RGC C150 User manual

8 GPM
MINI HYDRACUTTER
INSTRUCTIONS
REIMANN & GEORGER CORPORATION
CONSTRUCTION PRODUCTS BUFFALO, NY
P/N 6122092 3/5/15

TABLE OF CONTENTS
CHAPTER TITLE PAGE
1 SAFETY .................................................................................................................................1
1.1 Introduction .............................................................................................................................1
1.2 Safety Definitions....................................................................................................................1
1.3 Power Source and Saw Safety Labels......................................................................................1
1.4 Mini HydraCutter Safety Rules................................................................................................1
2 SPECIFICATIONS ...............................................................................................................3
2.1 Introduction .............................................................................................................................3
2.2 Technical Data.........................................................................................................................3
2.3 Recommended Hydraulic Oil...................................................................................................3
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.........................................................................................................7
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 Nose Sprocket Replacement...................................................................................................11
4.4 Drive Sprocket Inspection and Installation.............................................................................12
4.5 Chain Inspection and Maintenance.........................................................................................13
4.6 Chain Installation and Tensioning ..........................................................................................13
5 TROUBLESHOOTING.......................................................................................................15
6 FACTORS AFFECTING CHAIN LIFE ............................................................................18
6.1 How Diamond Segments Work ..............................................................................................18
6.2 Material Factors Affecting Chain Life....................................................................................18
6.3 Operational Factors Affecting Chain Life...............................................................................19
6.4 Chain End-of-Life Modes.......................................................................................................20
7 PARTS LIST.........................................................................................................................21
RGC CONSTRUCTION PRODUCTS PHONE: [phone]

LIST OF FIGURES
FIGURE DESCRIPTION PAGE
2-1 Typical Mini HydraCutter Product Nameplate .......................................................................4
3-1 Proper Chain Mounting...........................................................................................................7
4-1 Dressed Bar Rail ....................................................................................................................11
4-2 Nose Sprocket Clearance .......................................................................................................11
4-3 Sprocket Assembly.................................................................................................................12
4-4 Sprocket Wear Measurement.................................................................................................13
7-1 Mini HydraCutter Frame & Valve Assembly.........................................................................22
7-2 Mini HydraCutter Assembly-Front View...............................................................................23
7-3 Mini HydraCutter Assembly-Back View ...............................................................................24
RGC CONSTRUCTION PRODUCTS PHONE: [phone]

