RGC C120 HYDRACUTTER User manual

C120 HYDRACUTTER
INSTRUCTIONS
REIMANN & GEORGER CORPORATION
CONSTRUCTION PRODUCTS BUFFALO, NY
P/N 6129006 04/10/2019

TABLE OF CONTENTS
CHAPTER TITLE PAGE
RGC CONSTRUCTION PRODUCTS PHONE: [phone]
1 SAFETY .................................................................................................................................1
1.1 Introduction .............................................................................................................................1
1.2 Safety Definitions....................................................................................................................1
1.3 Power Source and Saw Safety Labels......................................................................................1
1.4 C120 HydraCutter Safety Rules...............................................................................................1
2 SPECIFICATIONS ...............................................................................................................3
2.1 Introduction .............................................................................................................................3
2.2 Technical Data.........................................................................................................................3
2.3 Recommended Hydraulic Oil...................................................................................................4
2.4 Nameplate and Serial Number Tag..........................................................................................4
3 OPERATION.........................................................................................................................5
3.1 Chain Selection........................................................................................................................5
3.2 Before Operating the Saw........................................................................................................5
3.2.1 Checking the System Hydraulics .............................................................................................5
3.2.2 Checking Water Supply...........................................................................................................6
3.2.3 Checking Chain and Bar..........................................................................................................6
3.3 Planning the Cut ......................................................................................................................7
3.4 Breaking in a New Chain.........................................................................................................8
3.5 Cutting Procedure....................................................................................................................8
3.6 Shutting Down and Storing the Saw ........................................................................................8
4 INSPECTION AND MAINTENANCE ..............................................................................10
4.1 General Maintenance Rules....................................................................................................10
4.2 Bar Inspection and Maintenance.............................................................................................10
4.3 Drive Sprocket Inspection and Installation.............................................................................12
4.4 Chain Inspection and Maintenance.........................................................................................13
4.5 Chain Installation and Tensioning ..........................................................................................13
5 TROUBLESHOOTING.......................................................................................................14
6 FACTORS AFFECTING CHAIN LIFE ............................................................................17
6.1 How Diamond Segments Work ..............................................................................................17
6.2 Material Factors Affecting Chain Life....................................................................................17
6.3 Operational Factors Affecting Chain Life...............................................................................18
6.4 Chain End-of-Life Modes.......................................................................................................19
7 PARTS LIST.........................................................................................................................20

LIST OF FIGURES
FIGURE DESCRIPTION PAGE
RGC CONSTRUCTION PRODUCTS PHONE: [phone]
2-1 Typical C120 HydraCutter Product Nameplate ......................................................................4
3-1 Proper Chain Mounting...........................................................................................................7
4-1 Dressed Bar Rail ....................................................................................................................10
4-2 Nose Sprocket Clearance .......................................................................................................11
4-3 Sprocket Assembly.................................................................................................................12
4-4 Sprocket Wear Measurement.................................................................................................12
7-1 C120 HydraCutter Handle & Valve Assembly.......................................................................23
7-2 C120 HydraCutter Assy Right Side View (Bar Side).............................................................24
7-3 C120 HydraCutter Assy Left Side View (Motor Side)...........................................................25

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1SAFETY
1.1 INTRODUCTION
Your Reimann & Georger Corporation C120 HydraCutter has been engineered to provide sawing performance, long term
economics and safety advantages that no other type can match. However, even a well-designed and well-built saw can
malfunction or become hazardous in the hands of an inexperienced and/or untrained user. Therefore, read this manual and
related equipment manuals thoroughly before operating your saw to provide maximum safety for all operating personnel,
and to get the maximum benefit from your equipment.
1.2 SAFETY DEFINITIONS
A safety message alerts you to potential hazards which could injure you or others or cause property damage. The safety
messages or signal words for product safety signs are DANGER, WARNING, and CAUTION. Each safety message is
preceded by a safety alert symbol and is defined as follows:
DANGER: Indicates an imminently hazardous situation which, if not avoided, will cause death or serious injury. This
safety message is limited to the most extreme situations.
WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It
may also be used to alert against unsafe practices that may result in property-damage-only accidents.
1.3 POWER SOURCE AND SAW SAFETY LABELS
These labels warn you of potential hazards that could cause injury. Read them carefully. If a label comes off or becomes
illegible, contact Reimann & Georger Corporation for a replacement.
1.4 C120 SAW SAFETY RULES
1. Only trained personnel shall operate the saw or do repairs. A trained person is one who has read and thoroughly
understands this instruction manual and related equipment manuals and, through training and experience, has shown
knowledge regarding the safe operational procedures.
2. Sawing area must be kept clear of unauthorized personnel at all times. Place barricades or secure the area with signs
and a roped boundary to prevent personnel injury.
3. Never use the saw in an explosive atmosphere and/or near combustible material that could be ignited by a spark.
4. Do not use a saw that shows any signs of damage. Do not use the saw if the chain does not stop rotating when the
power-activating trigger lever is released.
5. The guard provides protection against contact with moving parts, ejected debris, broken chain, thrown water and
concrete slurry. Never run the saw without the chain guard in place.
6. Never run saw for any extended periods with water supply turned off. Excessive wear to bar and chain will result.
7. Never allow anyone to stand in front of, or in line with, the chain forward of the guard.
8. Always use safety footwear, a snug fitting wet suit, safety goggles or face shields, and hearing and head protection
devices. Safety shoes MUST provide good footing to prevent slipping or falling down. Gloves protect the hands
from chips and should be worn.
9. Do not use the saw when you are tired or fatigued.
10. Never operate the saw under the influence of drugs, alcohol, or medication.

