Bosch fret saw DIY repair

In detail: do-it-yourself Bosch jigsaw repair from a real master for the site my.housecope.com.

Among the hand tools used in the household, the jigsaw is the most popular. This is an electrically driven device designed to produce a curved cut.

Demand determines supply. The power tool market is represented by a wide range of both household and professional models from domestic and foreign manufacturers. Any equipment requires technical maintenance and repair if necessary.

Using examples of real breakdowns and methods for their elimination presented in this article, the user will learn about the repair of jigsaws from different manufacturers in general.

The design of jigsaws from different companies is not much different. It consists of a body, a sole, a saw blade, a cutting tool mechanism, a gearbox and an electric motor that drives the working body of the tool.

The difference in the models of a particular manufacturer lies in the design features of some units. It is natural that the malfunctions and the reasons for their occurrence are also identical.

Knowing the most common power tool failures and the preventive measures to prevent them will help both the novice DIYer and the experienced professional.

Among the typical failures of electric jigsaws are:

Sawing curvature.
Change in shape or destruction of the support roller.
Breakage of the cutting tool attachment.
Damage to the gears of the reducer.
Destruction or bending of the support rod.
Broken teeth on the jigsaw collet.
Early wear of the armature worm gear.

Video (click to play).

The jigsaw is designed to perform rough curvilinear cuts, so it's not worth talking about the ideality of sawing. Although in models of hand tools from different manufacturers, this indicator is also different. When using cheap models, they don't pay much attention to this, and the cut turns out to be completely crooked. You need to deal with this in service centers, but you can try to get rid of the curvature at home.

The platter roller can break if you use poor quality saw blades or a blunt tool. The use of a cutting tool in an inappropriate load mode. This can result in a jammed or cutting of the platter roller.

To avoid such a problem, you need to use well-sharpened cutting blades of acceptable quality, observing the optimal cutting conditions and following the recommendations of the manufacturer.

As a rule, almost all models of jigsaws are equipped with a toolless saw blade fixation unit. This simplifies the process of changing cutting tools. But the operation of the mechanism in conditions of constant dustiness leads to the ingress of wood chips into it, and this leads to the failure of the device.

In order to exclude a breakdown of the unit, it must be constantly cleaned of dust and lubricated with a special compound such as WD-40. During operation, it is necessary to use a vacuum cleaner by connecting it to the tool.

Failure of the gearbox elements is the result of wood dust entering through the ventilation holes. Here, as in the previous case, you cannot do without a dust collector.

Breakage or bending of the support rod occurs during the careless use of the power tool. This can happen when it falls or unintentionally collides with the jigsaw body, directly the support rod with protruding elements of the machined surfaces.

Tooth decay on the collet of an electrically powered jigsaw can only occur through the fault of the performer.This is the result of an attempt to inadvertently tighten the not fully inserted cutting blade.

The armature worm gear will not last long if the cutting process is started before the tool motor reaches its optimum power. To prolong the life of the mechanism, do not start work before reaching full engine speed.

It is worth paying attention to the domestic production of the Interskol jigsaw. It is produced in Izhevsk. For domestic use, this is a perfectly acceptable option. It has many positive qualities, and the most impressive is its low cost. But there are also disadvantages.

This is the curvature of the cut. What is the problem and can you get rid of it? The blame was the quick-release fastening of the file. The fact is that it is designed for the maximum saw blade thickness. All thinner cutting tools in the mount just dangle.How to get out of this situation? It is necessary to replace the quick-release mount with a simple device with ordinary bolts. It is not difficult to make it. You need to take a square rod, cut off two blanks, drill holes in them and connect with two M5 bolts with nuts. The procedure for attaching the saw blade will be somewhat more complicated, but the tool will produce an even cut.In addition, you can modify the very design of the tool and limit the movement of the file in the transverse plane.

take sheet aluminum and cut the plate to fit the sole of the jigsaw;

in the front part of the workpiece, it is necessary to make a cutout according to the size of the working area of the cutting tool. File all edges; make bevels on the inner longitudinal edges of the cutout;

from plexiglass, you need to cut a plate to the size of the working area of the saw blade. File all sharp edges and make reverse bevels on the outer longitudinal edges;

the aluminum plate must be marked for its installation on the sole of the jigsaw. Drill and chamfer holes for the installation of countersunk head screws;

a piece of plexiglass must be inserted into an aluminum plate, after having made a cut at the place of its position.

