Cengar JP901 User manual
ECDeclaraonofConformity
Cengar. Ltd.
Springfield Works, Saddleworth Road
Halifax, England HX4 8LZ
We the undersigned, declare under our sole responsibility that the
following apparatus: ‐
Machine descripon: Cengar Air Saw
Machine Type: JP901
Is in conformity with the following relevant EC legislaon:
Machinery Direcve 2006/42/EC
Atex Direcve 94/ 9/EC
Based on the following Harmonised Standards:
EN13463‐1:2009
And therefore complies with the essenal requirements of those
direcves.
Addional Informaon:
ATEX Coding II 2G T5
Nofied Body TRAC Global Ltd, Unit 1, Pendle Place
Skelmersdale WN8 9PN U.K.
Idenficaon number 0891
Cerficate 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 Consumpon
Air Pressure
Weight
Length
Height
Width
Vibraon Level averaged
Sound Pressure Level
Sound Power Level
Atex Cerficaon
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
CengarAirSawModelJP901
We recommend normal safe working pracces
should be followed as per the Health and Safety at
Work Act, or the appropriate Naonal and State
Laws. We recommend that eye protecon be worn
CENGARSAWS
are hand held reciprocang saws designed to cut metals and plascs in
producon 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 lasng coang properes for best
results. Cengar Green Oil is specially prepared to: ‐
1 Emulsify the water generally found in compressed air lines.
2 Give perfect mist lubricaon.
3 Remain fluid at the low working temperature of compressed air tools.
4 Contains corrosion and oxidaon inhibitors.
Incorrect oils if used will soon “break down” forming a sludge which will
slow and eventually stop the acon of the saw. See maintenance details.
INSTALLATIONOFBLADES.
Before aempng to insert or change a blade, ensure that the air supply is
isolated by operang the isolaon valve provided. Loosen the retaining
grub screws with the key provided, insert blade through nosepiece so that
the teeth are cung on the pull stroke.
Locate the back screw in the hole in the end of the blade, for a posive
drive, the front screw can then be ghtened to grip the blade firmly.
BLADES
Cengar “Shaerproof” Bi‐Metal blades are specially prepared for use with
Cengar saws, to withstand the high operang speeds, and give maximum
cung life.
Choose the teeth per inch to suit the characteriscs of the material being
cut.
Choose pitch to ensure that at least 3 or 4 teeth are cung at the same
me.
OPERATINGTHESAW
We recommend that eye protecon be worn, and normal safe
working pracces observed as per the Health and Safety at work
act, and the appropriate Naonal and State Laws.
Set the isolator to “on” posion, rest the blade on the material to
be cut with the nosepiece firmly abued 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 operang
efficiently. Normal airline pressure of 5 to 6 Bar is required, any
higher pressure only accelerates internal wear of the machine.
USEINHAZARDOUSAREAS
We strongly advise that the contact area of the blade on the work
piece be quenched with coolant or water during cung to
dissipate any heat which may be created by the cung process.
An‐stac conducve air hose must be used, with adequate
earth bond connuity (resistance below 1 ohm), to ground any
electrostac charges.
MAINTENANCEANDGENERALHINTS
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 lubricaon.
The tool depends upon oil which acts not only as a lubricant, but
also as a PISTONSEAL.No oil will result in overheang, piston
scorching, excessive wear, and a costly repair.
Very lile maintenance is required if the correct oil is used, but
incorrect oil will soon break down into sludge, slowing down the
acon of the saw, necessitang its removal by use of Cengar M.S.
Cleaner. It is imperave that the saw is re‐oiled immediately aer
cleaning, with Cengar Green Oil.
JP901ExplodedView
ItemPartNo.DescriponNumber
PerTool
ItemPartNo.DescriponNumber
Pertool
19337Body1189331CHoseIsolatorAssy1
29335ValveUnit1199334LStarterValveAssy1
39336Gasketrear19334DStarterBodyLong1
49339TopCover19334CStarterSpindle1
59341Frontend19334AStarterSpring1
69342SilencerGuard15007StarterSeal1
75045Nosepiece12050412Screws—Nosepiece2
82253PistonRear1219343SilencerSteady1
92252PistonFront12254200ScrewsFrontend5
109340GasketFront1239338Seal—TopCover2
119333Trigger1249344Pedestal1
1250034ValveinHandle1255068BladeGripScrews2
132257OilCup1265206Seal—OilCup1
149332Oiler1275108Seal‐Various3
1554500ScrewValvetoBody62893412BleedTube1
16W54SerratedWasher11295056BleedScrew2
175068Screwtopedestal2AK3AllenKey1
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 mounng 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, unl it is level with the top of the hole, refit the
trigger bar, and finger ghten screws. Reconnect air supply, and
check operaon 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.
Alwaysremovethesawfromtheairlinebeforecommencingany
maintenancework.
OnlyfitgenuineCengarpartsandaccessories,orsafetymaybe
compromised
OILER MECHANISM ADJUSTMENT
The oiler is preset at the factory, and should not need aenon,
but slight adjustment can be made if desired. Always ensure
adequate lubricaon.
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 agitaon of
the oil during saw operaon. (bubbles present in the oil) If no
agitaon 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 secon 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 unl the tool runs smoothly.
REPLACEMENT OF PISTONS
Eventually the pistons will wear, but oversize pistons can be fied
at the factory, resulng 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 shaer 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 vibraon
above safe levels
5 NEVER hold the Cengar saw in a vice by the body, this will dis‐
tort the bores, rendering the tool inoperave.
6 NEVER screw nameplates to the body, as the screws may pen‐
etrate an airway or bore.
7 NEVER operate the Cengar saw without lubricaon.
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 Shaerproof blades, for safety,
and best cung performance
3 ALWAYS isolate the air supply when changing blades.
4 ALWAYS wear eye protecon when using sawing machines.
5 ALWAYS keep the nosepiece abued to the work to prevent
excessive vibraon
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 vibraon tested annually to ensure
exposure is kept to the minimum
ACCESSORIES
SawBlades
MYT 150/18 Tapered yellow blade for glassfibre and general purpose 18 TPI
MYN 150/18 Notched yellow blade for scrolling & fine work 18 TPI
MC 220/24 220 mm long by 12 mm deep blade for general cung 24 TPI
A range of 19 mm deep blades could be fied in certain circumstances. Replace the
nosepiece 5045 with 5075 to use 19 mm blades
CengarGreenOil
GO 9107P Cengar Green Oil 250 ml plasc boles for all air tools
GO 9109 As above in 5 litre container
GO 9110 As above in 25 litre container
M.S.Cleaner
MS 9105 1 litre General purpose cleaning fluid for air tools.
MS 9125 50 ml. In a dropper bole. ‐Enough for 10 tools
AlwaysuseplentyofCengargreenoilaerwards.
Nosepiece
5045 Replacement nosepiece/blade guide for 12 mm deep blades
5075 Alternave nosepiece/blade guide for 19mm deep blades
Cengar. Ltd.
Springfield Works, Saddleworth Road
Halifax, England HX4 8LZ
Tel: 01422 377904 Fax: 01422 377161
enquiries@cengar.com
www.cengar.com
SERVICE
We offer a full factory repair and refurbishment service for
Cengar Saws, ‐normally within 5 working days. Quotaons at
no charge can be given before work is carried out.
DISTRIBUTORADDRESS
Original Instrucons Document No. MAN901ENG/01 Issue 07(June ‘14)
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