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11. Always carry the saw in its de-energized state.
12. Keep the saw handles dry, clean, and free of oil or fuel.
13. Do not start cutting without first de-energizing electrical wiring near the cutting site or imbedded in the concrete.
14. Before cutting through a wall, check both sides for possible obstructions.
15. Prior to cutting, plan your cuts to prevent pinching of the bar or personnel injury from falling concrete.
16. Always hold the saw with both hands during operation. Use a firm grip on the handles.
17. Never exceed the flow and pressure rating of the saw which is 12gpm at 2500 psi.
18. Do NOT attempt to adjust the saw during operation.
19. Keep clothing and all parts of the body away from moving parts of this saw when connected to a power source or
being used.
20. The slurry formed during cutting operations is very slick. Remove while still wet to prevent yourself or others from
slipping while cutting. Slurry that has been allowed to dry is very difficult to remove.
21. Always shut off the hydraulic power and cooling water sources before disconnecting the hoses or servicing the saw.
22. Always shut off the hydraulic and cooling water sources when not using the equipment.

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2SPECIFICATIONS
2.1 INTRODUCTION
Your Reimann & Georger Corporation C120 HydraCutter hydraulic hand-held chainsaw is a rugged versatile tool that makes
clean, fast, precise, and straight cuts through concrete, reinforced concrete, masonry, stone, and other aggregates. As with most
hydraulic tools, the hydraulic system requirements detailed in the following sections must be met but not exceeded to support
tool performance and longevity of equipment.
2.2 TECHNICAL DATA
The following specifications apply to the C100 HydraCutter.
ENGLISH METRIC
Tool Physicals
Weight 23 lbs. (10.5 kg.)
Bar Size (10 in. bar) 17.5 in. x 2.813 in. (44.5 x 7.15 cm)
Bar Size (15 in. bar) 20.5 in. x 2.813 in. (52.1 x 7.15 cm)
Bar Size (20 in. bar) 25.25 in. x 2.813 in. (64.1 x 7.15 cm)
Bar Size (25 in. bar) 30.625 in. x 2.813 in. (77.8 x 7.15 cm)
Bar Size (30 in. bar) 35.375 in. x 2.813 in. (89.9x 7.15 cm)
Dimensions (with 10 in. bar) 45 x 10.25 x 12 in. (114.3 x 26.04 x 30.5 cm)
Dimensions (with 15 in. bar) 48 x 10.25 x 12 in. (121.9 x 26.04 x 30.5 cm)
Dimensions (with 20 in. bar) 52.5 x 10.25 x 12 in. (133.4 x 26.04 x 30.5 cm)
Dimensions (with 25 in. bar) 58 x 10.25 x 12 in. (147.3 x 26.04 x 30.5 cm)
Dimensions (with 30 in. bar) 62.5 x 10.25 x 12 in. (158.8 x 26.04 x 30.5 cm)
Depth of Cut (with 10 in. bar) 12 in. (305 mm)
Depth of Cut (with 15 in. bar) 15 in. (381 mm)
Depth of Cut (with 20 in. bar) 20 in. (508 mm)
Depth of Cut (with 25 in. bar) 25 in. (635 mm)
Depth of Cut (with 30 in. bar) 30 in. (762 mm)
Chain
Segments (for 10 in. bar) 50
Segments (for 15 in. bar) 57
Segments (for 20 in. bar) 67
Segments (for 25 in. bar) 79
Segments (for 30 in. bar) 90
Segment Dimensions 0.472 x 0.228 x 0.275 in. (12 x 5.8 x 7 mm)
Bar
Nose Sprocket 12 tooth
Hydraulic Requirements
Type of System Open-Center
Flow Rate 12 gpm (45 lpm)
Max Pressure Range 2500 psi (172 bar)
Back Pressure (Max) 250 psi (17 bar)
Hose Length (Max) 100 ft. (30 m)
Couplings 1/2” HTMA flush face
Water Requirements
Flow Rate 2.5 gpm (9.5 lpm)
Pressure (Min) 50 psi (3 bar)
Operation
Power @2500 psi 17.5 Hp (13 kw)
Torgue @2500 psi 170 in.-lbs. (19.2 Nm)

