Cengar JP901 User manual

EC Declaration of Conformity
Cengar. Ltd.
70, Lister Lane, Halifax
England HX1 5DN
We the undersigned, declare under our sole responsibility that the
following apparatus: -
Machine description: Cengar Air Saw
Machine Type: JP901
Is in conformity with the following relevant EC legislation:
Machinery Directive 2006/42/EC
Atex Directive 94/ 9/EC
Based on the following Harmonised Standards:
EN13463-1:2009
And therefore complies with the essential requirements of those
directives.
Additional Information:
ATEX Coding II 2G T5
Certificate No. TRAC09ATEX21236X
Technical File No. CEEX-0803
Authorised Signature:
Date: 15/12/09
Title of Signatory: General Manager - Cengar Ltd.

SPECIFICATIONS
Speed
Stroke
Air Consumption
Air Pressure
Weight
Length
Height
Width
Vibration Level averaged
Sound Pressure Level
Sound Power Level
Atex Certification
10,000 strokes per minute
9 mm
0.116m3/minute
5-6 Bar
1.6 Kgs.
270 mm.
70 mm.
40 mm.
6.5 m/s2 typical, 9.1 m/s2 Max
68.6 db.
78.0 db.
CE II 2G T5 X
CengarAir Saw Model JP901
We recommend normal safe working practices
should be followed as per the Health and Safety at
Work Act, or the appropriate National and State
Laws. We recommend that eye protection be worn
when using Cengar Saws

CENGAR SAWS
are hand held reciprocating saws designed to cut metals and plastics in
production environments and can be used in Atex zoned areas where
appropriate. They should only be used by trained operators who are
responsible for the safety of themselves and others in the vicinity. Saw
blades are capable of causing serious injury
Think safe Act safe Be safe
LUBRICATION
Use Cengar Green Oil with longer lasting coating properties for best
results. Cengar Green Oil is specially prepared to: -
1 Emulsify the water generally found in compressed air lines.
2 Give perfect mist lubrication.
3 Remain fluid at the low working temperature of compressed air tools.
4 Contains corrosion and oxidation inhibitors.
Incorrect oils if used will soon “break down” forming a sludge which will
slow and eventually stop the action of the saw. See maintenance details.
INSTALLATION OF BLADES.
Before attempting to insert or change a blade, ensure that the air supply is
isolated by operating the isolation valve provided. Loosen the retaining
grub screws with the key provided, insert blade through nosepiece so that
the teeth are cutting on the pull stroke.
Locate the back screw in the hole in the end of the blade, for a positive
drive, the front screw can then be tightened to grip the blade firmly.
BLADES
Cengar “Shatterproof” Bi-Metal blades are specially prepared for use with
Cengar saws, to withstand the high operating speeds, and give maximum
cutting life.
Choose the teeth per inch to suit the characteristics of the material being
cut.
Choose pitch to ensure that at least 3 or 4 teeth are cutting at the same time.

OPERATING THE SAW
We recommend that eye protection be worn, and normal safe
working practices observed as per the Health and Safety at work
act, and the appropriate National and State Laws.
Set the isolator to “on” position, rest the blade on the material to be
cut with the nosepiece firmly abutted to the work piece, with
forward hand pressure, to prevent judder. Allow the Cengar Saw to
cut under its own weight, with just a slight downward hand pressure
to keep the teeth engaged in the cut. It is not necessary to put
excessive downward pressure on the saw, this only accelerates
blade wear, and prevents the saw from operating efficiently. Normal
airline pressure of 5 to 6 Bar is required, any higher pressure only
accelerates internal wear of the machine.
USE IN HAZARDOUS AREAS
We strongly advise that the contact area of the blade on the work
piece be quenched with coolant or water during cutting to dissipate
any heat which may be created by the cutting process.
Anti-static conductive air hose must be used, with adequate
earth bond continuity (resistance below 1 ohm), to ground any
electrostatic charges.
MAINTENANCE AND GENERAL HINTS
Always ensure sufficient oil in the tool, especially when the saw is
in constant use, and ALWAYS leave a small air bubble inside the
oil container when refilling, to prevent ‘Hydraulic Lock’ which
would impede lubrication.
The tool depends upon oil which acts not only as a lubricant, but
also as a PISTON SEAL. No oil will result in overheating, piston
scorching, excessive wear, and a costly repair.
Very little maintenance is required if the correct oil is used, but
incorrect oil will soon break down into sludge, slowing down the
action of the saw, necessitating its removal by use of Cengar M.S.
Cleaner. It is imperative that the saw is re-oiled immediately after
cleaning, with Cengar Green Oil.

