North Star 49157 Owner's manual

Brand: North Star

Model: 49157

Type: Owner's manual

SAVE THESE INSTRUCTIONS

163cc Concrete Cutter

Owner’s Manual

WARNING: Read and understand all instructions, warnings, and cautions before using this

product. Failure to follow the instructions, warnings, and cautions may result in serious personal

injury and/or property damage.

Item #49157

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Thank you very much for choosing a North Star 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.

This concrete cutter is designed for certain applications only. Northern

Tool and Equipment cannot be responsible for issues arising from

modification or use of this product in 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.

Page 3 of 30

Table of Contents

Intended Use .......................................................................................................................................... 4

Technical Specifications ...................................................................................................................... 4

Important Safety Information ............................................................................................................... 4

Specific Operation Warnings ............................................................................................................... 7

Main Parts of Concrete Cutter ............................................................................................................. 8

Before Each Use .................................................................................................................................. 10

Operating the Concrete Cutter........................................................................................................... 11

Start the Engine .............................................................................................................................. 11

Operation ........................................................................................................................................ 11

After Each Use ..................................................................................................................................... 12

Maintenance ........................................................................................................................................ 13

Installing the Saw Blade ................................................................................................................. 14

Setting the Saw Blade Depth .......................................................................................................... 17

Changing the V-Belt ............................................................................................................................ 18

Parts Diagram ...................................................................................................................................... 19

Engine Mount .................................................................................................................................. 19

Blade Shaft ..................................................................................................................................... 21

Adjust Handle ................................................................................................................................. 23

Wheel Shafts .................................................................................................................................. 25

Frame & Water Tank ...................................................................................................................... 26

Troubleshooting .................................................................................................................................. 27

Replacement Parts .............................................................................................................................. 28

Limited Warranty ................................................................................................................................. 29

Page 4 of 30

Intended Use

This Concrete Cutter is designed to cut concrete, asphalt, or both at the same time. (The cutter is not

designed to cut through concrete with rebar however.) The rotating handle adjusts the cutting depth

from 3.9 in. to 4.7in. The cutter includes a built-in water distribution system that supplies water to both

sides of blade for cooling.

Technical Specifications

Length

37 in. (940 mm)

Width

20.85 in. (530 mm)

Height

33 in. (838 mm)

Blade Rotation

3,200 rpm

Blade Diameter (not included)

12 & 14 in. (305 & 356 mm)

Cutting Depth

3.9 to 4.7 in. (99 to 119 mm)

Depth Adjustment

By Handle Rotation

Travel Mechanism

Manual Push

Blade Cooling

Gravity-Fed Water

Water Tank Capacity

5 gal. (19 Liters)

Weight (shipping)

183 lbs. (83 Kg)

Engine

Honda GX160, 5.5 HP, 163cc

Important Safety Information

 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 assemble or operate this product until they have read this manual and

have developed a thorough understanding of how the product works.

 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. It will

do the job better and more safely 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.

Page 5 of 30

 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 dust masks that are specially designed to filter out microscopic

particles.

 Handling the power cord on corded products may expose you to lead, a chemical known to the

State of California to cause cancer and birth defects or other reproductive harm. Wash hands

after handling.

WORK AREA SAFETY

 Inspect the work area before each use. Keep the work area clean, dry, free of clutter, and well lit.

Cluttered, wet, or dark work areas can result in injury.

 Do not use the Concrete Cutter where there is a risk of causing a fire or an explosion; e.g., in the

presence of flammable liquids, gases, or dust. The cutter can create sparks, which may ignite the

flammable liquids, gases, or dust.

 Do not allow the Concrete Cutter to come into contact with an electrical source. The cutter is not

insulated and contact will cause electrical shock.

 Keep children and bystanders away from the work area while operating the Concrete Cutter. Do

not allow children to handle the cutter.

 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.