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Speed (Max) 6500 rpm
Vibration and Sound
Vibration level a= 5.65 M/S^2
Sound pressure @ 1Meter 88 dba
2.3 RECOMMENDED HYDRAULIC OIL
Viscosity 140-225 SUS @ 100°F (28-45 cSt @ 38°C)
40 min. SUS @ 210ºF (8 min. cSt @ 99ºC)
Flash Point 340ºF min. (170ºC min.)
Pour Point -30ºF min. (-34ºC min.)
Many types of compatible hydraulic oil are available through your local dealer/distributor. As an original equipment
manufacturer, RGC uses a Grade ISO VG 32 hydraulic turbine oil.
Hydraulic oil types are too numerous to list in this manual. If you have any question concerning the type of oil suitable for C120
operation, please consult your local supplier or Reimann & Georger Corporation for details.
2.4 NAMEPLATE AND SERIAL NUMBER TAG
It is important to identify the saw completely and accurately whenever ordering spare parts or requesting assistance in service.
The saw has a product nameplate that states the model and serial numbers. The saw label should appear as the sample nameplate
shown in Figure 2-1. Record the model and serial numbers for future reference.
Figure 2-1.
Typical C120 HydraCutter Product Nameplate
MODEL ___________________________________
SERIAL NUMBER __________________________
HYDRA TOOL
MODEL
SERIAL NO.
GPM PSI

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3OPERATION
3.1 CHAIN SELECTION
Correct chain type selection is critical in maximizing chain life and cutting performance. Refer to the table below as a
guide in the chain selection. However, no direct rule determines which chain type is optimum because many material
factors also influence selection. Refer to Chapter 6 for more information on factors affecting chain life.
Model
Description
MX-3 S (H)
49 Segments
(Faster
Cutting
Speed)
For cutting very hard aggregate concrete (flint, chert, granite, etc.) with heavy steel reinforcing,
medium/hard aggregate concrete (granite, quartz, river rock, etc.) with light steel reinforcing,
or natural stone (e.g. granite).
Heavy steel reinforcing is defined as (5/8” [16 mm] diameter & larger) rebar— closer than 4” o.c.
(“on center”).
Light steel reinforcing is defined as (1/2” [13 mm] diameter & smaller) rebar— farther than 4” o.c.
It is not advisable to use this chain on soft aggregate concrete, masonry brick, concrete block, or
under highly abrasive conditions.
MX-3 L (H)
(Longer
Cutting
Life)
For cutting soft to medium aggregate such as abrasive and “green” concrete with light steel
reinforcing, concrete block, masonry brick, soft stone (limestone, sandstone, marble, etc.) or under
highly abrasive conditions.
Light steel reinforcing is defined as (1/2” [13 mm] diameter & smaller) rebar—1/2 farther than 4” o.c.
It is not advisable to use this chain on heavy steel reinforcing (5/8” [16 mm] diameter & larger), hard
natural stone (flint, chert, granite etc.) or very hard aggregate concrete.
3.2 BEFORE OPERATING THE SAW
The following systems must be checked before you can use the saw safely. Running the saw with an undetected defect in
any of these systems will quickly cause equipment damage.
1. Hydraulic system
2. Water supply and distribution
3. Chain and bar
3.2.1 Checking the System Hydraulics
1. Read and fully understand the operating manual for the hydraulic power source being used.
2. Always check the hydraulic power supply flow and pressure output. Never exceed the maximum hydraulic flow rate
of 12 gpm (45 lpm) and maximum pressure of 2500 psi (172 bar). Overspeeding the chain causes increased chain
wear, leading to loss of strength and possible chain breakage.
3. If the oil flow from the hydraulic power supply cannot be adjusted below the maximum flow rate, a flow divider must
be installed. This will ensure the saw receives the correct flow and excess oil is returned to the tank.
4. To protect the saw from excessive pressure, the pressure relief valve of the hydraulic power source must be set at
2500 psi (172 bar). If this is not possible, a separate pressure relief valve set at 2500 psi (172 bar) must be installed
in the system. If in doubt, contact your dealer.
5. The hydraulic power source must be fitted with a 10-25 micron oil filter.

