Types of faults
Mechanical faults
Engine malfunctions
Replacing the stem
Replacing the file holder
Replacing brushes
Replacing the start button
Tool prophylaxis
The overall efficiency of the whole mechanism depends on each of its separately taken parts. In the case of a modern electric jigsaw, with a relatively complex design, this is the case. Each element of this device is designed to perform a specific function for the sake of the overall result - the execution of a controlled cut. If a malfunction occurs on one of the components of the mechanism, the performance of the tool may decrease, down to zero. To get your apparatus back into operation, it is enough to find and eliminate the “weak link”. We will tell you how to fix a jigsaw with your own hands and reduce further wear and tear of its parts.
To learn how to identify and troubleshoot a mechanism, you must first understand how it works. The numerous components of the jigsaw design may seem rather difficult to understand at first glance. In fact, the principle of operation of this device is very simple, especially for those who know a little about technology. Next, we will tell you how an electric jigsaw works, outlining the main points in the most popular language, understandable even to an inexperienced reader in electrics.
The mechanism of any electric jigsaw is based on an electric motor, a gearbox and a rod. These are the main elements that make the file make the necessary movements. Often a cooling fan and pendulum mechanism are connected to the engine. The function of supplying energy and in some models of speed regulation is performed by a special start button with an electrical circuit. All of the above elements are compactly and reliably placed in a plastic case, interacting with each other.
Video (click to play).
To obtain high-frequency reciprocating movements of the saw blade, the energy supplied to the power tool undergoes significant transformations in its body. Bypassing the start button, electricity goes to the graphite brushes of the engine, forcing the rotor to rotate around its axis. The torque is transmitted to a special mechanism "reducer", which converts the movement from rotary to reciprocating, directing it to the rod. The final assembly is the fastener that reliably connects the stem to the saw blade, forming a strong movable structure.
VIDEO Prolonged or improper use of the tool can most likely cause damage to it. A malfunction of the device appears as a result of excessive pollution, wear of parts of the mechanism or a short circuit of the electric motor. Repair of a jigsaw, depending on the characteristics of the breakdown, is reduced to cleaning and lubricating the elements, or completely replacing them. Below, we will look at the most common types of breakdowns.
This category includes contamination, wear or complete breakdown of parts of the mechanism. At the same time, the engine of the tool works, but it does not come out to get the required cut. There may be several reasons for mechanical breakdowns requiring repair of jigsaws. Here are the most typical ones.
The jigsaw cuts crooked
Strong vibration and noise
The jigsaw hits when cutting
Oddly enough, numerous jigsaw breakdowns occur not only on moving parts, elements interacting with each other. Very often the device stops functioning (partially or completely) due to damaged electronics. To detect such malfunctions, a special instrument “multimeter” is required, which determines the characteristics of the current in the circuit of the device. It is necessary for a complete diagnosis, although some problems can be detected without it.
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The jigsaw does not turn on
Does not cut under load
Floating revs and burning smell
Sparking brushes during work
The procedure for removing a damaged stem with the installation of a new one is quite trivial and comes down to a banal analysis of the tool.Depending on the design of the jigsaw, you can access the element by unscrewing the front panel or the side panel, if the first is missing. The defective stem is removed and a new one is put in its place. When installing, pay attention to the moving metal parts located at the base of the stem. They must be positioned in such a way that they fall into the grooves of the upper mount and the metal frame serving as the base of the stem. The assembled structure must be abundantly lubricated with a thick grease such as lithol-24.
A more visual demonstration of replacing the stem can be seen in the video below about DIY Fiolent jigsaw repair.
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Replacing some types of fasteners is much easier than finding these parts. To perform a similar operation with shoe and screw clamps, you do not even need to unscrew the tool body. Saw holders of this type are attached to the end of the rod with one or two screws, which makes it quite convenient to change them. In the case of some screw mountings, replacement will require removal of the stem for a more convenient and secure fixation of the holder.
In the video below about repairing a jigsaw with your own hands, the process of replacing a block type of fastening is clearly demonstrated.
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If things are relatively simple with simple saw holders, then replacing the quick-clamping one can cause some difficulties, especially for an inexperienced craftsman. To begin with, these types of mounts, according to the arrangement of the levers, are divided into radial, side and frontal. The first type is the most common and spare parts for its repair can be found, but the last 2 are unique, which can be ordered directly from the manufacturer. In the case of a radial type of fastening, you can purchase a repair kit and try to sort it out on your own, but it would be best to buy it assembled, along with a stem.
Due to erasing, or burning of contacts, jigsaw brushes are very often the main contenders for replacement. In some models of power tools, such an operation does not require removing the case and occurs by simply unscrewing a pair of bots. Unfortunately, the quick access function is not provided on all models, so we will consider a more common option.
First of all, you need to get access to the electric motor. To do this, we disassemble the case or remove a certain part of it. Further, in the area of the collector, we are looking for brushes and study the principle of their attachment. On different models of tools, the attachment of these elements can vary significantly. Somewhere they are pressed by metal plates, somewhere they are snapped into place with special levers, and sometimes they are held at all by the tool body. The replacement process itself does not represent some incredibly complex do-it-yourself jigsaw repair. It is enough to carefully remove the defective brushes and replace them with new identical ones. A similar process is clearly demonstrated in the following video.
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In the case of choosing the latter option, all the difficulty will be in the search, since the trigger must be absolutely identical to the standard one. Perhaps you are lucky and the necessary item will be found in the nearest store. It all depends on the place and model of the instrument. The installation process fully corresponds to the removal, only in the reverse order. We connect the wires to the contacts and twist the body of the device.
If you want to repair the jigsaw button yourself, we recommend that you familiarize yourself with the video below, in which this process is demonstrated in great detail.
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Long service life and constant efficiency of the tool depend not only on the peculiarities of its operation, but also on the timely maintenance of its mechanism. Regular preventive maintenance will significantly reduce wear on parts, reducing the likelihood of serious breakdowns.
Carrying out a similar procedure will require only a screwdriver, a piece of cleaning cloth and a little grease. The whole process takes no more than an hour and consists in disassembling the jigsaw and carefully cleaning its parts. Most thoroughly it is necessary to clean and lubricate the gearbox and stem assembly. Prevention should be carried out as soon as the tool becomes dirty, based on the frequency of its use.
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The jigsaw is designed for cutting various materials. The design is simple, but breakdowns are also inevitable. Do-it-yourself jigsaw repair usually consists in replacing a blade that has worn out, fixing units, and a support roller. In the event of a breakdown of the motor, it is recommended that the device be returned to the master for repair.
Jigsaw device diagram.
How to determine if the jigsaw needs repair or preventive measures? There are a number of signs to look out for:
the body began to heat up too much during operation;
when switching on and further operation, uncharacteristic sounds are heard;
collector brushes sparkle;
the engine cannot be adjusted, there are other problems.
Replacing the jigsaw rod guide bushings.
When the listed symptoms are found, you must immediately turn off the jigsaw, then inspect it, determine the malfunction. All types of such breakdowns can be conditionally divided into 2 large groups.
Electrical breakdowns:
A factory defect in the form of a rotor breakdown (cannot be repaired, you must contact the service center).
The stator or rotor gets very hot during operation, there is a melting on the insulation. The reason is dust ingress, pollution, incorrect loading.
The brushes are worn out (replaced).
If the speed regulator does not work, then it needs to be replaced. It is best to contact a master.
Breakdown of the mechanical part of the jigsaw:
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. The balancers need to be replaced; 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.
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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.
VIDEO Replacement of certain parts is required in the following cases:
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Jigsaws are usually easy to repair. The job is to replace the worn out part. To extend the service life of the equipment, it is necessary to follow the operating rules and carry out preventive maintenance. In case of more complex breakdowns, it is better to immediately contact the master.
Do-it-yourself jigsaw repair is quite possible, but it is worth noting: there are troubles that cannot be eliminated with a conventional tool. For example, a breakdown of an electric motor requires qualified intervention, since only a specialist will be able to eliminate such a malfunction.
Consider what happens to the jigsaw during its operation. Now it is difficult to find a model that does not have the function of feeding the blade forward to reduce the load on the wearer's hand. The presence of such a mechanism of operation causes increased wear of individual structural elements. These are the guide roller as well as the stem sleeves. Other typical situations include:
Extremely high load ... Occurs with excessive diligence of the sawyer, which puts a lot of pressure on the horizontal feed. In inexpensive models, the file can damage the fragile holder. Another common breakdown is stem failure, as a result of which the jigsaw ceases to fulfill its purpose and the saw does not move.Lack of maintenance ... Causes increased bearing wear, abrasion of the cam block in some models, gears becoming unusable.Failure of electrical components systems. This is a start button that is often associated with an engine speed governor.Long run time ... Affects the state of the current-collecting surfaces of the motor, abrades the brushes. The repair consists in the replacement of the corresponding parts.
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Periodic maintenance - cleaning the insides of small sawdust, replacing brushes and grease - will extend the life of the electric jigsaw and prevent its failure.
Many modern jigsaws are equipped with bells and whistles, which are their weaknesses. For example, some models often require repair of the file attachment, due to the presence of functions such as:
Quick clamp , which does everything for the owner of the tool: just pull the lever, place the blade and work. Over time, the structure loosens, the fastening parts become unusable. Unfortunately, most of these clamps cannot be repaired, they can be completely replaced.Lightweight screw mount - a real problem for owners of cheap and medium-priced instruments. The rod end, made of weak alloys, has low strength, splits, bolts break seats. The repair consists only in the handicraft of the corresponding product from durable steel, since each line of cheap tools often has its own configuration of the file holder.
VIDEO If the jigsaw has a classic screw fastening of the saw, then it will not be difficult to repair it. It is a durable and time-tested design, you can use screws for a Phillips screwdriver or a wrench. The clamping units are standard, it is not difficult to find a replacement for an extremely worn part. There is a problem with thread wear, but in this case, you can cut a new one.
The tool is easy to disassemble. The body is divided into two halves, allowing access to all parts of the mechanics. The first step is to remove dirt and replace the grease, after which you can start repairing.
Let's note right away that there are no spare parts in stores. You can find the corresponding part by purchasing a broken tool at the flea market. Parts from other devices and mechanisms are often suitable. For example, jigsaws with a round stem are the easiest to repair. A round bushing is selected, if necessary, the inner diameter is increased by packing on a cone. This repair allows you to eliminate the runout and backlash of the rod, to improve the quality of the cut.
If necessary, unique fixing clips are made (depending on the jigsaw model). Copper foil can be used as small spacers when installed in a case.
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In inexpensive jigsaw models, the stem is a thin metal plate of complex shape. Under excessive load, it can simply burst. The part is replaceable, some jigsaw models are compatible with others. The device must be carefully disassembled, fixing the process in the photo in order to reassemble. Then, with the part removed, go to the market or store. Then install the part and apply grease.
For most models of jigsaws, if we are not talking about frankly budgetary ones, the kit comes with a pair of pullers ... To replace them, it is enough to open the case: in the back of the engine, on the contact block, the necessary elements are immediately visible. Repair is elementary: old parts are carefully removed, contact pads are cleaned of dust, wiped with alcohol. After that, it is enough to install new brushes.
You can purchase a replacement part both in specialized points and in stores selling spare parts for electronic devices. The body of the jigsaw opens, the corresponding part is freed from the wire leads. This should often be done after unscrewing the terminal block screws. Modern models are not forced to use a soldering iron. After removing the old, the new part is installed and connected.
It is better to disassemble the case and dismantle the button before going to the store in order to buy exactly the same part in the seat.
Jigsaw start button
Rather rare breakdowns include failure of the engine thermal fuse. The part is replaced. Sparks can be observed, which indicates not only a heavy load, but also wear of the brushes and a lack of lubrication. Therefore, periodic maintenance is the key to the reliable operation of the jigsaw.
When carrying out any repairs, precautions should be taken. The jigsaw must be disconnected from the mains. The first thing to check is the health and condition of the power cable, plug, contact in the socket. Some jigsaw models are equipped with a fuse located in the plug. This element is also worth inspecting and checking for serviceability.
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.
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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.
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.
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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.
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Another, no less popular manufacturer of domestic power tools, is the Smolensk company Diold. Electric jigsaws are distinguished by their low price and rather decent quality. For homework, this is a perfectly suitable budget option.
It also has points worth paying attention to. The first is the support roller. Over time, and this is about a year, it begins to lose its round shape. The reason is the material of the video or the technology of its production. It has insufficient hardness.
Its repair is to replace it. Still, it is better not to reinvent the wheel, but to purchase an original video from the manufacturer or take the tool to a service center, especially if it is under warranty.
If this option is not suitable or impracticable, then you can reanimate the jigsaw with the help of available tools. To do this, you need a regular M5 bolt with a nut. In this case, the bolt will serve as an axis, so you need to grind off the thread on it, and the nut with a roller, in it along the generatrix it is necessary to cut a groove along the thickness of the saw blade.
It is ideal to do this on a lathe, but you can also use a tool that is at hand, such as a drill and an angle grinder disc. The disk must be clamped in a vice, the bolt and nut - in the drill and cut into a groove. The repair option is not ideal, but it has the right to life, as it has been tested in practice.
Another nuance in using the Diold jigsaw is the ingress of wood dust into the start button. This happens due to the lack of tightness, and dust, getting inside the button, prevents the passage of current. The solution to the problem will be periodic, at least once a year, cleaning the contacts.
One of the best jigsaws on the world market are the models of the German company Metabo. Everything is good in him. High power, aluminum body, pendulum device. In addition, the tool is crammed with electronics, which allows you to customize the jigsaw to individual programs for each type of cut. And the cut is just perfect both in quality and straightness. The Metabo power tool is the best jigsaw today.
But not eternal. Breakdowns happen here too. The reasons can be very different. But as practice has shown, the weak point is mechanics. After significant loads, and in particular, cutting metal, it may fail.
Typically, the axle on the bearing bracket, arm and stem will not support.To restore the tool, it is better to purchase original spare parts, and assemble them at a service center by specialists.
When self-assembling the Metabo jigsaw, it is imperative to apply Castrol LMX grease to all rubbing surfaces with the addition of RiMET grease in a ratio of 3: 1.
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Consider another budget option for a jigsaw - the Crimean Fiolent. This is a perfectly acceptable model both in terms of price and quality. There are two problems in the operation of a jigsaw. This is a possible failure of the stem during improper handling of the tool and insufficient or illiterate lubrication.
In the first case, in order to avoid this damage, it is enough to carefully and carefully handle the tool. But if this does happen, you will have to replace the damaged stem. For this you need:
Remove the housing cover by unscrewing 4 screws.
Remove the rectangular washers and retaining rails from the stem.
Unscrew 4 bolts and remove mechanism cover. Below it is the flywheel and the stem itself.
Unscrew 2 screws each, remove the upper and lower stem holders. The latter is with a spring, so you need to clean it carefully.
Dismantle the destroyed stem with guide washers.
Lubricate the flywheel and eccentric with a special gear lubricant.
Put the guide washers on the new stem and install in place.
Attach the saw blade holder to the bottom of the stem.
Install the upper and lower holder, screw on the mechanism cover and install the washers and retaining rails.
Insert the cutting tool and test the jigsaw at idle speed and under load. If the check shows no abnormalities, install the housing cover.
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In the second case, everything is much more serious. It would seem, what is difficult about lubrication? But due to the fact that the tool constantly works in extreme conditions, the ingress of wood dust into the device cannot be avoided, it is necessary to carry out service work according to the intensity of operation, but at least once a year.
All mating parts and assemblies need to be lubricated. To do this, you need to disassemble the jigsaw. But if in the first case, for example, you limited yourself only to dismantling the stem, now we disassemble the tool completely and re-lubricate all the rubbing surfaces of the parts.
For lubrication, the manufacturer offers Litol 24, but it will not work in the jigsaw gearbox, due to its thick consistency, therefore, as a rule, it is lubricated with oils. You can combine Litol 24 with Feol 2U graphite grease in a ratio of 3: 1.
However, it should be borne in mind that now the fluidity of the lubricant mixture is higher, and after some operating time it will begin to enter the engine rotor. The reason for this is left-hand drive. When the rotor rotates, the lubricant mixture is captured by the teeth and is fed to the rotor like a screw. The oil separator installed inside the motor housing does not fulfill its function. In theory, it should throw away the incoming mixture, but in practice this does not happen. This is evidence of the imperfection of the design proposed by the manufacturer.
To avoid this problem, some work needs to be done. Or rather, put the oil separator not inside, but outside the motor housing. At the same time, in order for the oil separator snail to work and discard oil, it is turned over.
One more nuance. The bore diameter is Ø 9 mm, and the diameter of the outer part of the oil separator is Ø 9.2 mm - it ideally blocks the passage for the lubricant mixture. But when installing it, you need to apply a certain effort and a nozzle in the form of a pipe of a suitable size.
In addition, it is advisable to install a dust washer on the rear bearing of the armature. It will protect it from wood dust and extend its service life.
After that, you need to assemble the oiled jigsaw and test it for performance. After 10 hours of operation, the tool should be checked for grease penetration into the motor housing.If everything is done correctly, then such an option is excluded.
And of course Bosch. The power tool of this manufacturer is distinguished by the high quality of components, assembly and a long service life, provided that it is treated with care. He also has a drawback - the price. Moreover, both the product as a whole and the spare parts are expensive.
It should be noted that the Bosch tool practically does not break, but there are some nuances that appear during long-term use. For example, wear on the brushes of the electric motor, failure of the speed controller or the device for holding the saw blade. There are accidents and more complicated ones, failure of a rod or an anchor, but this is, rather, from incorrect handling.
As in the case of Metabo, Bosch jigsaws are best repaired at service centers. There they will install original spare parts and give a guarantee for the repair performed. But this is an expensive pleasure.
After reading the article, the user gained theoretical knowledge about jigsaw failures. Now, in the event of a breakdown, he will be able to determine the cause and make the right decision, and maybe even perform minor repairs.
Video (click to play).
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