PERSONAL SAFETY

 Stay alert, watch what you are doing, and use common sense when operating the Concrete

Cutter. Do not use the cutter while you are tired or under the influence of drugs, alcohol, or

medication.

 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.

 Use ANSI Z87.1-approved safety goggles or 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 adjusting keys or wrenches before starting the Concrete Cutter. A wrench or key that is

left attached to a rotating part of the cutter may cause personal injury.

 No smoking, matches, or open flames around machine. Fuel is flammable.

 Do not touch hot surfaces.

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 Equipment can tip over when moving, causing injury.

 Persons not operating should be at least 10 feet away while equipment is in use.

 Engine exhaust contains carbon monoxide. This is a poison you cannot see or smell. NEVER use

in doors.

 Do not operate without guards in place.

 Keep feet clear of cutting blade.

CONCRETE CUTTER USE AND CARE

 Do not force the Concrete Cutter to perform an operation other than its intended use. Concrete

cutters do a better and safer job when used in the manner for which they are designed. Plan your

work, and use the correct Concrete Cutter for the job.

 Check for damaged parts before each use. Carefully check that the Concrete Cutter will operate

properly and perform its intended function. Replace damaged or worn parts immediately. Never

operate the cutter with a damaged part.

 Place the power switch in the locked or off position before making any adjustments, changing

accessories, or storing the tool. Such preventive safety measures reduce the risk of starting the

tool accidentally.

 Store the Concrete Cutter when it is not in use. Store it in a dry, secure place out of the reach of

children. Inspect the cutter for good working condition prior to storage and before re-use.

 Use only accessories that are recommended by the manufacturer for use with the Concrete

Cutter. Accessories that may be suitable for one Concrete Cutter may create a risk of injury when

used with another Concrete Cutter.

 Keep guards in place and in working order. Never operate the Concrete Cutter without the guards

in place.

 Keep the Concrete Cutter blade clean.

 Do not leave the Concrete Cutter running unattended.

 Shut off the fuel valve when the engine is not in use.

 Only use the recommended fuel to avoid damaging the equipment.

 Oil does not come with the machine. Add oil to engine before the first use.

 Check oil levels before operating the machine.

 DO NOT refuel the engine while it is still hot. Fuel is flammable.

 DO NOT service engine while it is still hot.

Page 7 of 30

Specific Operation Warnings

To avoid fatal accident

 Stop the engine before refueling and be careful not to spill fuel during the refueling. Spilled fuel

may ignite causing a fire.

 Do not refuel the engine near flammable objects to avoid fire.

 Do not run the engine in enclosed areas to prevent carbon monoxide poisoning.

To protect the operator

 When fatigue from operation, the operator must stop the machine and take break.

 Hearing protection is required as this machine creates a noise emission while 1 m (3 feet) away

from the equipment.

To avoid injury or damage

 The Concrete Cutter is only operated by authorized persons who:

- are at least 18 years of age.

- are physically and mentally able to operate the cutter.

- are properly trained in the operation and the maintenance of the cutter by the owner or

authorized representative.

- are assessed to be able to carry out their duties reliably.

 People who are drinking alcohol beverages and/or taking drugs are not allowed to operate the

Concrete Cutter.

 People are not allowed to enter into the danger zone of the Concrete Cutter (10 feet).

 The operator has to monitor the 10 foot danger zone all the time. It is not allowed to operate if

there is a person in the danger zone.

 Operate the Concrete Cutter away from other workers because cracked and bounced rock may

injure other workers.

 The operator has to give warning signs in case of an emergency situation.

 The Concrete Cutter can only be operated when there is adequate stability.

 The operator has to control the running speed of the Concrete Cutter all the time during its

operation so that the cutter can be stopped at any time.

 The operator must turn off the Concrete Cutter completely as described in this manual before

leaving the operating position. Also, the cutter must be secured against unauthorized use.

 The engine has to be turned off and secured against re-starting by pulling out the sparking plug

cap during the maintenance and servicing.