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6. Before making any hydraulic connections, inspect all hoses for leaks and risks of rupture as follows:
a. Inspect each hose for breaks, cracks, worn spots, bulges, chemical attack, kinks or any other damage. Never try
to stop any detected leak with any body parts. Do not put your face close to suspected leaks. Hold a piece of
cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic oil.
b. Replace a damaged hose immediately. Never repair the hose.
WARNING:
LIQUID UNDER HIGH PRESSURE CAN PIERCE THE SKIN, CAUSING DEATH OR SERIOUS
INJURY. IN CASE OF INJURY, GET IMMEDIATE MEDICAL ATTENTION.
7. The saw uses flush-face quick-release couplings that are durable and easy to clean. Wipe the mating surfaces of the
couplings with clean rag prior to making connection. They are always fitted such that the male part gives oil and the
female part receives oil.
WARNING:
ENSURE HYDRAULIC HOSES ARE PROPERLY CONNECTED AND IN GOOD CONDITION.
3.2.2 Checking Water Supply
1. The water supply must be connected and tested before operating the saw. Check for proper water distribution by
triggering the saw with the hydraulic power supply off and the chain not yet installed. You should see water coming
out the three water ports each on the top and bottom of the bar and around the nose sprocket. If not, use a #10 wire to
clean the water ports, keeping in mind that the water ports are tilted forward at 30 degrees.
2. The water pressure at the saw must be between 50–160 psi (3–9.6 bar) with a flow rate of 2.5 gpm (9 lpm). For best
performance, use an RGC in-line water pump. Permanent chain, bar, and drive and nose sprocket damage will
occur if the saw is run without water, or with a water volume or pressure that is too low. This damage can
include excessive chain stretching, excessive drive and nose sprocket wear, and shorter chain life. The
recommended water pressure for most applications is between 80–100 psi.
CAUTION:
PERMANENT CHAIN, BAR, DRIVE SPROCKET, AND NOSE SPROCKET DAMAGE WILL
OCCUR IF SAW IS RUN WITHOUT WATER, OR WITH A WATER VOLUME OR PRESSURE
THAT IS TOO LOW. THIS DAMAGE CAN INCLUDE EXCESSIVE CHAIN STRETCHING,
EXCESSIVE DRIVE AND NOSE SPROCKET WEAR, AND SHORTER CHAIN LIFE.
3.2.3 Checking Chain and Bar
1. The bottom rail wears at a much faster rate than the top rail because of the downward motion during cutting. It is
recommended that the bar be turned over on a regular basis to ensure even wear.
2. Inspect the chain for cracks, missing segments or bumpers, or signs of overheating (discoloration) or other damage
before mounting and before each use.
3. Inspect the chain chassis for wear. Wearing of the chain chassis is typically referred to as “chain stretch.” If the bar
adjustment screw cannot be tightened sufficiently to prevent the drive tangs from coming completely out of the
groove, the chain chassis is considered to be excessively stretched. Discard the chain.
4. Inspect the cutting segment for wear. The segment is considered worn out when the segment height is worn to about
1/16”, or when the segment and chain chassis are the same width.

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Figure 3-1.
Proper Chain Mounting
5. The chain MUST be installed with the bumper/drive link tang arrow pointing towards bar nose on top side of bar. See
Figure 3-1. Backward (reverse) chain installation can cause excessive vibration, rough cutting, reduced chain
life, and chain breakage
6. Check for proper chain tension as described in Chapter 4.
7. Check that the drive sprocket cover mounting screws are tight.
WARNING:
DRIVE SPROCKET COVER PROVIDES PROTECTION AGAINST CONTACT WITH MOVING
PARTS, EJECTED DEBRIS, BROKEN CHAIN, THROWN WATER AND CONCRETE SLURRY.
NEVER OPERATE SAW WITHOUT COVER SECURELY IN PLACE.
8. Always operate a new chain at the rated rpm for two minutes with proper water supply before cutting to verify proper
chain mounting and tension. The chain should be moving away from you (i.e., forward direction) at the top of the
power bar. If it is not, change the position of the forward/reverse lever on the power unit, if equipped, or reverse
hydraulic connections at power unit.
CAUTION:
EXCESSIVE CHAIN OPERATING SPEED OR INSUFFICIENT WATER SUPPLY RESULTS IN
EXCESSIVE WEAR TO THE CHAIN, WHICH CAN LEAD TO LOSS OF STRENGTH AND
CHAIN BREAKAGE. OPERATE CUTTING CHAIN AT CORRECT SPEED WITH ADEQUATE
WATER.
3.3 PLANNING THE CUT
1. This saw is not insulated. Do not start cutting without first de-energizing electrical wiring imbedded in the concrete
and near the cutting site.
2. When cutting a structural member such as a wall, ensure the cut will not weaken the structure such that it will cause a
failure.
3. Plan the sequence of cuts to prevent the weight of the material being cut from pinching the bar and chain, causing it to
bind. Start with the base horizontal cut and proceed with the remaining cuts.
4. The material being cut must be rigidly supported to prevent it from falling and causing personnel injury.
5. The planned line of cut can be outlined with a permanent marker for a visual guide.