The saw blade will now restrict its lateral movement in the cutting area during operation, which will give it even more straightness.

The internal structure of the jigsaw.

The gear has been found to have wear or deformation of the teeth. It is possible to repair the jigsaw, a complete replacement of the gear is required, in the future it is necessary to carefully monitor the loads, the correct choice of the blade.
The stem breaks, there are kinks on it. It is required to repair the jigsaw by replacing the stem, in the future, choose the right saws in accordance with the type of material. For example, for wood or metal, take only specially designed devices.
The balancers that guide the rollers are worn out. Need to replace the balancers, in the future you need to monitor the loads.
If the bearings are worn out, they are replaced. It is best to contact a master.

Other types of breakdowns can also be observed. For example, a strong impact may cause the body to split. Do not drop the jigsaw, in this case, you can damage other parts of it. It is best not to fix engine breakdowns with your own hands, but immediately contact the service center. Replacing worn parts can be handled by yourself... To do this, the manufacturer provides instructions, following it, you can easily cope with the work yourself.

The main characteristics of household jigsaws.

How do I repair when I find a problem? The support roller can break if the load is applied too much, i.e. cutting technology is broken. The file is attached to this particular roller if it is broken, but the file cannot be used. To prevent a breakdown from occurring:

Use only high quality hacksaw blades.
Blunt files must not be used.
Hacksaw blades should be selected only in full accordance with the purpose. For example, for metal, only the fabric is used that is intended specifically for this material.

If the roller is not replaced when it is broken, the equipment may jam during operation. The repair will begin not with replacing the roller, but with cutting it with another tool and then replacing it. The renovation itself is not too difficult. The support roller with traces of damage must be removed, and then replaced with a new one corresponding to the used jigsaw model.

The blade fixation unit usually breaks when a large amount of dust gets on it. During operation, dust is not uncommon, therefore, for prevention, it is regularly required to clean the surface of the fasteners. Over time, the situation will get worse, the equipment may completely fail. Repair usually consists of completely replacing the retainer.

To prevent malfunctions, you can carry out regular preventive maintenance.

It consists in performing a number of actions:

The assembly must be constantly cleaned and then lubricated.

During work, you must use a dust collector, which will prevent a large amount of dust from getting on the tool.

Repairs may be required in other cases as well. Breakdowns can be associated with physical wear and tear of the equipment.

Collector single-phase electric motor

As you understand, an explanation will be given to the collector motor used in electric jigsaws.

For a better understanding of this topic, the photograph shows an enlarged version of such an electric motor, which in its electrical circuit does not differ in any way from the electric motor used in electric jigsaws - connected to an external source of alternating voltage with one phase.

Collector motors are capable of operating from power sources:

direct current;
alternating current.

The electrical diagram in Fig. 1 shows a method of serial connection of two stator windings of an electric motor, followed by a connection: brush - collector.

In the next photo, an image of the stator windings of an electric motor is given - with three wire leads.

Why does the stator winding of the electric motor have exactly three wire leads? - You ask.

Two wire leads from the three stator windings of the electric motor are intended for connection in the electrical circuit of the working capacitor.

The capacitor in the electrical circuit in Fig. 2 has a connection between the beginnings of the leads of the wires of the two stator windings - working and starting.

When replacing a capacitor, it is taken into account:

capacity;
nominal voltage value.

Previously, before connecting the capacitor, it is clarified - between which wires the display indicator of the device will indicate the multimeter to the total value of the resistance of the two stator windings. It is this connection of the capacitor in the electrical circuit that will be correct.

A separate stator winding has its own resistance value. So for the starting winding - the resistance value will be greater than for the working winding.

By conducting diagnostics both for the total total value of the resistance of the two stator windings and for each individual winding, it is possible to determine either the serviceability or the gap in the windings.

Figure 3 shows an image of the rotor of a collector single-phase electric motor. The ends of the rotor winding wires are connected to the collector plates.

