Ironton 61448 User manual

READ & SAVE THESE INSTRUCTIONS
3 3/8 Inch 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 #61448

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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 saw 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
Technical Specifications......................................................................................................................4
Important Safety Information...............................................................................................................4
Specific Operation Warnings...............................................................................................................6
Grounding..............................................................................................................................................6
Extension Cords....................................................................................................................................8
Main Parts of Saw .................................................................................................................................8
Assembly Instructions..........................................................................................................................9
Before Each Use..................................................................................................................................10
Operating Instructions........................................................................................................................10
After Each Use.....................................................................................................................................12
Maintenance ........................................................................................................................................12
Troubleshooting..................................................................................................................................13
Parts Diagram......................................................................................................................................14
Parts List..............................................................................................................................................15
Replacement Parts..............................................................................................................................16
Limited Warranty.................................................................................................................................17

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Intended Use
The Ironton 3 3/8 Inch 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
Property
Specification
Motor Rating
110V, 6.8A
No Load Speed
4500 RPM
Max Blade Diameter
3-3/8 in.
Arbor
5/8 in.
Saw Blade Required
3-3/8 in., Rated for 4500 RPM
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.
⚠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 saw 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.

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Do not allow the saw 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 saw.
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.
Secure the work with clamps or a vise instead of your hand when practical. This safety precaution
allows for proper tool operation using both hands.
⚠CAUTION
SAW USE AND CARE
Do not force the saw. 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
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.

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Store the saw 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 saw running unattended.
Specific Operation Warnings
⚠DANGER
Keep hands and body away from and to the side of the blade. Contact with blade will result in
serious injury.
⚠WARNING
To reduce the risk of injury, user must read this manual.
To reduce the risk of injury, check the guarding system. It must cover the blade instantly!
Hold saw with both hands.
Support and clamp work.
To reduce the risk of injury, always wear eye protection
Hold power tools by insulated gripping surfaces, when performing an operation where the cutting
tool may contact hidden wiring or its own cord.
Always use blades with correct size and shape.
Never attempt to remove the saw from the work or pull the saw backward while the blade is in
motion or KICKBACK may occur.
Do not use dull or damaged blades.
Never stop the saw blade by applying pressure to the saw or to the side of the blade.
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.
Never lock the blade guard in its open position.
Grounding
⚠WARNING
This machine must be grounded while in use to protect the operator from electrical shock. This

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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
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.
Main Parts of Saw
Subassembly
Guard
Blade
Trigger
Spindle Lock
Handle
Stand
Carbon Brush

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Assembly Instructions
⚠WARNING
Always be sure that the saw is switched OFF before adjusting, adding accessories, or checking a
function on the saw.
USE ONLY a 3-3/8 inch saw blade rated to at least 4500 RPM.
Mounting and Removing Blade
1. Hold in the spindle lock button and rotate the saw blade until the spindle shaft lock catches and
the blade stops (image above).
2. Remove the blade bolt, turning it counter-clockwise. (See Figure A: Blade Installation, below.)

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3. Remove the blade.
4. 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.
5. Hold the spindle lock button while using the hex wrench to replace the blade bolt, turning it
clockwise.
Before Each Use
⚠WARNING
Always check for damaged or worn parts before using the saw. Broken parts will affect the toe-kick
saw operation.
MAKE SURE that all guards are in place and in proper working order before operation.
Operating Instructions
⚠DANGER
Keep hands and body away from and to the side of the blade. Contact with blade will result in
serious injury.
⚠WARNING
To reduce the risk of injury, user must read this manual.
To reduce the risk of injury, check the guarding system. It must cover the blade instantly!
Hold the saw with both hands.
Support and clamp work.
To reduce the risk of injury always wear eye protection
Hold power tools by insulated gripping surfaces, when performing an operation where the cutting
tool may contact hidden wiring or its own cord.
Keep hands away from the 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.
NEVER hold a piece being cut in your hands or across your leg. Secure the workpiece to a stable
platform.
Always use blades with correct size and shape.
DO NOT use with the trigger locked on.
DO NOT depress the spindle lock when starting or during operation.
DO NOT use blades made from high-speed steel, abrasive blades, metal-cutting blades or

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masonry-cutting blades. The guards of this saw are not designed to protect against the failure of
such blades.
Never attempt to remove the saw from the work or pull the saw backward while the blade is in
motion or KICKBACK may occur.
Do not use dull or damaged blades.
Never stop the saw blade by applying pressure to the saw or to the side of the blade.
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.
Never lock the blade guard in its open position.
1. Press in (and hold) the safety button with your thumb, and at the same time, squeeze the trigger
with your index finger.
2. 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.
Note: If a loud grinding noise is heard, the saw blade is contacting the cement foundation.
Immediately raise the saw blade.

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After Each Use
⚠WARNING
Release the trigger and hold the saw in place until the saw blade comes to a complete stop.
Keep children away from the saw.
When the toe-kick is not in use, store it in a secure place out of reach of children.
Inspect the saw for good condition prior to storage and before re-use.
Maintenance
⚠WARNING
If the supply cord on this saw is damaged, ONLY a qualified service technician should replace it.
Maintain the saw 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 all cutting tools sharp and clean.
Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to
control. Keep handles dry, clean, and free from oil and grease. The following chart is based on a
normal operation schedule.
Maintenance Interval
Maintenance Point
Before each use.
Inspect the general condition of the saw. 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.
After the motor
performance of the saw
decreases or stops
working completely.
The carbon brushes require maintenance. Follow these instructions:
1. Remove the carbon brush cover on each side of the motor housing.
2. Remove the carbon brushes from the housing. Keep track of which direction the
old carbon brushes were in to prevent needless wear if they will be reinstalled.
3. If either carbon brush is worn down more than halfway, replace them both.
4. To clean old carbon brushes before reusing them, rub the contact areas with a
pencil eraser.
5. Reinsert the old carbon brushes in the same direction to reduce wear.
6. 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.
7. Replace the carbon brush covers. Do not overtighten.
Note: When first used, new carbon brushes tend to spark until they wear and
conform to the motor’s armature.
After use.
Regularly inspect and tighten all mounting screws and knobs.
Keep the saw blade clean and sharp. Sharp blades minimize stalling and kickback.
Keep the motor air vent clean of dust and debris.
Clean the saw with a damp cloth and light detergent. Do not use solvents as they
can damage and crack the housing.

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Troubleshooting
⚠WARNING
Disconnect power supply before service.
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
Saw will not start.
Cord was not connected.
Check that the cord is plugged in.
Saw’s thermal reset breaker tripped (if
equipped).
Turn off the saw and allow it to cool.
Press the reset button on the saw.
Internal damage or wear (carbon
brushes or trigger, for example).
Have a technician service the saw.
No power at the outlet.
Check the power at the outlet. If the
outlet is not powered, turn off the saw
and check the circuit breaker. If the
breaker is tripped, make sure the
circuit is the right capacity for the saw
and the circuit has no other loads.
Saw operates
slowly.
Forcing the saw to work too fast.
Allow saw to work at its own rate.
The extension cord is too long or
diameter of the cord is too small.
Do not use an extension cord. If an
extension cord is needed, use one with
the proper diameter for its length and
load.
Performance
decreases over
time.
Carbon brushes are worn or damaged.
Have a qualified technician replace the
brushes.
Blade is dull or damaged.
Keep the blades sharp. Replace as
needed.
Excessive noise
or rattling.
Internal damage or wear (carbon
brushes or bearings, for example).
Have a technician service the saw.
Saw overheats.
Forcing saw to work too fast.
Allow the saw to work at its own rate.
Blade is misaligned.
Check and correct the blade to the
proper alignment.
Blade is dull or damaged.
Keep blades sharp. Replace as
needed.
Blocked motor housing vents.
Wear ANSI-approved safety goggles
and NIOSH-approved dust
mask/respirator while blowing dust out
of motor using compressed air.
Motor is being strained by long or small
diameter extension cord.
Do not use an extension cord. If an
extension cord is needed, use one with
the proper diameter for its length and
load.

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Parts Diagram

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Parts List
Part Number
Part Description
Quantity
1
Screw M8*16
1
2
Blade
1
3
Locating Plate
1
4
Check Ring
1
5
Protecting Plate
1
6
Torsional Spring
1
7
Screw M4*10
3
8
Guard
1
9
Pinion Spring
2
10
Steel Ball
2
11
Guard Base
1
12
Screw M4*8
3
13
Spring Washer
3
14
Flat Washer
3
15
Block of Depth Adjustment
1
16
Output Shaft
1
17
Woodruff Key
1
18
Bearing
2
19
Circlip for Hole
1
20
Screw M5*18
4
21
Spring Washer
8
22
Front Cap
1
23
Large Gear
1
24
Check Ring
1
25
Alex Bearing
1
26
Gear Box
1
27
Bearing
1
28
Rubber Pin
1
29
Brake Spring
1
30
Stopping Plate
1
31
Rotor
1
32
Bearing
1
33
Screw ST4*14
10
34
Handle Cap
1
35
Wind Baffle
1
36
Screw ST4*60
2
37
Stator
1
38
Bearing Cover
1
39
Cable Clamp
1
40
Plug
1
41
Cable Jacket
1
42
Brush Cap
2
43
Carbon Brush
2
44
Brush Holder
2
45
Stand
1
46
Housing
1
47
Screw M5*50
4
48
Flat Washer 5
4
49
Switch
1
50
Hex Wrench
1

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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.

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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.

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