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6. For long vertical or horizontal cuts, the cutting line can be first scored with a groove using the nose of the bar. The
groove will help guide the bar for a straight cut.
3.4 BREAKING IN A NEW CHAIN
1. Before using a new chain, the cutting segments must be dressed by cutting in an abrasive material such as cinder
blocks or bricks.
2. Looking at the cutting segment closely, you should be able to see the diamond particles exposed, raised slightly higher
than the surrounding surface.
3. Check the chain tension frequently during the first thirty minutes of operation of a new chain.
3.5 CUTTING PROCEDURE
WARNING:
THE DRIVE SPROCKET COVER MUST BE IN PLACE BEFORE STARTUP AND DURING SAW
OPERATION. FAILURE TO DO THIS CAN CAUSE SERIOUS PERSONAL INJURY.
1. Review all safety procedures in Chapter 1 of this manual and in the manual supplied with your hydraulic power unit.
2. Grasp the auxiliary handle with your left hand. Use the appropriate part of the handle for making the first cut.
3. Grasp the trigger with your right hand.
4. Position the saw in the appropriate place to make the desired cut.
5. Disengage (press & hold) the trigger lockout. Then depress (squeeze) the trigger to start the saw.
6. When putting the chain into an existing cut, the cut must be the same width as the chain. Putting the chain into an
existing cut narrower than the chain will rapidly wear the side clearance of the chain and could cause chain breakage.
7. When starting a cut, do not bang the chain into the cutting medium. Jarring impacts can decrease the life and
performance of the chain.
8. Plan the cutting strategy before starting. Once the saw starts cutting, you cannot change direction of a cut easily. Do
not twist the bar in the cut.
9. Do not apply excessive feed force. A constant chain speed is important for optimum cutting.
10. When plunge cutting, increase the opening of the cut by rocking the saw up and down. Aggressive plunge forces may
cause the saw to jam when exiting the cut. If the saw does become jammed in a plunge cut, you can release the saw as
described in Chapter 5.
11. Check chain tension frequently during cutting.
3.6 SHUTTING DOWN AND STORING THE SAW
1. Stop the saw by releasing the trigger lever.
2. Stop the hydraulic power source following the procedure in the respective instruction manual.
3. Clean the slurry off the saw with water before it dries.
4. Shut off water supply.
5. Disconnect the hydraulic hoses from the saw.

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WARNING:
NEVER DISCONNECT ANY HYDRAULICALLY OPERATED PART OF THE SAW OR
REMOVE HYDRAULIC COMPONENTS, LINES, OR FITTINGS WHILE THE POWER
SOURCE IS RUNNING OR WHENEVER THE HYDRAULIC FLUID IS HOT.
6. Allow the water to drain out of the saw by pointing the nose down and triggering the valve on. If available, blow the
water out of the saw with compressed air. Spray entire saw with a light coating of oil to make cleanup easier next
time. Make sure the chain, bar, and bar nose sprocket have a coating of oil to prevent rusting.
7. Secure the saw and hydraulic power source to prevent unauthorized use.
8. Store the saw away from excessive heat or moisture. Store in a clean, dry area away from exposure to high humidity,
water, other liquids, or freezing temperatures. Avoid temperatures low enough to cause condensation on the chain
when moving it from storage to a higher temperature. Always handle and store chains carefully.
9. Do not stack material on top of the saw that may cause the chain or bar to bend or deform.

