Challenge JS80JD User manual

710W Heavy Duty Jigsaw
JS80JD
ALWAYS READ THESE OPERATING INSTRUCTIONS PRIOR TO USE
KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE
MADE IN CHINA
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SAFETY INSTRUCTIONS: WARNING
To use this tool properly, you must observe the safety regulations, the assembly
instructions and the operating instructions to be found in this Manual. All
persons who use and service the machine have to be acquainted with this
Manual and must be informed about any potential hazards.
Children and infirm people must not use this tool. Children should be supervised
at all times if they are in the area in which the tool is being used. It is also
imperative that you observe the accident prevention regulations in force in your
area. The same applies for general rules of occupational health and safety.
The manufacturer shall not be liable for any changes made to the tool nor for
any damage resulting from such changes.
Even when the tool is used as prescribed it is not possible to eliminate all
residual risk factors. The following hazards may arise in connection with the
tools construction and design:
zDamage to the lungs if an effective dust mask is not worn
zDamage to hearing if effective ear defenders are not worn
zAlways remove the plug from the power point before making any
adjustments or maintenance, including changing the blade.
WARNING! Read all instructions Failure to follow all instructions listed below
may result in electric shock, fire and/or serious injury. The term "power tool" in
all of the warnings listed below refers to your mains operated (corded) power
tool or battery operated (cordless) power tool.
SAVE THESE INSTRUCTIONS
1) Work area
a) Keep work area clean and well lit. Cluttered and dark areas invite
accidents.
b) Do not operate power tools in explosive atmospheres, such as in the
presence of flammable liquids, gases or dust. Power tools create sparks
which may ignite the dust or fumes.
c) Keep children and bystanders away while operating a power tool.
Distractions can cause you to lose control.
2) Electrical safety
a) Power tool plugs must match the outlet. Never modify the plug in any
way. Do not use any adapter plugs with earthed (grounded) power tools.
Unmodified plugs and matching outlets will reduce risk of electric shock.
b) Avoid body contact with earthed or grounded surfaces such as pipes,
radiators, ranges and refrigerators. There is an increased risk of electric
shock if your body is earthed or grounded.
c) Do not expose power tools to rain or wet conditions. Water entering a

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power tool will increase the risk of electric shock.
d) Do not abuse the cord. Never use the cord for carrying, pulling or
unplugging the power tool. Keep cord away from heat, oil, sharp edges or
moving parts. Damaged or entangled cords increase the risk of electric shock.
e) When operating a power tool outdoors, use an extension cord suitable
for outdoor use. Use of a cord suitable for outdoor use reduces the risk of
electric shock.
3) Personal safety
a) Stay alert, watch what you are doing and use common sense when
operating a power tool. Do not use a power tool while you are tired or
under the influence of drugs, alcohol or medication. A moment of inattention
while operating power tools may result in serious personal injury.
b) Use safety equipment. Always wear eye protection. Safety equipment
such as dust mask, non-skid safety shoes, hard hat, or hearing protection used
for appropriate conditions will reduce personal injuries.
c) Avoid accidental starting. Ensure the switch is in the off position before
plugging in. Carrying power tools with your finger on the switch or plugging in
power tools that have the switch on invites accidents.
d) Remove any adjusting key or wrench before turning the power tool on.
A wrench or a key left attached to a rotating part of the power tool may result in
personal injury.
e) Do not overreach. Keep proper footing and balance at all times. This
enables better control of the power tool in unexpected situations.
f) Dress properly. Do not wear loose clothing or jewellery. Keep your hair,
clothing and gloves away from moving parts. Loose clothes, jewellery or
long hair can be caught in moving parts.
g) If devices are provided for the connection of dust extraction and
collection facilities, ensure these are connected and properly used. Use of
these devices can reduce dust related hazards.
4) Power tool use and care
a) Do not force the power tool. Use the correct power tool for your
application. The correct power tool will do the job better and safer at the rate
for which it was designed.
b) Do not use the power tool if the switch does not turn it on and off. Any
power tool that cannot be controlled with the switch is dangerous and must be
repaired.
c) Disconnect the plug from the power source before making any
adjustments, changing accessories, or storing power tools. Such
preventive safety measures reduce the risk of starting the power tool
accidentally.
d) Store idle power tools out of the reach of children and do not allow
persons unfamiliar with the power tool or these instructions to operate the
power tool. Power tools are dangerous in the hands of untrained users.
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e) Maintain power tools. Check for misalignment or binding of moving
parts, breakage of parts and any other condition that may affect the power
tools operation. If damaged, have the power tool repaired before use. Many
accidents are caused by poorly maintained power tools.
f) Keep cutting tools sharp and clean. Properly maintained cutting tools with
sharp cutting edges are less likely to bind and are easier to control.
g) Use the power tool, accessories and tool bits etc., in accordance with
these instructions and in the manner intended for the particular type of
power tool, taking into account the working conditions and the work to be
performed. Use of the power tool for operations different from intended could
result in a hazardous situation.
5) Service
a) Have your power tool serviced by a qualified repair person using only
identical replacement parts. This will ensure that the safety of the power tool
is maintained.
WARNING:
•The use of an accessory or attachment, other than those
recommended in this Instruction Manual, may present a risk of
personal injury.
•The tool must be used only for its prescribed purpose. Any use other
than those mentioned in this Manual will be considered a case of
misuse. The user and not the manufacturer shall be liable for any
damage or injury resulting from such cases of misuse.
ADDITIONAL SAFETY RULES FOR JIGSAWS
zEnsure that the lighting is adequate.
zDo not use the saw unless the guards are in place
zKeep the shoe flat on the work piece.
zDo not put pressure on the saw, such that it slows the motor down. Allow
the saw blade to cut without pressure. You will get better results and you
will be taking better care of your tool.
zKeep the area free of tripping hazards.
zOnly use blades in good condition.
zBefore cutting, check that there is sufficient clearance for the blade under
the work piece.
zDo not touch the blade after operation. It will be very hot.
zKeep your hands away from under the work piece.
zNever use your hands to remove sawdust, chips or waste close to the
blade.
zRags, cloths, cord, string and the like should never be left around the work
area.
zAvoid cutting nails. Inspect the work piece and remove all nails and other
foreign objects before beginning sawing.