The two rotor windings are connected in series with each other. Electrical contact with the rotor windings is made by connecting the graphite brushes to the rotor collector. The electric circuit of the electric motor is closed on two rotor windings.

To measure the resistance of two rotor windings, it is enough to connect two probes of the device, an ohmmeter, a multimeter with this measurement function to the contacts of the graphite brushes.

If the resistance indicator on the display of the device is zero during measurement:

two rotor windings;
two stator windings,

- from this it will follow that these constituent elements in the electrical circuit are unusable. The same applies if there is no resistance in the electric circuit of the electric motor.

The graphite brushes of the collector electric motor, when they are worn out, must be replaced. These parts, like others, are commercially available for each individual power tool.

Jigsaw blades

In order not to create an unnecessary load on the electric motor itself, the blade of this power tool must have a sharpened edge of the teeth.

The blade teeth are sharpened with the appropriate natfil. There are a wide range of needle file sets available on the market.

A set of needle files Bison with a clamping plastic handle

The blade is preliminarily clamped in a bench bench vise.

Locksmith table vise

As for the details of diagnostics for power tools, you can get more information by looking at this blog.

Hello everyone! We continue to repair household appliances and this time we will repair the jigsaw. Everyone knows what a jigsaw is for and many are familiar with it. Many in childhood were fond of wood crafts, I was also no exception. I sawed a lot and different crafts, to whom it was a birthday present, I did a lot just like that .... I didn't have a jigsaw then, well, it was not that time. Now progress does not stand still and much is being done to facilitate the work of cabinetmakers.And so, according to custom, before repairing the jigsaw, we will get acquainted with the device and the principle of its operation.

Modern high-quality jigsaws contain electronics that ensure a stable cutting speed, and the electric drive has minimal vibration.

Accordingly, these jigsaws work almost silently and accurately. In a simple jigsaw, the file moves strictly up and down. The pendulum jigsaw cuts faster, moving the saw not only up and down, but also forward on the up stroke and backward on the down stroke. This helps to clear the cut from chips. The vertical movement of the file is carried out using a hinge, which is fixed with an eccentric on a gear driven by an electric motor.

In many jigsaws, a cooling fan blows air through the air duct to remove sawdust from the cutting area. In slightly other models, the sawdust is removed from the sawing area using a household vacuum cleaner hose connected to the back of the jigsaw.

Electric jigsaws are made with one-speed or continuously variable speed control for sawing various materials. In such jigsaws, the number of working cycles for moving the saw blade is controlled by a trigger switch. It also serves as a power switch.

To maximize the effect of using a jigsaw, adhere to the following recommendations:

-Replace the files as soon as they become dull. Blunt saws not only cut poorly, but also cause increased stress on the electric motor and gearbox.

-Use special saws for cutting various materials.

-Do not neglect the recommendations for choosing the optimal speed for cutting different materials.

-Lubricate the support roller with a drop of machine oil in time.

-Clean the jigsaw from dust and chips with a brush.

Clean the ventilation grill and sawdust drain holes.

Jigsaw leads to the side

1. Dull and bent file. Replace this file as soon as possible.

2. The saw blade support roller needs adjustment.

On some jigsaw models, the support roller can be adjusted back and forth so that it only touches the rear edge of the saw.

3. Incorrect cutting technique. Excessive pressure on the jigsaw in the direction of sawing can cause the saw to misalign. Therefore, do not push the instrument too far forward, but do it little by little.

Jamming of the support roller of the rack

If you forget to lubricate the platter roller, it may jam after a while. If subsequent lubrication does not work, then the roller must be replaced. To replace the roller, remove the file and place the jigsaw on the table so that you can separate the two halves of the case.

Remember the position of the parts and wires. Slide the roller out of its groove and install a new one. Reassemble the case without disturbing the position of its internal components.

The jigsaw stops suddenly during operation.

This can happen if the power cord of the jigsaw is cut while cutting, if the cord is in front of the jigsaw or is under the workpiece. If this happens, connect the cord and insulate well. And it is best to replace the cord with a new one.

Doesn't work at all

1. There is no power supply. Check for voltage at the outlet. The plugs may have burned out or the machine on the power panel has turned off.

2. The jigsaw is not plugged in.

3. The fuse in the power plug has blown. If the power plug of your jigsaw is equipped with a fuse, then disassemble it and check its serviceability with a tester.

4. Broken power cord. To test the power cord, disconnect it from the screw terminals inside the case and connect the ends together. Use a tester to check for continuity by applying the test leads of the multimeter to the pins on the plug. If the cord is broken, then the reading will be equal to infinity. In this case, replace the power cord with a new one.

5.Thermal overheating protection has tripped. Basically, all models of jigsaws are equipped with thermal protection against overheating or, in other words, a thermal switch to protect the electric motor from overheating. It can be triggered due to contamination of the air intake grilles with dust and sawdust. Clean the grates and let the jigsaw cool down a little and after a while the thermal switch turns on automatically.

6. Defective switch. The switch is combined with a speed regulator, therefore it has a somewhat complex device.

The regulator is an electronic control circuit. You can see an example of a circuit in this article.

7. Bad contact. During the operation of the jigsaw, harmful vibration occurs, which often leads to a violation of the contact connections of the electrical installation. Disassemble the device and tighten or crimp the contact connections using pliers and a screwdriver.

8. If your jigsaw is running on battery power, the battery may be dead. Charge it and test it in different modes. If charging does not help, then you need to replace the battery with a new one. When using the cordless jigsaw, do not allow deep discharge of the battery. This is very harmful to her and greatly affects its service life.

9. Defective motor. Check the motor. Read about it here.

I think self-repairing a jigsaw will save you a lot of time and money.

Dear forum participants, the keyless chuck on the Bosch jigsaw, where the file is inserted, has broken. The photo shows that two antennae have come out. The question is, is it possible to repair this damage on your own? If so, how, are there instructions on how to repair such damage on the network?

IMHO is a tricky spring. A pair of screwdrivers, pliers, mat and patience and there will be a result.

Krage. And what a jigsaw model. Sednya also received the 900th in the order.

Bosch PST6800PE. Yesterday I contacted the Bosch service in Moscow ">
They replied that the diagnosis takes up to 7 working days and costs from 300 to 450 rubles. I can imagine how much they will ask for the renovation!

BEARDED wrote:
IMHO is a tricky spring. A pair of screwdrivers, pliers, mat and patience and there will be a result.

More. As I understand it, some kind of spring has flown off?

By the way, how would you find the part number for this part? Otherwise, you can change it yourself without contacting diagnostics.

Krage wrote:
They replied that the diagnosis takes up to 7 working days and costs from 300 to 450 rubles. I can imagine how much they will ask for the renovation!

you escalate the situation. if you come to the service not to make a scandal, but just ask the master, he will most likely fix everything in front of you.

For the PST 680 E model, the running rod part number is 2 600 780 148.

svetliy1963 wrote:
For the PST 680 E model, the running rod part number is 2 600 780 148.

... and the cost is 600 rubles + work. Total 1000 with a ponytail.

Krage wrote:
Dear forum participants, the keyless chuck on the Bosch jigsaw, where the file is inserted, has broken.

There was a case that the file was not clamped. I disassembled it and cured it somehow. It was true for a long time, and I don’t remember what I did. I remember that

BEARDED wrote:
checkmate and patience

svetliy1963 wrote:
For the PST 680 E model, the running rod part number is 2 600 780 148.

I did not find such a detail in the official on-line catalog ”>.

Mikael wrote:
There was a case that the file was not clamped. I disassembled it and cured it somehow. It was true for a long time, and I don’t remember what I did. I remember that
were for sure.

The most interesting is how to disassemble. It looks like this stem is seamed.

Krage wrote:
I did not find such a detail in the official on-line catalog ”>.

In the “Brand name” column, enter the PST 680 E, select the model and look at the part at number 40. If you want to find the part by number, follow your link in the column on the left to go down the fad-Information about the spare part- and there enter the number itself details.

svetliy1963 wrote:
In the “Brand name” column, enter the PST 680 E, select the model and look at the part at number 40. If you want to find the part by number, follow your link in the column on the left to go down the fad-Information about the spare part- and there enter the number itself details.

Video (click to play).

Thanks a lot for the detailed tips! Found this boom, but the price is not visible ?! Another question, if I buy this part, can I change it myself, or does this require special tools?