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4INSPECTION AND MAINTENANCE
4.1 GENERAL MAINTENANCE RULES
Hydraulic fluid can become contaminated after extended periods of use which can cause restrictions in the system. Check to see
that the fluid is clean, and change at recommended intervals to extend saw’s life. Refer to the respective manual for maintenance
information on the hydraulic power source.
CAUTION:
FAILURE TO MAINTAIN CUTTING SYSTEM REGULARLY AND PROPERLY CAN LEAD TO
PREMATURE WEAR AND INCREASE PROBABILITY OF CHAIN BREAKAGE.
1. Proper maintenance of the saw and related equipment requires timely adhering to all the guidelines given in this chapter.
Proper maintenance is required to maintain the system in good condition and free of defects.
2. Review and follow all the safety rules given in Chapter 1 before attempting any maintenance.
3. Only authorized personnel should be allowed in the maintenance area. Authorized personnel are the trained people as
defined below and their supervision.
4. Repairs must be made only by trained personnel. A trained person is one who has read and thoroughly understands this
instruction manual and related equipment manuals and, through training and experience, has shown knowledge regarding the
safe operational procedures.
CAUTION:
BEFORE STARTING ANY MAINTENANCE, DISCONNECT SAW FROM HYDRAULIC POWER
SOURCE TO PREVENT ACCIDENTAL STARTUP.
WARNING:
DURING ANY MAINTENANCE OR REPAIR PROCEDURES, DO NOT ATTEMPT ANY
SAWING. THIS CAN CAUSE EQUIPMENT DAMAGE AND/OR PERSONAL INJURY.
4.2 BAR INSPECTION AND MAINTENANCE
1. Before installing the bar, ensure the bar is not bent or twisted.
2. Ensure that the bar rails are dressed squarely as shown in Figure 4-1 with the wire edges removed. As the bar rails wear
down, sharp burrs are formed on the edge of the rails, which are typically referred to as wire edges. If ignored, wire edges
mushroom over and affect cutting performance.
Figure 4-1
Dressed Bar Rail
3. Ensure the nose sprocket rotates freely.

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4. Check the clearance between the nose of the bar side-plates and the chain chassis; when new, there is 1/32” clearance. The
bar must be replaced before the chain chassis begins to ride directly on the nose of the bar side-plates. Refer to Figure 4-2.
Figure 4-2
Nose Sprocket Clearance
5. The bottom rail wears at a much faster rate than the top rail because of the downward motion during cutting. It is
recommended that the bar be turned over on a regular basis to ensure even wear.
6. Check the bar rail wear. The bar is considered worn-out when any section of the chain groove bottom contacts the chain.
7. Install the bar by aligning the mounting holes on the bar with the bar mount studs (#33) as shown in Figure 7-1. Install chain
and replace sprocket cover. Securely attach with two hex nuts (#30).
8. Check the water ports for proper water distribution by triggering the saw with the water connected and hydraulics
disconnected. Water should be coming out of the three water ports each on the top and bottom of the bar and around the
nose sprocket. If not, use tip cleaner (#60) or #10 wire to clean the water ports. Note that water ports are tilted forward
(towards nose) at a 30°angle.
9. After usage be sure to flush all slurry off entire saw while still wet. Dry slurry is very difficult to remove and speeds
corrosion of surfaces. Ensure water is completely drained out of the saw. If available, blow the water out with compressed
air.
CAUTION:
NEVER RUN THE SAW WITH PLUGGED WATER PORTS. THIS CAN CAUSE
OVERHEATING AND RESULTING EQUIPMENT DAMAGE.
10. Ensure the bar, nose sprocket, and chain all have a light coat of oil to prevent rusting between uses.

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4.3 DRIVE SPROCKET INSPECTION AND INSTALLATION
Refer to Figure 4-3. The sprocket assembly consists of external retaining ring (#28) and drive sprocket (#27).
Proceed as follows:
1. Check the wear marks on the driving face. Replace the drive sprocket before the wear marks are deeper than 1/32” as shown
in Figure 4-4. The outside diameter is also a wearing surface. Do NOT turn around and continue using a worn drive
sprocket. A worn drive sprocket will increase wear on the chain chassis.
28
27 26
Figure 4-3
Drive Sprocket Assembly
2. Before installing the drive sprocket, carefully inspect the motor shaft for scoring, dried slurry or other debris between the
moving parts of the assembly including the felt gasket. Replace gasket if needed.
3. Slide drive sprocket onto shaft so that shaft extends completely through the bore.
4. Install retaining ring using standard snap ring pliers.
.030"
Figure 4-4
Sprocket Wear Measurement

