Cengar JP901 User manual


ECDeclaraonofConformity
Cengar. Ltd.
Springfield Works, Saddleworth Road
Halifax, England HX4 8LZ
We the undersigned, declare under our sole responsibility that the
following apparatus: ‐
Machine descripon: Cengar Air Saw
Machine Type: JP901
Is in conformity with the following relevant EC legislaon:
Machinery Direcve 2006/42/EC
Atex Direcve 94/ 9/EC
Based on the following Harmonised Standards:
EN13463‐1:2009
And therefore complies with the essenal requirements of those
direcves.
Addional Informaon:
ATEX Coding II 2G T5
Nofied Body TRAC Global Ltd, Unit 1, Pendle Place
Skelmersdale WN8 9PN U.K.
Idenficaon number 0891
Cerficate No. TRAC09ATEX21236X
Technical File No. CEEX‐0803
Authorised Signature:
Technical Manager Roy Fletcher
Date: 09/06/14
Title of Signatory: General Manager ‐Cengar Ltd.

SPECIFICATIONS
Speed
Stroke
Air Consumpon
Air Pressure
Weight
Length
Height
Width
Vibraon Level averaged
Sound Pressure Level
Sound Power Level
Atex Cerficaon
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
CengarAirSawModelJP901
We recommend normal safe working pracces
should be followed as per the Health and Safety at
Work Act, or the appropriate Naonal and State
Laws. We recommend that eye protecon be worn

CENGARSAWS
are hand held reciprocang saws designed to cut metals and plascs in
producon 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 lasng coang properes for best
results. Cengar Green Oil is specially prepared to: ‐
1 Emulsify the water generally found in compressed air lines.
2 Give perfect mist lubricaon.
3 Remain fluid at the low working temperature of compressed air tools.
4 Contains corrosion and oxidaon inhibitors.
Incorrect oils if used will soon “break down” forming a sludge which will
slow and eventually stop the acon of the saw. See maintenance details.
INSTALLATIONOFBLADES.
Before aempng to insert or change a blade, ensure that the air supply is
isolated by operang the isolaon valve provided. Loosen the retaining
grub screws with the key provided, insert blade through nosepiece so that
the teeth are cung on the pull stroke.
Locate the back screw in the hole in the end of the blade, for a posive
drive, the front screw can then be ghtened to grip the blade firmly.
BLADES
Cengar “Shaerproof” Bi‐Metal blades are specially prepared for use with
Cengar saws, to withstand the high operang speeds, and give maximum
cung life.
Choose the teeth per inch to suit the characteriscs of the material being
cut.
Choose pitch to ensure that at least 3 or 4 teeth are cung at the same
me.

OPERATINGTHESAW
We recommend that eye protecon be worn, and normal safe
working pracces observed as per the Health and Safety at work
act, and the appropriate Naonal and State Laws.
Set the isolator to “on” posion, rest the blade on the material to
be cut with the nosepiece firmly abued 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 operang
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 cung to
dissipate any heat which may be created by the cung process.
An‐stac conducve air hose must be used, with adequate
earth bond connuity (resistance below 1 ohm), to ground any
electrostac 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 lubricaon.
The tool depends upon oil which acts not only as a lubricant, but
also as a PISTONSEAL.No oil will result in overheang, piston
scorching, excessive wear, and a costly repair.
Very lile maintenance is required if the correct oil is used, but
incorrect oil will soon break down into sludge, slowing down the
acon of the saw, necessitang its removal by use of Cengar M.S.
Cleaner. It is imperave that the saw is re‐oiled immediately aer
cleaning, with Cengar Green Oil.

JP901ExplodedView

ItemPartNo.DescriponNumber
PerTool
ItemPartNo.Descripon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 mounng screws in the body are ght, 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, unl it is level with the top of the hole, refit the
trigger bar, and finger ghten screws. Reconnect air supply, and
check operaon 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‐ghten 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 aenon,
but slight adjustment can be made if desired. Always ensure
adequate lubricaon.
The jet is screwed in to be level with the end of the body.
Tightening clockwise will reduce oil flow, and unscrewing an‐
clockwise will increase the oil flow.
Lubricator performance is visible in the oil container as agitaon of
the oil during saw operaon. (bubbles present in the oil) If no
agitaon 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 secon 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, ghten
the second bleed screw slowly unl the tool runs smoothly.
REPLACEMENT OF PISTONS
Eventually the pistons will wear, but oversize pistons can be fied
at the factory, resulng is an ‘as new’ performance. This can be
repeated several mes before the bore is worn beyond repair.

NEVER
1 NEVER fit breakable “All‐Hard” blades in Cengar saws, these
can shaer causing injury to yourself and others.
2 NEVER operate saw without wearing safety glasses
3 NEVER operate saw whilst you, or others are near the saw
blade, which can cause serious injury or trapping
4 NEVER use excessive force, this may increase vibraon
above safe levels
5 NEVER hold the Cengar saw in a vice by the body, this will dis‐
tort the bores, rendering the tool inoperave.
6 NEVER screw nameplates to the body, as the screws may pen‐
etrate an airway or bore.
7 NEVER operate the Cengar saw without lubricaon.
8 NEVER be tempted to clean internal parts with anything other
than a clean lint free cloth, and M.S. Cleaner, or Cengar Green
oil.
9 NEVER modify Cengar saws or use non Cengar parts, this will
invalidate ATEX approval, and warranty.
ALWAYS
1 ALWAYS use Cengar green oil for best results. Keeping the saw
clean and well oiled will give excellent reliability, and a long
life.
2 ALWAYS use Cengar Bi‐Metal Shaerproof blades, for safety,
and best cung performance
3 ALWAYS isolate the air supply when changing blades.
4 ALWAYS wear eye protecon when using sawing machines.
5 ALWAYS keep the nosepiece abued to the work to prevent
excessive vibraon
6 ALWAYS isolate the machine when not in use
7 ALWAYS keep others away from the saw blade to prevent inju‐
ry or trapping
8 ALWAYS have machines vibraon tested annually to ensure
exposure is kept to the minimum