 Discovered defects must be reported to supervising personnel and to the operator. Do not leave

the defects which may cause serious injury of the operator.

 Do not operate the Concrete Cutter when a defect endangers the safety of the operator until the

defect is rectified.

 The Concrete Cutter has to be checked by an expert in regular bases (at least once a year). And

it must be checked by an expert before the initial use and after the essential modification.

 The Concrete Cutter generates heat so do not touch the body of engine, muffler or other parts

during operation, which may cause a burn.

 The operator must be fully equipped with safety equipment including a crash helmet, safety

gloves, safety shoes, safety glasses and mask before operating the Concrete Cutter.

Page 8 of 30

 Do not insert hands or fingers between pulley cover and engine during operation, this will cause

injury.

 Do not transport the Concrete Cutter with fuel in its fuel tank by the motor vehicle.

 Do not lift the Concrete Cutter by a person when putting on and off from vehicle. Always use a

proper lifting crane to move. Lifting by person may cause personal injury due to its heavy weight.

 Make sure to securely fasten the Concrete Cutter for transportation. Improper fastening as

holding the handle of the cutter during the transportation may cause an injury.

 Also refer to the enclosed engine manual if there is a problem or a question on engine. Safety

Labels

Main Parts of Concrete Cutter

Height Adjust Handle

Engine Base Plate

Handle Stopper

Engine Muffler

Elevator Screw Stopper

Belt Cover

Water Tank

Guide Wheel

Water Valve

Front Wheel

Lift Handle

Blade Cover

Water Tank Cap

Blade Holder

Frame

Rear Wheel

Engine Fuel tank Cap

Gauge Pin

Handle

Engine Recoil Starter

Handle Grip

Wrench (32/36mm)

Engine Stop Switch

Throttle lever

Page 9 of 30

Elevate Bar

Page 10 of 30

Before Each Use

Engine

Recommended Fuel

The cutter engine requires fresh, clean, regular, unleaded gasoline. Fuel containing water or dirt will

damage the fuel system. Consult to engine owner’s manual for complete fuel specifications.

DANGER: Adding fuel to the tank should be done only when the engine is stopped and has had

an opportunity to cool down to avoid a risk of an explosion or fire from a fuel spill. In the event of

a fuel spill, DO NOT attempt to start the engine until the fuel residue has been completely wiped

up, and the area surrounding the engine is dry.

Before starting

 Read and understand the safety and operating instructions in the engine manual.

 On the engine check:

- Oil level; refill if necessary.

- Fuel level; refill the tank if necessary.

- Condition of fuel line.

- Condition of air filter.

- The spark plug

Cutter

 Check all the bolts, nuts and belts and tighten any if necessary.

 Check the belt tension.

 Check the condition of the saw blade. Replace the blade if it is damaged.

 Check the general condition of the cutter and its components and clean any foreign material

(dirt, fragments, etc.) from it.

 Check the fluid level in the water tank and fill it if necessary.

Page 11 of 30

Operating the Concrete Cutter

Operators must be trained in the use of the concrete cutter and maintain practiced skill. It is

dangerous to operate this machine improperly or by an untrained person. An operator should read

and understand the manual and follow its directions.

Do not stop the engine when the concrete cutter is at high speed or the engine temperature will rise

suddenly, possibly causing engine parts to jam or the oil to deteriorate. Minimize the engine speed

and allow it to idle for a few minutes before stopping it.

Start the Engine

1. Ensure that the saw blade is off the ground. If not, turn the height adjust handle clockwise to

raise the blade off the ground.

2. Check that the throttle switch is pushed fully away from the operator.

3. Open the fuel valve on the engine.

4. Turn the engine switch to ON.

5. Choke the engine. A warm engine may not need to be choked.

6. Pull the starter rope to start the engine.

7. Open the choke and allow the engine to warm up at slow speed for 5 minutes.

Operation

Start Cutting

1. Turn the height adjust handle clockwise raise the saw blade off the ground and move the cutter to

the cutting area.