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4.4 CHAIN INSPECTION AND MAINTENANCE
Inspect the chain before mounting and before each use.
1. Ensure there are no missing segments or bumpers. There must be 49 segments with a bumper link between each segment.
2. Ensure there are no signs of cracking, overheating, or other damage.
3. Check the wear of the chain chassis, typically referred to as “chain stretch”, by tensioning the chain as described in Section
4.5. The chain chassis is considered worn out or excessively “stretched” if the chain cannot be tensioned sufficiently to
prevent the drive tangs from coming completely out of the groove. Discard the chain.
4. Check the segment wear. The segment is considered worn-out when the height is worn down to about 1/16”, or when the
segment width is the same as the chain chassis.
After each use clean the slurry and debris off the chain; then apply a light coating of oil to prevent rusting.
4.5 CHAIN INSTALLATION AND TENSIONING
Refer to the Figure 7-1 assembly drawing in Chapter 7 throughout the following procedure.
WARNING:
FAILURE TO DISCONNECT THE POWER SUPPLY BEFORE STARTING CAN CAUSE
EQUIPMENT DAMAGE AND/OR PERSONAL INJURY.
1. Ensure the hydraulic hoses to the saw are disconnected before starting.
2. With the drive sprocket cover removed, back out the bar adjustment screw (#36) all the way by turning it counter-clockwise.
3. Inspect the drive sprocket (#27) and the bar (#34) as described in sections 4.3 and 4.2 respectively.
4. Install the chain by placing it around the drive sprocket making sure the bumpers lead the segments. Then, run the drive
tangs into the top groove of the bar (tang arrows pointing towards bar nose) and rotate it around the bar. Backward
(reverse) chain installation can cause excessive vibration, rough cutting, reduced chain life, and chain breakage.
Make sure all drive link tangs are positioned inside the groove of the bar.
5. Tighten the bar adjustment screw (#36) clockwise until chain is snug to the bar but still able to rotate around the bar. Chain
tension needs to be readjusted before the drive tangs can come completely out of the groove.
WARNING:
IF THE CHAIN IS TOO LOOSE DURING SAW OPERATION, THERE IS AN INCREASED
RISK OF CHAIN THROWING. A CHAIN THROW CAN CAUSE EQUIPMENT DAMAGE
AND/OR PERSONAL INJURY.
6. Secure the drive sprocket cover assembly in place by tightening both flange nuts (#30).
WARNING:
NEVER OPERATE THE SAW WITHOUT THE DRIVE SPROCKET COVER INSTALLED.
FAILURE TO DO THIS CAN CAUSE SERIOUS PERSONAL INJURY.

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5TROUBLESHOOTING
The following chart is intended to assist with troubleshooting the C120 HydraCutter. While not all inclusive, the chart outlines
the most common causes of a problem and the recommended course of action.
Consult your hydraulic power supply manual for troubleshooting this part of your system.
SYMPTOM
CAUSE
CORRECTIVE ACTION
Saw will not cut
straight.
Operator feed force not
applied directly over centerline
of bar.
Frame is bent.
Uneven bar rail wear.
Uneven chain segment profile.
Operator unable to maintain a
level and straight saw position.
Bent or twisted bar.
Move hand closer to centerline of bar.
Repair or replace frame.
Dress rails square or turn bar over as described in Section 4.2.
Replace bar.
Redress segment by cutting in an abrasive medium such as
concrete, cinder blocks, or bricks.
Use an attached guide on wall (i.e., 2 x 4, wood rails).
Use a precut slot in the wall the full length of desired cut to be
made.
Replace bar.
Premature chain
stretch.
Chain is mounted backwards
with bumper side of diamond
segment not being the side to
first contact the cutting groove.
Insufficient water supply.
Hydraulic flow is exceeding
12gpm (45lpm).
Loose chain tension.
Excessive groove worn in
drive sprocket.
Improper operator technique.
Inspect chain as described in Section 4.4 before re-installing.
Plugged bar water ports:
(a) Clean ports with #10 wire.
(b) Check and verify that water supply is clean.
(c) Install inline water filter.
(d) If unable to maintain water pressure between 50–160 psi
(3.5–9.6 bar) with a minimum flow rate of 2.5 gpm (9.5
lpm), use an RGC inline water pump.
Adjust power supply or use a flow divider to limit hydraulic
flow to 12gpm (45lpm).
Maintain the chain tension as described in Section 4.5.
Replace drive sprocket.
Minimize impacting when cutting steel.
Minimize rapid chain stops, such as jamming.