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zSupport the work properly.
zNever reach over the blade to remove waste or off cuts.
zDo not attempt to free a jammed blade before first switching off the
machine.
zIf you are interrupted when operating the saw, complete the process and
switch off before looking up.
zPeriodically check that all nuts, bolts and other fixings are properly
tightened.
zDo not store material of equipment above a machine in such a way that
they could fall into it.
zAlways hold the saw on parts that are insulated. If you accidentally cut into
hidden wiring or the saw’s own cable, the metal parts of the saw will
become ‘live’.
zCheck the voltage on mains matches that of rating plate before plugging in
the tool.
zDo not secure the jigsaw upside down in a vice or work bench and use it as
a saw bench. This can lead to serious injury.
zWhen using the jigsaw, use safety equipment including safety goggles or
shield, earmuffs, dust mask and protective clothing including safety gloves.
Always wear eye
protection with this
tool.
Always wear ear
protection with this
tool.
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Component List:
1. Locking button 7. Roller support
2. Trigger switch 8. Pendulum setting stick
3. Variable speed switch 9. Bevel setting screw
4. Set screw 10. Hex wrench
5. Safety guard 11. Dust extraction adaptor
6. Base plate
Accessories:
1PC metal cutting blade, 1PC plastic cutting blade, 2PCs wood cutting blade
1PC hex wrench, 1PC dust extraction adaptor, 1PC blow moulded case
Technical specifications:
Voltage: 230V~ 50Hz
Wattage: 710W
No-load speed: 500-3000/min
Cutting depth 80mm(wood)
10mm(steel)
Rated operating time: On for 30 mins / Off for 30 mins
Insulation Class: Double Insulation
Vibrations: 2.10m/s2
Noise emission: Lp 81 dB(A);
Lw 92 dB(A)
Weight: 2.14 kgs

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OPERATING INSTRUCTIONS
Fitting the Saw Blade
To fit saw blades first raise the safety
guard (5) (if lowered). Use the hex
wrench (10) provided to loosen the
mounting block set screws (4) on the
mounting block (the hex key is located
at the base of the dust extractor
outlet). The blade’s cutting edge
should be facing forward. Insert the
blade’s mounting section into the
Groove in the mounting block and in the small notch in the blade stock until it
touches the bottom of the clip. Then firmly tighten the set screw.
Note: Loose set screws may cause damage to the blade. Tighten the
screws regularly and ensure that the plunger groove is clear and free of
sawdust so that proper blade mounting and set screw clamping can be
achieved.
Hex Key Storage
The hex key (10) is stored at the base of the jigsaw, please return here when
not in use.
Operating the Trigger Switch
To operate the Jigsaw, depress the trigger switch (2). If you wish to use the
Jigsaw continuously, the trigger lock button (1) can be pushed in after the trigger
switch has been depressed. To release the lock button simply push in the trigger
switch.
Using the Jigsaw
Before using the saw and connecting the mains cable make sure the trigger
switch is in the (OFF) position and the safety guard is down. Press the trigger
switch and wait until blade has reached maximum speed. Place the front of the
base plate on the workpiece and line up the cutting line with the line you wish to
cut. Push slowly forward. Keep the base plate flat against the workpiece.
Cutting Metal
An appropriate cutting agent (such as spindle oil, small amounts of soapy water,
etc.) should always be used. If there is no available liquid cutting agent, grease
can be applied to the back surface of the material to be cut.
Cutting Grooves/window Holes
For wood: Align the blade direction with the grain of the wood. Then position the
rounded part at the front of the base plate on surface to be cut, and then slowly
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lower the saw into material at chosen point of entry. Lower the saw in a pivoting
action until the blade has cut through and base plate is lying flat on material.
For other materials: In materials other than wood when cutting window holes,
firstly use one or similar tool to drill a hole from which initial cutting will begin.
Angular Cutting
For adjustment of the angle of
inclination, loosen the two Allen screws
on the base of saw, see left diagram.
Move the base plate forward or
backwards until the vertical slots in the
base plate align with the two Allen
screws, you will then be able to rotate
the base plate to the required angle.
Angle of inclination numbers is stamped
onto the curved bracket on top of the
base plate to help you set the correct
angle. Check the roller support before
tightening. Firmly tighten the two bevel
setting screws when finished.
Variable Speed Control
Adjust the thumb-wheel to increase or decrease the speed according to the
material, material thickness and blade specification to be used (also possible
during no load operation).
Stroke Rate Selection:
1-2 = low stroke rate
3-4 = medium stroke rate
5-6 = high stroke rate
The stroke rate required depends upon the material and the working conditions:
fast speed to make considerable progress, but slow speed to keep a clean and
finer cut and to avoid straining the machine. Generally, finer saw blades use a
higher speed, coarser blades use a slow speed. Avoid prolonged use at very
low speeds as this may damage your Jigsaw’s motor. After working for a period
at low stroke speed, set the machine running at maximum speed without load
for approximate 3 minutes to cool down the motor.
Pendulum Action Control
The saw blade pendulum action that is adjustable in three steps makes the
optimum adaptation of sawing advance (cutting speed) possible. Cutting
performance and cut appearance of the material to be worked. For each
downward movement, the saw blade is lifted off the material which facilitates
sawdust ejection, reduces the service life of the saw blade. At the same time the
reduction fatigue-free working possible. The pendulum action switch makes
possible the adjustment of the pendulum action in three steps.