2. Align both saw blade and the guide wheel on the cutting line.

3. Pull the throttle lever back toward the operator to increase the speed of the engine.

4. Turn the height adjust handle counter-clockwise to lower the saw blade until the blade reaches

the desired depth as shown on the gauge pin.

5. Slowly push the cutter forward keeping the guide roller on the cutting line.

Stop Cutting

1. Turn the height adjust handle clockwise raise the saw blade off the ground.

2. If the engine has been running for a while and is hot, push the throttle lever fully away from the

operator to minimize the engine speed and allow the engine to idle for a few minutes to cool.

3. Set the engine switch to OFF.

4. Close the fuel valve on the engine.

Page 12 of 30

After Each Use

Cleanup

Check that the cutter engine is turned off and cooled before attempting any maintenance, cleaning, or

inspection to avoid an accidental start and possible injury.

 Remove foreign substances from the saw blade and rinse it with water.

 Remove foreign substances such as soil, cement, asphalt and/or dirt from the concrete cutter and

wash it but do not get water on the engine.

 Clean the engine cylinder cooling fins. A broom or old brush are good tools to remove dirt,

concrete and bits of rock.

Refer to the engine manual for additional information about engine maintenance.

Storage

If storing the cutter for an extended period of time (more than 30 days) or transporting it:

 Clean the cutter and saw blade as described above.

 Remove the saw blade.

 Drain the water tank.

 Drain the fuel tank and run the engine briefly until the fuel in the the carburetor is completely

consumed.

 Clean or replace the air filter.

 Change the engine oil.

 Follow the procedures described in the engine manual for engine storage.

 Store the cutter and saw blade separately in a clean, dry area.

 Cover the cutter and blade completely with a cloth or tarp.

If transporting the concrete cutter, lift it from the top center of the frame using a proper lifting crane

when moving it on and off a truck. Lifting the cutter by hand may cause personal injury due to its

heavy weight.

Page 13 of 30

Maintenance

Check that the concrete cutter engine is turned off and cooled before attempting any maintenance,

cleaning, or inspection. Performing maintenance on an operating concrete cutter can cause injury.

Maintain the Concrete Cutter by adopting a program of conscientious repair and maintenance in

accordance with the following recommended procedures. Also refer to the engine manufacturer’s

instruction manual for additional information about engine maintenance. The following chart is based

on a normal operation schedule.

Maintenance Interval

Maintenance Point

Daily before operating

See the Before Each Use section

After the first 20 operating hours

Check and adjust the belt tension

Change the engine oil

After the first 50 operating hours or

every week

Check and adjust the belt tension

Clean the engine air cleaner

Change the engine oil

Check and clean the engine spark plug

After the first 100 operating hours or

every month

Clean the engine fuel strainer

Change the engine oil

After the first 300 operating hours or

every year

Change the grease in gear operating parts

Check and adjust the valve clearance

Clean the cylinder head

Change the engine oil

Page 14 of 30

Installing the Saw Blade

Check that the cutter engine is turned off and cooled before attempting any maintenance, cleaning, or

inspection to avoid an accidental start and possible injury.

Note: The saw blade is not supplied.

Diamond Saw Blade Specifications

 Diameter (A): 14-inch

 Arbor Hole (B): 25.4mm(1-inch)

 Pin Hole (C): 13mm

 Center to Center (D): 28.7mm.

 Be sure to check the blade's direction of

rotation (01).

 DO NOT use a blade that is missing a

segment (02) or is cracked. Damaged

and/or missing segments or cracks may

cause damage to your saw and injury to

the user or others in the operating area.

Figure 1

See Figure 2.