1SAFETY
1.1 INTRODUCTION
Your Reimann & Georger Corporation Mini HydraCutter has been engineered to provide cutting performance, long term
economics and safety advantages that no other type can match. However, even a well-designed and well-built HydraCutter
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 HydraCutter 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 HYDRACUTTER 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 MINIHYDRACUTTER SAFETY RULES
1. Only trained personnel shall operate the HydraCutter 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. HydraCutting 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 HydraCutter in an explosive atmosphere and/or near combustible material that could be ignited by a
spark.
4. Do not use a HydraCutter that shows any signs of damage. Do not use the HydraCutter 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 HydraCutter without the chain guard in place.
6. Never allow anyone to stand in front of, or in line with, the chain forward of the guard.
7. 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.
8. Do not use the HydraCutter when you are tired or fatigued.
9. Never operate the HydraCutter under the influence of drugs, alcohol, or medication.
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10. Always carry the HydraCutter in its de-energized state.
11. Keep the HydraCutter handles dry, clean, and free of oil or fuel.
12. Do not start cutting without first de-energizing electrical wiring near the cutting site or imbedded in the concrete.
13. Before cutting through a wall, check both sides for possible obstructions.
14. Prior to cutting, plan your cuts to prevent pinching of the bar or personnel injury from falling concrete.
15. Always hold the HydraCutter with both hands during operation. Use a firm grip on the handles.
16. Never exceed the flow and pressure rating of the HydraCutter which is 8 gpm at 2500 psi.
17. Do NOT attempt to adjust the HydraCutter during operation.
18. Keep clothing and all parts of the body away from moving parts of this HydraCutter when connected to a power
source or being used.
19. 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.
20. Always shut off the hydraulic power and cooling water sources before disconnecting the hoses or servicing the
HydraCutter.
21. 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 MiniSaw hydraulic hand-held chain saw 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 MiniSaw.
ENGLISH METRIC
Tool Physicals
Weight 16 lbs. (7.3 kg.)
Bar Size (15 in. bar) 15 in. x 2.25 in. (38.1 x 5.72 cm)
Bar Size (13 in. bar) 13 in. x 2.25 in. (33.0 x 5.72 cm)
Dimensions (with 15 in. bar) 29.23 x 11.13 x 12 in. (74.2 x 28.3 x 30.5 cm)
Dimensions (with 13 in. bar) 27.23 x 11.13 x 12 in. (69.2 x 28.3 x 30.5 cm)
Depth of Cut (with 15 in. bar) 15 in. (381 mm)
Depth of Cut (with 13 in. bar) 13 in. (330 mm)
Chain
Segments (for 15 in. bar) 55
Segments (for 13 in. bar) 50
Segment Dimensions 0.39 x 0.22 x 0.16 in. (10.0 x 5.5 x 4.0 mm)
Bar
Nose Sprocket 11 tooth
Hydraulic Requirements
Type of System Open-Center
Flow Rate 8 gpm (30 lpm)
Max Pressure Range 2000–2500 psi (138–158 bar)
Back Pressure (Max) 200 psi (13.8 bar)
Hose Length (Max) 100 ft. (30 m)
Couplings ½” HTMA flush face
Water Requirements
Flow Rate 2.5 gpm (9 lpm)
Pressure (Min) 50 psi (3 bar)
Operation
Power @2000 psi 8.0 Hp (6.0 kw)
Power @2500 psi 10.0 Hp (7.5 kw)
Torque @2000 psi 118 in.-lbs. (13.3 Nm)
Torque @2500 psi 148 in.-lbs. (16.7 Nm)
Speed (Max) 5000 rpm
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.
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Hydraulic oil types are too numerous to list in this manual. If you have any question concerning the type of oil suitable for
MINISAW 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 MiniSaw completely and accurately whenever ordering spare parts or requesting assistance in
service. The MiniSaw has a product nameplate that states the model and serial numbers. The MiniSaw 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 MiniSaw Product Nameplate
MODEL ___________________________________
SERIAL NUMBER __________________________
HYDRA TOOL
MODEL
SERIAL NO.
GPM PSI
4