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The switch can take place with the machine running:
Pendulum Setting:
Step Pendulum action Material
0 No rubber, ceramic, aluminum, steel
1 Small plastic, wood, aluminum
2 Large wood
TROUBLESHOOTING
If your Jigsaw will not operate, check the fuse and the power at the mains plug.
If the Jigsaw is not cutting properly check the blade and support roller, replace
blade if worn. Also check the cutting angle, the blade must be at exactly
90º(degrees) to the base for normal use. There are no user serviceable parts in
the Jigsaw. If a fault cannot be found return the Jigsaw to an authorized dealer
for repair.
MAINTENANCE
1. Store the tool, instruction manual and accessories in a secure place. In this
way you will always have all the information and parts ready to hand.
2. Keep the tool’s air vents and the dust extraction holes in the base free of
dust and dirt.
3. Remove dust and dirt regularly. Cleaning is best done with compressed air
or a rag.
4. Lubricate all moving parts at regular intervals.
5. Never use caustic agents to clean plastic parts. Wipe clean with a dry cloth.
6. When the brushes are worn, the tool will stop.
7. Have new brushes fitted by an authorized service facility.
CAUTION:
Do not use cleaning agents to clean the plastic parts of the tool. A mild
detergent on a damp cloth is recommended. Water must never come into
contact with the tool.
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PLUG FITTING
This Jigsaw is supplied with a fitted plug; however if you should need to fit a
new plug follow the instruction below.
IIMPORTANT
The wires in the mains lead are
colored in accordance with the
following code:
Blue = Neutral
Brown = Live
As the colours of the wires in the
mains lead of this appliance may
not correspond with coloured
markings identifying the
terminals in your plug, proceed as follows:
The wire which is coloured blue must be connected to the terminal which is
marked with Nor coloured black. The wire which is coloured brown must be
connected to the terminal which is marked with the letter Lor coloured red.
No connection is to be made to the earth terminal of the plug.
If a 13 AMP (BS1363/A) Plug is used, a 13 AMP Fuse must be fitted, of if any
other type of plug is used a 13Amp Fuse must be fitted, either in the Plug or
Adaptor, or on the Distribution Board.
NOTE:
If moulded plug is fitted and has to be removed take great care in
disposing of the plug and severed cable, it must be destroyed to prevent
re-use, or connection to any electrical supply.
If the supply cord is damaged it must be replaced by a service agent or a
similarly qualified person in order to avoid hazard.
ENVIRONMENTAL PROTECTION
Recycle unwanted materials instead of disposing of them as waste. All tools and
packaging should be sorted, taken to the local recycling center and disposed of
in an environmentally safe way.

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GUARANTEE
This product is guaranteed against faulty materials and workmanship for 12
months from purchase. Please keep your till receipt as proof of purchase. If the
product is found to be defective within the duration of the guarantee period, we
will either replace all defective parts or, at our discretion, replace the unit free of
charge with the same item or items of a greater value and /or specification.
This warranty is invalid where defects are caused by or result from:
1.Misuse, abuse or neglect.
2.Trade, professional or hire use.
3.Repairs attempted by unauthorized repair centers.
4.Damage caused by foreign objects, substances or accident.
This warranty is offered in addition to, and does not impact upon your statutory
rights, which may additionally enable you to cancel the contract. The warranty is
only valid within the UK.
ARG, Retail Group,
MK9 2NW
Ver:08/2004