1. Raise the Concrete Cutter by turning the Elevator Handle clockwise.

2. Remove the Hose (03) from the One Touch Fitting (02).

3. Remove Nut (05), and then remove Bolt (04) using a 17mm wrench (not included).

4. Using the handle on the Blade Cover (01) rotate the cover back exposing the saw blade mounting

fixtures.

Figure 2

Page 15 of 30

See Figure 3.

5. Remove Counterclockwise Nut (06) with the supplied 36mm wrench (07). If the shaft spins, hold it

in place with the supplied 32mm wrench (08).

6. Remove the Blade Holder Outer (09).

Figure 3

See Figure 4.

7. Install the Saw Blade (11) on the blade shaft (10) making sure that the pin hole in the Saw Blade

engages the pin of the Blade Holder Inner (12). Make sure that the Saw Blade is installed in the

correct direction of rotation (A).

Figure 4

Page 16 of 30

See Figure 5.

8. Replace the Blade Holder Outer (09) and Nut (06).

9. Tighten Nut (06) to approximately 45-50 ft. lb. (61-68 N/m).

Figure 5

10. Replace the blade cover and hose by performing steps 1 – 4 in reverse order.

Page 17 of 30

Setting the Saw Blade Depth

Check that the cutter engine is turned off before making adjustments to the cutter to avoid an

accidental start and possible injury.

Use the procedure below to adjust the gauge pin correctly to zero depth (ground level). Once the pin

is set, an accurate depth reading can be obtained when cutting concrete.

1. Check that the saw blade is off the ground then put the concrete cutter on a level surface for this

procedure.

2. Turn the height adjust handle counter-clockwise to lower the Saw Blade until it just touches the

ground.

3. Loosen the right wheel nut.

4. Move the black Gauge Pin to zero (0) on the scale as shown below.

5. Retighten the wheel nut.

Page 18 of 30

Changing the V-Belt

Check that the concrete cutter engine is turned off and cool before attempting to change the V-belt.

Changing the V-belt while the cutter is still hot or operating will cause injury.

1. Remove the four Bolts (02) and lift off the Belt Cover (01).

2. Remove the V-Belts.

3. Place the new V-Belts (03) first on the Lower Pulley (04) and then on the Upper Pulley (05). Use

the 36mm wrench (06) and turn it clockwise.

4. Check that the amount of flex in the V-Belts midway between the pulleys is 3/8" by pressing down

on the belt with your finger.

If belt tension is not correct, adjust the tension by loosening the bolts at the engine base and

sliding the engine in the base plate slots to correctly tighten the belts, then retightening the bolts.

5. Replace the Belt Cover (01) and the four Bolts (02).

Page 19 of 30

Parts Diagram

Engine Mount

Page 20 of 30

Engine Mount

Ref.

Parts No.

Description

Qty.

Remark

GX-160S

Engine

Honda GX160

CA110-000

Inner Belt Cover

QKY-5x5x50

Key

50X50X50L

CA040-25.4

Engine Pulley

QWS-SPM8

Plain Washer

M8-Large

QWS-SM8

Spring Washer

QBL-M8x35

Bolt

M8x35L

PA130-001

Belt Cover

QWS-PM8

Plain Washer

QBL-FM8x20

Flange Bolt

M8x20L

QBL-M8x80

Bolt

M8X80L

QBL-M8x70

Bolt

M8X70L

CA010-000B

Engine Base Plate

FIX45-000

Engine Fixing Bolt

CA140-004

Dust Cover

QNT-FM8

Flange Nut

QNT-M8

Nut

QWS-PM10

Plain Washer

M10

QWS-SM10

Spring Washer

M10

QNT-M10

Nut

M10

QBL-M10x30

Bolt

M10x30L

CA120-002

Belt Cover Bushing

QBL-SHCM8x20

Socket Head Cap Bolt

M8x20L

QBT-A27

V-Belt

A27

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North Star 49157 Owner's manual

North Star 49157 Owner's manual

North Star 49157 Owner's manual

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