15
Excessive vibration
and rough cutting.
Segment(s) broken or missing
from chain.
Loose chain tension.
Loose bar mounting bolts.
Chain installed backwards on
saw as described under the
heading “Chain Inspection”.
Worn bar nose sprocket.
Worn drive sprocket.
Excess feed force when cutting
rebar.
Replace chain.
Maintain chain tension as described in Section 4.5.
Tighten bolts as described in Section 4.5.
Inspect chain as described in Section 4.4 and 4.5 before re-
installing.
Replace bar.
Replace drive sprocket.
Reduce feed force.
Bar nose sprocket
does not turn
Nose bearings worn and are
jammed between inner and
outer race.
Bent or twisted bar.
Replace bar.
Replace bar.
Saw cuts slowly
Loss of diamond segment side
or top clearance.
Chain segment dulled because
of continuous use in hard
material or steel.
Wire edged bar rails.
Hydraulic flow is below 12
gpm.
Hydraulic pressure relief is set
below 2500 psi.
Chain tension too tight or too
loose.
Chain slipping through worn
teeth on drive sprocket.
Hydraulic hoses too long or
too small in diameter.
Hydraulic oil leaking on chain.
Replace chain.
Redress segment by cutting in abrasive material such as
concrete building block or brick.
Choose the right chain for the cutting condition. Select either
S, or L as described in Section 3.1 & Sec. 6.
Dress the top and sides of the bar rails squarely with a grinder
or belt sander. See Section 4.2.
Adjust hydraulic power source.
Adjust hydraulic power source.
Readjust chain tension as described in Section 4.5.
Install new drive sprocket. See Section 4.3.
Select the shortest hose that is feasible. The maximum hose
length for 1/2” hose is 100 feet.
Check the following locations for leaks:
(a) Quick disconnect fittings.
(b) Saw control valve assembly.
(c) Saw motor hydraulic fittings.
(d) Saw motor shaft.
(e) O-ring leak at valve spool assembly which controls
both oil and water flow—replace O-ring.
Adjust or replace appropriate part.

16
Saw wedged tightly
in plunge cut.
Excessive feed force when
exiting back side of plunge cut.
Turn off power supply; then loosen chain tension and remove
saw from cut.
Saw is binding in
the cut.
Bar is bent or twisted.
Frame is bent.
Saw not cutting a straight line.
Side clearance of chain worn.
Wire edged bar rails.
Replace bar.
Repair or replace frame.
Refer to “Saw Will Not Cut Straight” part of troubleshooting
chapter.
Replace chain.
Dress top and sides of the bar rails squarely with a grinder or
belt sander. See Section 4.2.

17
6FACTORS AFFECTING CHAIN LIFE
Optimum performance from your chain saw will depend largely on selecting the proper chain for the application. If the cutting
medium is too soft for the chain rating used, you may get fast chain wear. If the cutting medium is too hard for the chain rating
used, you will get segment glazing and/or very poor cutting performance. This chapter is a guide in making the proper chain
selection.
6.1 HOW DIAMOND SEGMENTS WORK
Cutting concrete, stone, and other hard, brittle materials is a grinding or abrading action. Cutting segments are composed of
hard, abrasion resistant diamond particles distributed randomly in a metal matrix. The diamonds abrade or scratch out particles
of the hard substrates during the cutting operation. Even though diamond is the hardest substance known to man, it does wear out
or break down. New diamonds are exposed as the metal bond wears away. Abrasive particles will wear down a metal bond
faster than hard, brittle particles.
6.2 MATERIAL FACTORS AFFECTING CHAIN LIFE
There are several material factors that affect the performance and life of diamond segmented chain. Six major factors are
summarized as follows:
1. Aggregate Hardness—There are many different types of rocks used as concrete aggregate. Some aggregates are very hard
like flint and some are very soft like limestone. A general rule is that the harder the aggregate, the softer the segment bond
that is needed. Another general rule is that the harder the aggregate, the slower the chain will cut. A common way of
measuring aggregate hardness is the Moh’s Scratch Test.
MOH’S SCALE
HARDNESS CRITERIA
STANDARD
SCALE
HARDNESS CRITERIA
DIAMOND
CORUNDUM
TOPAZ
10
9
8
Very hard aggregates (flint, chert, some basalt, some quartz, some trap rock)
QUARTZ
FELDSPAR
APATITE
7
6
5
Hard aggregates (some quartz, some granite, some basalt, some river gravel,
some trap rock)
Medium hard aggregates (some granite, some river rock)
FLUORITE
CALCITE
GYPSUM
TALC
4
3
2
1
Medium aggregates (dense limestone, sandstone, dolomite, marble)
Medium soft aggregates (soft limestone)
2. Aggregate Size—As the rock size increases, cutting generally will be slower and the chain life will decrease. Common U.S.
aggregate sizes are sieved at 1-1/2”, 1”, 3/4”, and 3/8”.
3. Size and Quantity of Reinforcing—Steel reinforcing critically affects diamond chain life. Quantifying the amount of
reinforcing can generally be divided into two levels: