not touch the blade or any other part, in all angles and depths of
cut.
•Check the operation and condition of the guard return spring. If the guard and the spring
are not operating properly, they must be serviced before use. Guard may operate
sluggishly due to damaged parts, gummy deposits, or a build-up of debris.
•Assure that the guide plate of the saw will not shift while performing the ″plunge cut″
when the blade bevel setting is not at 90°. Blade shifting sideways will cause binding and
likely kick back.
•Always observe that the guard is covering the blade before placing saw down on bench
or floor. An unprotected, coasting blade will cause the saw to walk backwards, cutting
whatever is in its path. Be aware of the time it takes for the blade to stop after Trigger is
released.
•DO NOT USE THIS SAW WITH THE SAW HELD UPSIDE DOWN IN A VISE. The saw is not
designed for such use and cannot be used safely in that position.
•Do not use to cut logs, tree limbs, or uneven lumber.
•Wet lumber, green (unseasoned) lumber, and pressure treated lumber all have an
increased potential for kickback and should only be cut with a blade for cutting that
lumber type. Wear a NIOSH-approved respirator and have appropriate ventilation
whenever cutting pressure treated lumber.
•Do not use blades made from high-speed steel, abrasive blades, metal-cutting blades or
masonry-cutting blades. The guards of this saw are not designed to protect against the failure
of such blades.
•Place the larger portion of the saw base on the larger, supported part of the workpiece.
This will help maintain balance and control while the cut is completed.
•Blades must be rated to at least the maximum speed marked on the tool.
•Maintain labels and nameplates on the tool. These carry important safety information. If
unreadable or missing, contact the distributor for a replacement.
•Avoid unintentional starting. Prepare to begin work before turning on the tool.
•Do not lay the tool down until it has come to a complete stop. Moving parts can grab the surface
and pull the tool out of your control.
•When using a handheld power tool, maintain a firm grip on the tool with both hands to resist
starting torque.
•Do not depress the spindle lock when starting or during operation.
•Do not 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.
•This product is not a toy. Keep it out of reach of children.

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•People with pacemakers should consult their physician(s) before use. Electromagnetic fields in
close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure.
In addition, people with pacemakers should avoid operating alone.
•Do not use with Trigger locked on.
•Properly maintain and inspect to avoid electrical shock.
•Properly ground power cord. Ground Fault Circuit Interrupter (GFCI) should also be
implemented – it prevents sustained electrical shock.
Vibration Safety
This tool vibrates during use. Repeated or longterm exposure to vibration may cause temporary or
permanent physical injury, particularly to the hands, arms and shoulders. To reduce the risk of
vibration-related injury:
1. Anyone using vibrating tools regularly or for an extended period should first be examined by a
doctor and then have regular medical check-ups to ensure medical problems are not being
caused or worsened from use. Pregnant women or people who have impaired blood circulation
to the hand, past hand injuries, nervous system disorders, diabetes, or Raynaud’s Disease
should not use this tool. If you feel any symptoms related to vibration (such as tingling,
numbness, and white or blue fingers), seek medical advice as soon as possible.
2. Do not smoke during use. Nicotine reduces the blood supply to the hands and fingers,
increasing the risk of vibration-related injury.
3. Wear suitable gloves to reduce the vibration effects on the user.
4. Use tools with the lowest vibration when there is a choice.
5. Include vibration-free periods each day of work.
6. Grip tool as lightly as possible (while still keeping safe control of it). Let the tool do the work.
7. To reduce vibration, maintain the tool as explained in this manual. If any abnormal vibration
occurs, stop use immediately.
WARNING: TO PREVENT ELECTRICSHOCK AND DEATH FROM INCORRECT
GROUNDING WIRE CONNECTION. Do not use the tool if the power cord or plug is damaged. If
damaged, have it repaired by a service facility before use. If the plug will not fit the outlet, have a
proper outlet installed by a qualified electrician.

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Double Insulated Tools: Tools with Two Prong Plugs
1. 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.
2. Double insulated tools may be used in either of the 120 volt outlets shown in the preceding
illustration. (See Outlets for 2-Prong Plug.)
Extension Cords
1. Double Insulated tools can use either a two or three wire extension cord.
2. 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 Table A.)
3. 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 Table A.)
4. 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. (See Table A.)
5. 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. (See Table A.)
6. 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.
7. Make sure the 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.
8. Protect the extension cords from sharp objects, excessive heat, and damp or wet areas.

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Symbology

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ASSEMBLY
TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION: Make sure that the
Trigger is in the off position and unplug the tool from its electrical outlet before performing
any procedure in this section.
TO PREVENT SERIOUS INJURY FROM FLYING FRAGMENTS: Do not use blades made from
high-speed steel, abrasive blades, or metal- or masonry-cutting blades. The guards of this
saw are not designed to protect against the failure of such blades.
Mounting and Removing Blade
1. Use only a 3-3/8 inch Saw Blade rated to at least 4500 RPM.
2. Hold in the Spindle Lock Button. Rotate the Saw Blade until the spindle Shaft Lock catches and
the blade stops.
3. Remove the Blade Bolt, turning it COUNTERCLOCKWISE. See Figure A: Blade Installation,
below.

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4. Remove the Blade.
5. Install the new blade over the Arbor Adaptor Plate. Make sure the Arbor Adapter Plate is
properly seated on the Shaft. Guide the Saw Blade onto the pins of the Arbor Adaptor Plate.
The Saw Blade teeth at the bottom of the Saw Blade should be pointing toward the front of the
Saw.
6. Hold the Spindle Lock Button while using the Hex Wrench to replace the Blade Bolt, turning it
clockwise.
Adjusting Depth
7. Set the Base flat against the edge of the workpiece.
8. Twist Depth Adjustment around guard Base to adjust depth of cut.
WARNING: To reduce the risk of serious injury, adjust the depth of cut to just barely clear
the workpiece and remove shavings.
Workpiece and Work Area Setup
1. Workpiece selection:
a. Workpiece must be free of foreign objects and loose knots.
b. Do not use to cut logs, tree limbs, or uneven lumber.
c. Wet lumber, green (unseasoned) lumber, and pressure treated lumber all have an increased
potential for kickback and should only be cut with a blade designed for cutting that lumber.
Wear a NIOSH-approved respirator and have appropriate ventilation whenever cutting pressure
treated lumber.
2. Designate a work area that is clean and well lit. The work area must not allow access by
children or pets to prevent distraction and injury.

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3. Route the power cord along a safe route to reach the work area without creating a tripping
hazard or exposing the power cord to possible damage. The power cord must reach the work
area with enough extra length to allow free movement while working.
4. There must not be objects, such as utility lines, nearby that will present a hazard while working.
This is especially critical for plunge cuts.
OPERATION
1. Make sure that the Trigger is in the off position, then plug in the tool.
2. Make sure that all guards are in place and in proper working order before operation.
3. Insert the Saw at an angle, then lower it to the floor surface.
4. Grip handles firmly.
5. Press in (and hold) the safety button with your thumb, and at the same time, squeeze the
Trigger with your index finger.
6. When the motor starts turning, release the safety button. As the motor reaches full speed, begin
to move the saw slowly forward and away from your body to complete the cut. If a loud grinding
noise is heard, the saw blade is contacting the cement foundation. Immediately raise the saw
blade.
7. CAUTION: never pull the saw backwards since the saw blade will climb out of the cut
and kickback will occur.
8. When the flush cut is complete, release the trigger and hold the saw in place until the saw blade
comes to a complete stop. Unplug the power cord from the electrical outlet.
9. To prevent accidents, turn off the tool and unplug it after use. Clean, then store the tool indoors
out of children’s reach.
MAINTENANCE
•Maintain your Toe-Kick Saw. It is recommended that the general condition of any Toe-Kick
Saw be examined before it is used. Keep your Toe-Kick Saw in good repair by adopting a
program of conscientious repair and maintenance. Have necessary repairs made by qualified
service personnel.
•BEFORE EACH USE, inspect the general condition of the tool. Check for:
. loose hardware, misalignment or binding of moving parts, damaged cord/electrical wiring,
. cracked or broken parts, and any other condition that may affect its safe operation.
.
•CARBON BRUSH MAINTENANCE. The carbon brushes may require maintenance when the
motor performance of the tool decreases or stops working completely. To maintain the brushes:
•a. Remove the Carbon Brush Cover on each side of the motor housing.

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. b. Remove the carbon brushes from the housing. Keep track of which orientation the old
carbon brushes were in to prevent needless wear if they will be reinstalled.
. c. If either carbon brush is worn down by more than 1/2, replace them both.
. d. To clean old carbon brushes before reusing them, rub the contact areas with a pencil eraser.
. e. Reinsert the old carbon brushes in the same orientation to reduce wear.
. f. When installing, make sure the carbon portions of the brushes contact the motor armature,
and that the springs face away from the motor. Also, make sure the springs operate freely.
. g. Replace the Carbon Brush Covers. Do not overtighten.
.
Note: New carbon brushes tend to spark when first used until they wear and conform to the motor’s
armature.
•AFTER USE, wipe external surfaces of the tool with clean cloth.
•Before remounting the Saw Blade, remove all sawdust that has accumulated around the Safety
Guard and Blade Guard Frame.
•Regularly inspect and tighten all mounting screws and knobs.
•Keep Saw Blade clean and sharp. Sharp blades minimize stalling and kickback.
•Keep guards in good working order.
•Keep motor air vent clean of dust and debris. Vacuum periodically.
•If the tool is not operating normally, making unusual noises, or appears defective, stop using it
immediately and get it repaired.
•Clean tool with a damp cloth and light detergent. Do not use solvents as they can damage and
crack the housing.
•For blade changing instructions see Tool Set Up on page 10.
•WARNING! If the supply cord of this power tool is damaged, only a qualified
service technician must replace it.

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DIAGRAM AND PARTS LIST

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NO.
Part Name
Qty
NO.
Part Name
Qty
1
Screw M8*16
1
27
Bearing
1
2
Blade
1
28
Rubber Pin
1
3
Locating Plate
1
29
Brake Spring
1
4
Check Ring
1
30
Stopping Plate
1
5
Protecting plate
1
31
Rotor
1
6
Torsional Spring
1
32
Bearing
1
7
Screw M4*10
3
33
Screw ST4*14
10
8
Guard
1
34
Handle Cap
1
9
Pinion Spring
2
35
Wind Baffle
1
10
Steel Ball
2
36
Screw ST4*60
2
11
Base of guard
1
37
Stator
1
12
Screw M4*8
3
38
Bearing Cover
1
13
Spring Washer
3
39
Cable Clamp
1
14
Flat Washer
3
40
Plug
1
15
Block of depth adjustment
1
41
Cable Jacket
1
16
Output Shaft
1
42
Brush Cap
2
17
Woodruff Key
1
43
Carbon Brush
2
18
Bearing
2
44
Brush Holder
2
19
Circlip for hole
1
45
Stand
1
20
Screw M5*18
4
46
Housing
1
21
Spring Washer
8
47
Screw M5*50
4
22
Front Cap
1
48
Flat Washer 5
4
23
Large Gear
1
49
Switch
1
24
Check Ring
1
50
Hex Wrench
1
25
Alex Bearing
1
26
Gear Box
1

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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

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