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
SL25
(50 or 55
segments)
For cutting hard/very hard aggregate concrete (flint, chert, granite, etc.) with heavy steel reinforcing.
Heavy steel reinforcing is defined as 5/8” [16 mm] or larger rebar—1/2 closer than 4” o.c. (“on
center”). The SL25 has a higher diamond concentration than the SL45 with a softer matrix.
It is not advisable to use this chain on soft or medium aggregate concrete, masonry brick, concrete
block, or under highly abrasive conditions.
SL25
(50 or 55
segments)
For cutting medium soft/medium hard aggregate concrete (granite, quartz, river rock, etc.) with
moderate steel reinforcing. Moderate steel reinforcing is defined as (1/2” [13 mm] or 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), soft
or very hard aggregate concrete, masonry brick, or concrete block.
SL45
(50 or 55
segments)
For cutting soft/medium soft aggregate such as abrasive and “green” concrete, concrete block,
masonry brick or under highly abrasive conditions
Do NOT use this chain on any type of steel reinforcing, or medium or very hard aggregate concrete.
3.2 BEFORE OPERATING THE HYDRACUTTER
The following systems must be checked before you can use the HydraCutter safely. Running the HydraCutter 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 8 gpm (30 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 HydraCutter receives the correct flow and excess oil is returned to the tank.
4. To protect the HydraCutter from excessive pressure, the pressure relief valve of the hydraulic power source must be
set at 2300 psi (158 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.
6. Before making any hydraulic connections, inspect all hoses for leaks and risks of rupture as follows:
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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.
The HydraCutter 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 HydraCutter. Check for proper water distribution
by triggering the HydraCutter 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 HydraCutter 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 HydraCutter 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.
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 link leading the diamond segment. 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 chain guard is in the mounting grooves and that the socket head screw is tight.
8. Always operate a new chain at the rated rpm for two minutes 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.
3.3 PLANNING THE CUT
1. This HydraCutter 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.
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.
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3.5 CUTTING PROCEDURE
WARNING:
THE CHAIN GUARD 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 HydraCutter in the appropriate place to make the desired cut.
5. Disengage the trigger lockout. Then depress (squeeze) the trigger to start the HydraCutter.
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 HydraCutter 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 HydraCutter up and down. Aggressive plunge
forces may cause the HydraCutter to jam when exiting the cut. If the HydraCutter does become jammed in a plunge
cut, you can release the HydraCutter as described in Chapter 5.
11. The wall walker attachment, shown in Figure 3-2, can be used to provide mechanical advantage during horizontal and
vertical cuts. By inserting the wall walker into the HydraCutter kerf, a forward feed force is changed into a downward
feed force.
12. Check chain tension frequently during cutting.
3.6 SHUTTING DOWN AND STORING THE HYDRACUTTER
1. Stop the HydraCutter 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 HydraCutter with water before it dries.
4. Shut off water supply.
5. Disconnect the hydraulic hoses from the HydraCutter.
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.
Allow the water to drain out of the HydraCutter by pointing the nose down and triggering the valve on. If available, blow
the water out of the HydraCutter with compressed air. Spray entire HydraCutter 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.
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6. Secure the HydraCutter and hydraulic power source to prevent unauthorized use.
7. Store the HydraCutter 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.
8. Do not stack material on top of the HydraCutter 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 MiniSaw’s life. Refer to the respective manual for
maintenance information on the hydraulic power source.
1. Proper maintenance of the MiniSaw 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, insure 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.
3. Ensure the nose sprocket rotates freely.
4. Check the clearance between the nose of the bar side-plates and the chain chassis; when new, there is 1/32” clearance. The
nose sprocket must be replaced before the chain chassis begins to ride directly on the nose of the bar side-plates. Refer to
Figure 4-2.
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 on the two mounting studs (28) and align the bar adjust pin (45) to the hole on the bar as shown in Figure 7-2.
Install the chain cover and install the two flanged hex nut. Use the 9/16” box wrench to securely fasten the flanged nuts
(#29).
8. Check the water ports for proper water distribution by triggering the MiniSaw 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 a #10 wire to clean the water ports. Note that water ports are tilted forward at a 30°angle.
9. Ensure water is completely drained out of the MiniSaw. If available, blow the water out with compressed air.
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CAUTION:
NEVER RUN THE SAW WITH PLUGGED WATER PORTS. THIS CAN CAUSE
OVERHEATING AND RESULTING EQUIPMENT DAMAGE.
10. Ensure the bar and nose sprocket have a light coat of oil to prevent rusting.
Figure 4-1
Dressed Bar Rail
4.3 NOSE SPROCKET REPLACEMENT
The nose sprocket will wear more quickly than the bar rails under normal working conditions. When new, there is 1/32”
clearance between the nose of the bar side-plates and the chain chassis. The nose sprocket must be replaced before the chain
chassis begins to ride directly on the nose of the bar side-plates.
Figure 4-2
Nose Sprocket Clearance
1. Using the chain breaker, punch out the six rivets and discard.
2. Use a slotted screwdriver to carefully spread the bar side-plates apart. Be careful not to deform the bar side-plates by over-
bending them.
3. Use a rag or paper towel to clean the nose sprocket area. Inspect the inner surfaces where the bearings ride. If a groove has
formed, it is not advisable to replace the nose sprocket. Replace the bar instead.
4. With the side-plates spread apart the minimum space needed, install the new nose sprocket by sliding the assembly on the
insertion card into position. Align the six rivet holes. Insert the six rivets into the holes without breaking through the
insertion card and lightly hold them in place. Carefully remove the insertion card and screwdriver.
5. Place the insertion card over the rivets. Holding the rivets in place with the insertion card, turn the bar over onto a flat steel
surface. Remove and discard insertion card. With the bar solidly supported on a flat steel surface, carefully peen the rivet
heads with the flat end of a hammer. Be very careful not to hit the bar body because it will pinch the nose sprocket. Rivet
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heads must completely fill the countersinks in the bar body to hold the nose sprocket securely while still allowing the
sprocket to turn freely.
6. File the rivet heads as close to the bar body as possible.
A. Trantorque® bushing
B. Drive sprocket
Figure 4-3
Sprocket Assembly
4.4 DRIVE SPROCKET INSPECTION AND INSTALLATION
Refer to Figure 4-3. The sprocket assembly consists of the Trantorque® bushing “A” and the drive sprocket “B.” 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 wearing surface. Do NOT turn around and continue using a worn drive sprocket.
A worn drive sprocket will increase wear on the chain chassis.
2. Before installing the drive sprocket, carefully inspect the Trantorque® bushing for scoring on the inside diameter, dried
slurry or other debris on the threads and between the moving parts of the assembly. Do NOT lubricate the bushing.
3. Slide Trantorque® onto shaft so that shaft extends completely through the bore.
4. Slide the drive sprocket over the Trantorque® so that gold portion is within the bore approximately 1/16” past the edge. Be
sure the nut flats protrude so that a wrench can be used.
5. Hand tighten the Trantorque® nut clockwise until snug. Looking from the top, the center of the drive sprocket must be
centered with the bar groove.
6. Make any fine adjustments to the position of the drive sprocket. Holding the drive sprocket with the supplied drive sprocket
lock handle, tighten the nut of the unit with a torque wrench to 200 in.-lbs., 17 ft.-lbs., or 22.6 newton-meters. Do NOT use
a pipe wrench or pliers.
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Figure 4-4
Sprocket Wear Measurement
4.5 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 either 50 or 76 segments.
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
4.6. 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.
A broken chain that is not worn-out can be repaired. There is a complete line of chain repair accessories available from RGC.
Separate instruction manuals are provided for the chain breaker and rivet spinner. Read these manuals before attempting these
repair procedures.
4.6 CHAIN INSTALLATION AND TENSIONING
Refer to the Figure 7-1, 7-2, & 7-3 assembly drawings 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 MiniSaw are disconnected before starting.
2. Loosen and remove the two flanged hex nuts (#29) and remove chain cover (#19). Next back out the bar adjustment screw
(#45) all the way by turning it counter-clockwise.
3. Inspect the drive sprocket (#32) and the bar as described in sections 4.4 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 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.
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5. Install the chain cover (#19) and install the two flanged hex nuts (#29) but do not tighten at this time. Tighten the bar
adjustment screw (#45) 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.
CAUTION:
IF THE CHAIN IS TOO LOOSE DURING SAW OPERATION, THERE IS AN INCREASED
RISK OF CHAIN THROWING.
6. Tighten the two flanged hex nuts (#29).
WARNING:
NEVER OPERATE THE SAW WITHOUT THE GUARD INSTALLED. DOING THIS CAN
CAUSE PERSONAL INJURY.
14