JP901 Exploded View

Item Part No. Description Number
Per Tool Item Part No. Description Number
Per tool
1 9337 Body 1 18 9331C Hose Isolator Assy 1 2 9335 Valve Unit 1 19 9334L Starter Valve Assy 1 3 9336 Gasket rear 1 9334D Starter Body Long 1 4 9339 Top Cover 1 9334C Starter Spindle 1 5 9341 Front end 1 9334A Starter Spring 1 6 9342 Silencer Guard 1 5007 Starter Seal 1 7 5045 Nosepiece 1 20 50412 Screws—Nosepiece 2 8 2253 Piston Rear 1 21 9343 Silencer Steady 1 9 2252 Piston Front 1 22 54200 Screws Front end 5
10 9340 Gasket Front 1 23 9338 Seal—Top Cover 2 11 9333 Trigger 1 24 9344 Pedestal 1 12 50034 Valve in Handle 1 25 5068 Blade Grip Screws 2 13 2257 Oil Cup 1 26 5206 Seal—Oil Cup 1 14 9332 Oiler 1 27 5108 Seal - Various 3 15 54500 Screw Valve to Body 6 28 93412 Bleed Tube 1 16 W54 Serrated Washer 11 29 5056 Bleed Screw 2 17 5068 Screw to pedestal 2 AK3 Allen Key 1

IF THE SAW DOES NOT OPERATE
1 Check that the isolator is switched on.
2 Check air supply is correct.
3 Valve in handle (part no. 50034) could be worn and/or the seal
is broken, blocking an air passage. Check and replace if
necessary.
4 Ensure that all valve mounting screws in the body are tight, and
that air is not escaping from the gaskets at the front or rear.
5 Ensure the oil container is filled with Cengar Green Oil, leaving
a small air bubble to prevent ‘Hydraulic Lock’.
MAINTENANCE
REPLACEMENT OF TRIGGER VALVE - PART NO. 50034
To replace the trigger valve, loosen the six main screws securing
the valve block, but do not remove, this will allow the trigger bar to
be drawn out, revealing the valve.
Replace the valve, until it is level with the top of the hole, refit the
trigger bar, and finger tighten screws. Reconnect air supply, and
check operation of trigger. No air should flow when released, full
air should flow when depressed, if needed adjust height of valve 1/4
of a turn either way.
Re-tighten the six screws evenly and firmly.
Always remove the saw from the airline before commencing any
maintenance work.
Only fit genuine Cengar parts and accessories, or safety may be
compromised

OILER MECHANISM ADJUSTMENT
The oiler is preset at the factory, and should not need attention, but
slight adjustment can be made if desired. Always ensure adequate
lubrication.
The jet is screwed in to be level with the end of the body.
Tightening clockwise will reduce oil flow, and unscrewing anti-
clockwise will increase the oil flow.
Lubricator performance is visible in the oil container as agitation of
the oil during saw operation. (bubbles present in the oil) If no
agitation is observed, reset the oiler.
PEDESTAL CLEARANCE WHEN REFITTING
The pedestal, Item 24 (Part No 9344) must always be central to the
bore of the front end. To ensure this, set clearance between the
larger diameter blade grip section to be 0.025” (0.64 mm) above the
body.
Check for free movement in the nosepiece, without any hard
contact , which would cause wear and loss of power.
REPLACEMENT OF BLEED TUBE
Fit tube Item 28 (Part No. 93412) and loosely fit two bleed screws
Items 29 (Part No. 5056) Replace the nosepiece, and set one bleed
screw level with the surface.
Set the machine running which will sound and feel uneven, tighten
the second bleed screw slowly until the tool runs smoothly.
REPLACEMENT OF PISTONS
Eventually the pistons will wear, but oversize pistons can be fitted at
the factory, resulting is an ‘as new’ performance. This can be
repeated several times before the bore is worn beyond repair.

NEVER
1NEVER fit breakable “All-Hard” blades in Cengar saws, these
can shatter causing injury to yourself and others.
2NEVER operate saw without wearing safety glasses
3NEVER operate saw whilst you, or others are near the saw
blade, which can cause serious injury or trapping
4NEVER use excessive force, this may increase vibration
above safe levels
5NEVER hold the Cengar saw in a vice by the body, this will
distort the bores, rendering the tool inoperative.
6NEVER screw nameplates to the body, as the screws may
penetrate an airway or bore.
7NEVER operate the Cengar saw without lubrication.
8NEVER be tempted to clean internal parts with anything other
than a clean lint free cloth, and M.S. Cleaner, or Cengar Green
oil.
9NEVER modify Cengar saws or use non Cengar parts, this will
invalidate ATEX approval, and warranty.
ALWAYS
1ALWAYS use Cengar green oil for best results. Keeping the
saw clean and well oiled will give excellent reliability, and a
long life.
2ALWAYS use Cengar Bi-Metal Shatterproof blades, for
safety, and best cutting performance
3ALWAYS isolate the air supply when changing blades.
4ALWAYS wear eye protection when using sawing machines.
5ALWAYS keep the nosepiece abutted to the work to prevent
excessive vibration
6ALWAYS isolate the machine when not in use
7ALWAYS keep others away from the saw blade to prevent in-
jury or trapping
8ALWAYS have machines vibration tested annually to ensure
exposure is kept to the minimum