5TROUBLESHOOTING
The following chart is intended to assist with troubleshooting the Mini 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
HydraCutter 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 HydraCutter
position.
Bent or twisted bar.
Excessive clearance in wall
walker pivot points.
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.
Replace wall walker.
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 8
gpm (30 lpm).
Loose chain tension.
Excessive groove worn in
drive sprocket.
Improper operator technique.
Inspect chain as described in Section 4.5 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 8 gpm (30 lpm).
Maintain the chain tension as described in Section 4.6.
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
HydraCutter as described
above under the heading
“Premature Chain Stretch.”
Worn bar nose sprocket.
Worn drive sprocket.
Excess f
eed force when cutting
rebar.
Remove and repair broken chain section as described in
Section 4.5.
Maintain chain tension as described in Section 4.6.
Tighten bolts as described in Section 4.6.
Inspect chain as described in Section 4.5 before re-installing.
Replace parts as described in Section 4.3.
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 nose sprocket as described in Section 4.3.
Replace bar.
HydraCutter 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 8
gpm.
Hydraulic pressure relief is set
below 2500 psi.
Drive sprocket slipping on
drive shaft.
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.
Chain slipping through worn
teeth on drive sprocket.
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
CH, or CR as described in Section 3.1.
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 and tighten Trantorqueshaft adapter. See Section
4.4.
Readjust chain tension as described in Section 4.6.
Install new drive sprocket. See Section 4.4.
16

HydraCutter cuts
slowly. (continued)
Hydraulic hoses too long or
too small in diameter.
Hydraulic oil leaking on chain.
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) HydraCutter control valve assembly.
(c) HydraCutter motor hydraulic fittings.
(d) HydraCutter 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.
HydraCutter 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
HydraCutter from cut.
HydraCutter is
binding in the cut.
Bar is bent or twisted.
Frame is bent.
HydraCutter not cutting a
straight line.
Side clearance of chain worn.
Excessive clearance in wall
walker pivot points.
Wire edged bar rails.
Replace bar.
Repair or replace frame.
Refer to “HydraCutter Will Not Cut Straight” part of
troubleshooting chapter.
Replace chain.
Replace wall walker.
Dress top and sides of the bar rails squarely with a grinder or
belt sander. See Section 4.2.
17