The jigsaw works and stops, what is the reason. Do-it-yourself jigsaw repair (the most common breakdowns). Jigsaw maintenance and prevention

10 minutes to read. Published 05/02/2019

A home craftsman's arsenal must include power tools. One of the useful and indispensable devices is an electric jigsaw, which allows you to cut various materials along straight or winding lines with visual control of the direction. The tool is unusual, does not require the installation of guides, and is capable of cutting materials at an angle. Let's take a closer look at it.

Design and principle of operation of a jigsaw

Figure 1 – Jigsaw structure

A jigsaw is a universal tool for cutting various, mainly sheet, materials:

• plywood;
• MDF, chipboard or fiberboard;
• drywall;
• plastic;
• solid wood (up to 9 cm thick, depending on the working length of the file).

In addition to these materials, a jigsaw is capable of cutting aluminum or steel sheets, you just need to install a special file with a fine tooth. Unlike circular saws, a jigsaw performs a curved cut, allowing the master to cut out the contours of various geometric shapes. The device is somewhat more complicated than other power tools, since to operate it is necessary to convert the axial rotation of the electric motor into reciprocating motion in the direction perpendicular to the rotor axis of rotation. This problem is solved by a special mechanism located in the front part of the tool. It ensures the movement of the rod up and down.

For convenience and safety of work, there is a support plate that slides over the surface of the material being processed. The file is attached to the bottom of the rod using a clamping screw. All elements are installed in a plastic case, the upper part of which is a handle with a push button and a speed controller. In addition to the main functions, there is a regulator for the pendulum movement of the saw, which makes cutting dense and hard materials easier. The sawdust is partially blown away using an impeller mounted on the motor shaft and acting as a fan.

Types of faults

Figure 2 – Disassembled jigsaw

Most often, a jigsaw fails due to excessively high loads.

They occur due to prolonged use, working with an incorrectly selected file, or other operational errors.

The main, if not the only reason for all malfunctions is a one-time or constant overload of a tool whose power is too low to solve the assigned tasks.

During operation, all components and parts of the tool withstand forces that can cause them to fail.

This applies equally to both the mechanical and electrical parts of the jigsaw. Possible problems can be conditionally divided according to belonging to one or another group, so they should be considered separately.

Mechanical problems

Problems in the operation of a mechanical type jigsaw arise due to breakdowns or wear of components and mechanism parts. At the same time, the electric motor operates in normal mode, but it is not possible to get the tool to operate normally. There are several typical faults:

1. During operation, the saw blade moves strongly to the side. Most often, the cause of this condition is contamination or wear of the tool parts. The solution to the problem will be cleaning and replacing problematic elements.
2. Noise, strong vibration or knocking in the gearbox. The appearance of such signs, uncharacteristic sounds or twitching of the instrument indicates a problem with the converter - severe contamination, dryness or lack of lubricant, wear or breakage of gear teeth. The solution to the problem is to inspect the mechanism with the side cover removed, identify the source of the problem and replace the failed part with a new, functional one.
3. The jigsaw hits while cutting. This problem occurs due to breakdowns of the rod, pendulum mechanism, large amounts of dust or other contaminants on the moving elements. This malfunction is eliminated by replacing or, less commonly, cleaning the problem unit from contaminants.

Attention! All problems with the mechanical part of a jigsaw can be solved quite simply; the difficulty lies in identifying the defective unit or element. As a rule, they are coated with a layer of black grease, to which fine dust from the material being processed sticks. Before you begin inspecting and assessing the condition of the parts, you should wipe them with a soft cloth. After completing the work, it is necessary to re-apply lubricant to all moving elements of the mechanism.

Engine malfunctions

Figure 3 – Internal structure.

Problems with the electrical part of the tool arise quite often, since the load on it is large and constant.

The power of electric motors installed on such tools is usually in the range of 600-900 W, and the load on the saw must be transmitted through a gearbox.

Therefore, the total load on the electrical part is close to the limit value and requires caution and attention during operation.

Problems that often occur with the electrical part of the tool:

• When pressing the button the jigsaw does not work. Most often, the cause of this situation is a lack of power supply caused by a broken button or problems with the power cord. First, always check the wire by ringing it with a tester. Then, if it is in order, they briefly apply voltage to the electric motor directly, bypassing the button. If it starts to rotate, the problem lies in the button, which needs to be repaired or replaced;
• When even a slight force appears, the jigsaw slows down and stops. This problem indicates a failure of the motor armature. As a rule, the cause is a short circuit of the windings, which are capable of creating an impulse for idle rotation, but there is no longer enough power for normal operation under load. Typically, such malfunctions are accompanied by strong sparking, cracking, and a characteristic smell of burnt insulation appears. The best option is to replace the armature or the entire engine, but in some cases restoration repairs are possible;
• Unstable operation, the jigsaw smells like burning, the speed drops under load. This behavior of the tool is to blame for weak contact with the power wires or failure of the wiring. The exact source of the problem can only be determined after removing the cover. Usually the defective area is immediately visible - the problem contact has traces of soot, carbon deposits, and the connection is very hot. The solution will be to restore the reliability of contacts, soldering, sometimes it is necessary to replace a failed wire;
• Sparking of brushes during engine rotation. This is a sign indicating the need to replace them. The graphite from which the brushes are made wears out over time, and with constant use of the tool, their service life ends quite quickly. The design of the electric motors is equipped with convenient sockets, making replacing the brushes a fairly simple and quick task. To replace, there is no need to contact a specialist, since the brushes are simply inserted into the appropriate slots without any additional steps.

It is necessary to take into account that any repair of the electrical part of the instrument is carried out according to the “from the outlet” rule, i.e. first, the presence of voltage is determined, then the condition of the power cord, buttons, etc. is checked.

Electric motor diagnostics

Figure 4 – Jigsaw diagnostics

To identify electric motor malfunctions, it is necessary to carry out a number of diagnostic measures.

To do this, you will have to disassemble the engine and prepare a multimeter.

Then you need to do the following:

• inspect the engine, a wire may be torn off, there may be chips, burnt or smoked areas;
• measure the resistance of the armature winding: set the tester to a range of 200 Ohms (or in testing mode);
• check the quality of the insulation by alternately touching the collector plates with one probe and the core with the other. If a short circuit is detected, the winding will have to be changed;
• check the quality of the insulation between the collector plates by touching the adjacent plates with probes one by one. The first one is marked with a marker so as not to get lost. If there is a difference in resistance of more than 120%, you will have to change the armature;
• An interturn short circuit may occur, but it cannot be determined with a multimeter. If there is a suspicion of an interturn short circuit, you should simply replace the rotor.

To check the stator, perform the following steps:

• check the breakdown of the winding on the body: touch the terminals with one probe and the steel body with the other;
• check the winding resistance. Measure the resistance at all terminals one by one. If a noticeable difference in the readings is detected, it means that the winding is defective and must be rewinded;
• Check the condition of the steel core plates. They must be laid tightly; if delamination is detected, the stator must be replaced.

Important! Problems with the electric motor are the same on any model, since the design of the motor is no different for different tools.

Replacing the rod

Figure 5 – Rod

The jigsaw rod is the part to which the file is attached.

During operation, it makes reciprocating movements, experiencing maximum load.

To repair a jigsaw with your own hands, you will need to remove the faulty rod by disassembling the jigsaw (remove the front cover or the side cover if the body consists of only two halves).

It is necessary to remove the faulty rod and install a new element in its place, monitoring the position of the metal parts.

Before removing, you should carefully examine the position of the rod, remember which elements come into contact or interaction, so that nothing is changed when installing a new rod. The installed part must be generously lubricated with lithol to reduce wear and extend the service life.

Replacing the saw holder

Figure 6 – Saw holder

There are several types of saw holders.

Changing them is not difficult; it is much more difficult to find the same element to replace it.

The procedure is simple and does not require disassembling the jigsaw; just pull the rod to its lowest position.

The block and screw holders are secured with two screws, so replacement is easy.

If you use a quick-release saw blade, you will have to spend time and effort searching for a replacement.

Sometimes you can only find a repair kit from the tool manufacturer. Experts recommend purchasing the entire rod assembly, since it is difficult and impractical to sort out the quick-release saw holder with your own hands.

Replacing brushes

Sparking and a burning smell indicate heterogeneity in the operating mode of the windings. This is usually due to brushes that are worn out and require replacement. During operation, the graphite is gradually erased, the length of the brushes decreases, and the density of contact with the commutator surface decreases. Loose contact causes heating and strong sparking, melting the surface of the collector and destroying its plates. Therefore, when the first signs of wear appear, you need to remove the brushes, inspect them, and, if necessary, change them. When buying brushes, it is recommended to have old ones with you as a sample, so as not to miss the size.

In addition to brushes, the motor may have problems with the windings or insulation breakdown. All these issues can be resolved only by disassembling the motor and fully examining the rotor and stator, checking the windings and identifying the defective unit. A decision on repair or replacement should be made only after accurately determining the extent of the damage; however, for an inexperienced person it is always easier (and more correct) to immediately purchase a new engine. Figure 7 – Start button

Lack of response to pressing a button is usually a consequence of a failure of the power cord or the button itself.

In any situation, first of all, determine the source of the problem, the presence of voltage in the outlet (perhaps the extension cord is simply not connected or the corresponding circuit breaker on the panel is turned off), and the condition of the wire.

When it is finally determined that the cause of the tool failure lies in the button, it is replaced with a new one or repaired.

Often carbon deposits appear on the inside of the contacts, preventing connection. It needs to be cleaned and the button reassembled. If the microcircuit on the speed controller fails, you will have to completely replace the button assembly.

Repairing the speed controller on an electric jigsaw - instructions

Most often, no one undertakes to repair the speed controller, preferring to immediately replace it with a new copy. However, for various reasons, it is sometimes easier to try to restore an existing regulator. Its design is simple; even an untrained person can repair such a unit. It is necessary to disassemble and carefully inspect the regulator. A failed element is immediately noticeable; it is charred, covered with soot, or simply darkened. All repairs consist of replacing the burnt part. If the problematic element is a microcircuit, it is easier to completely replace the regulator.

Figure 8 – Prevention

Careful and careful operation, avoiding overloads and excessive effort, and avoiding overheating of the tool will help extend the life of the jigsaw.

The nominal operating mode is indicated in the user manual, which should be carefully studied before starting work.

In addition, it is necessary to regularly perform preventive maintenance of the tool:

• cleaning from dust and dirt;
• replacing lubricant;
• periodic inspection and timely replacement of brushes;
• using only suitable tools;
• compliance with operating rules.

Fulfilling these simple requirements will help increase the life of the jigsaw and free the user from the need to repair or buy a new tool.

Conclusion

Every hand-held power tool fails at some point. There are many reasons for breakdowns and malfunctions, and most of them are associated with illiterate or careless operation. To avoid such problems, you should find out in advance what materials the jigsaw works with, their thickness and parameters, what files are used for cutting and when they should be changed.

All rules and requirements are set out in the instructions; during operation, you must also monitor the behavior of the tool. If alarming signs, vibration, burning smell or other symptoms appear, you should stop working and inspect the tool. A fault detected and corrected in a timely manner will increase the service life of the jigsaw and save money on repair work.

Saw holders for jigsaws are divided into 2 types. Each of them has its own advantages and disadvantages. When purchasing, it is recommended to first find out what types and features of jigsaw files there are.

Choosing a jigsaw file requires careful attention. It is necessary to take into account the material, type of work, cutting requirements, etc.

Types of saw shanks

The type of shank is one of the main parameters. There are 2 main types:

1. T-shaped. The type was introduced by Bosch and has become widespread among power tool manufacturers. T-shaped files are often called “Bosh” files. They are used in jigsaws from almost all manufacturers: Makita, DeWalt, Zubr, Skil, Interskol, etc.
2. U-shaped. Used in older American-made models: DeWalt, Stayer, Skil, Black&Decker, etc.

There are saw blades with Makita and Bosch shanks, which were used in older models of equipment from the respective manufacturers. Now they are not only not used, but they are difficult to find on sale.

Dimensions

When choosing a canvas, pay attention to its size. The choice depends on the work and materials to be used.

The length of the saw ranges from 40 to 250 mm. The larger the parameter, the thicker the material the device can process. However, it is necessary to take into account the characteristics of the equipment itself, because it also has operating restrictions.

To cut thin workpieces, you should choose short equipment. It does not cause severe deformation, and the cut is smooth, without burrs.

The width of the file is selected in accordance with the operations performed. For straight cuts, use wide blades. They provide an even, neat cut. For shaped work, narrow files are used, allowing you to create all kinds of curves and patterns.

The thickness of the file affects the production of an even vertical cut. The larger the parameter, the less likely it is that the cut will deviate from perpendicular. However, when selecting the thickness, it is necessary to take into account the characteristics of the jigsaw itself. Thus, not all devices with a quick-release fastening system can work with thick files.

Types of files according to cutting edge geometry

Jigsaw blades differ in the layout of the cutters and the geometry of the cutting edge. The further the teeth are retracted, the faster it will be possible to cut the workpiece. However, this reduces the quality of the cut. The choice of geometry is also influenced by the material to be worked with. The following types of files are distinguished:

• Milled with a classic pattern. In such paintings, the even incisors are bent in one direction, and the odd incisors in the other. This geometry helps reduce saw heating and increase processing speed. However, the quality of the cut suffers. Milled blades are intended for processing wood, polymer materials and metal blanks.
• Milled with wavy pattern. In this case, the incisors are moved in opposite directions not 1 piece at a time, but 5-10 at a time. In this case, the teeth in the group are bent from the axis by different amounts. The result is a wave-like edge shape. These blades are intended for clean cutting of wood, plastic, plywood, and chipboard.
• Polished with a classic pattern. The cutters of the files are bent one at a time in different directions, after which they are ground. After cutting, a wide cut line of medium cleanliness is obtained. Used for working with wood, plywood, chipboard, etc.
• With conical grinding without streaking. The cutters of the blades are not moved apart, but only ground. This type of equipment produces a thin cutting line with high cleanliness. The blade is intended for cutting wood, plastic and laminated-coated workpieces.

Classification according to the type of material being processed

Jigsaw files are classified according to the material they are intended for processing. However, the main function of the tool is wood processing. Therefore, wood paintings are the most common and numerous. They are divided into the following types:

1. For quick cutting. They provide a quick cut with low quality. Distinctive features: maximum file length - 60 mm, large cutters - up to 6 mm, large setting - about 1 mm.
2. For a clean cut. Provides an even, burr-free cut. They differ in the average size of the incisors (up to 3 mm) and small setting. The teeth may be inclined away from the jigsaw or towards it. For laminate work, it is recommended to use version 2 of the canvas. If you cut plywood with a jigsaw, you can use any of the options.
3. For figured cutting. Used for cutting curves, incl. with a small radius. Often used when cutting plywood. Distinctive features of a saw for figured cutting: a blade with a small width of no more than 4 mm, cutters - up to 2 mm, length - no more than 40 mm, the back part is beveled.

The next type of files is designed for metal work. Although the tool is rarely used for processing material, blades for the work are produced.

Distinctive features of the equipment: made of high-strength steel, have small teeth no larger than 1 mm in size and wavy routing. The blades, in turn, are divided for work on aluminum, steel and other non-ferrous metals.

Blades for processing glass and ceramics are produced. For their manufacture, special high-strength alloys are used, and tungsten carbide is sprayed onto the cutting edge. Diamond coating is less common. Use a power tool only for curved cutting.

Files for drywall and other materials with abrasive particles have hard alloy soldering on the working edge.

The equipment for processing workpieces made of soft materials resembles a knife. The edge has a wavy ground surface without cutters.

We also produce universal blades that are used for sawing various materials. High-speed steel is used for their manufacture. Cutting with such files is of poor quality.

How to decipher the marking?

There are no uniform requirements for marking blades for jigsaws, but many manufacturers adhere to Bosch standards.

The main information is marked in the tail section. The first letter indicates the type of shank (T- or U-shape).

Then comes a number characterizing the length of the file:

• 1 - short (up to 75 mm);
• 2 - standard (from 75 to 90 mm);
• 3 - extended (from 90 to 150 mm);
• 4 - long (from 150 mm).

The second and third numbers indicate the purpose of the canvas.

Then again there is a letter indicating the size of the incisors:

1. A - small;
2. B - medium;
3. C and D are large.

The final letter gives additional information:

• F - bimetallic files;
• O - narrow blade;
• P - thick fabric;
• R - files with reverse teeth;
• X - files with variable cutter sizes.

The purpose of the blade is also characterized by the color of the shank:

1. gray - for wood;
2. white - for wood and metal workpieces;
3. blue - for metal blanks;
4. red - for plastic;
5. black - other materials.

The steel grade is indicated on the neck of the equipment:

• CV - chrome vanadium (for wood blanks and wood boards);
• HCS - high carbon (for wooden and plastic blanks);
• HSS - high-speed cutting (for metal workpieces);
• HM - hard alloy based on tungsten carbide (file for tiles, glass, ceramics, etc.);
• BM (BIM or Bi-Metal) is a combination of HSS and HCS (professional equipment for cutting wood and metal workpieces).

The canvas is also marked with a designation that characterizes its purpose:

1. Wood - for soft wood and fiberboards;
2. Hardwood - for hardwood and laminated panels;
3. Inox - for cutting stainless steel;
4. Alu - for cutting aluminum;
5. Metal - for cutting sheet metal, metal profiles and pipes;
6. Fiber&Plaster - for cutting fiberglass;
7. Acrylic - for cutting plexiglass and polycarbonate;
8. Soft-material - for cutting cardboard, rubber, etc.

Types of saw holders

There are 2 types of fastening of a file in a jigsaw: automatic and mechanical.

Automatic quick clamping system

With an automatic system, the blade is placed in the gripper with a shank and secured with grooves.

To replace the blade, a special lever is provided, thanks to which there is no need to remove the protective casing. Using the adjusting screw, the required position of the file is achieved.

The advantages of this method are the speed and ease of replacement, which do not require special skills.

The disadvantage is the wear of parts, leading to a decrease in the quality of the cut, and the difficulty of repair due to the lack of spare parts (especially for Chinese equipment).

Mechanical (manual) fastening method

With the mechanical fastening method, replacing the file and adjusting its position is carried out manually. This fastening is reliable, durable, and has good cutting quality. In the event of a breakdown, repairs are cheap. Parts are easy to find (bearings, Interskol jigsaw rollers, etc.). The disadvantage is the complexity of the process and the skill to correctly insert the file into the jigsaw.

The mechanical fastening method is divided into block and screw.

In the first case, the jigsaw blade holder is made in the form of a block with a slot, which is clamped with 2 front screws.

This clamp is suitable for various files. However, uneven tightening of the screws leads to skew of the blade, which affects the quality and speed of the cut.

With a screw clamp, the file is secured and adjusted using 1 screw. This ensures correct installation and high-quality operation of the equipment.

The overall efficiency of the entire mechanism depends on each of its individual parts. In the case of a modern electric jigsaw, with a relatively complex design, this is exactly the case. Each element of this device is designed to perform a specific function for the sake of the overall result - performing a controlled cut. If problems occur on one of the mechanism components, the performance of the tool may decrease, down to zero. To return your device to service, it is enough to find and eliminate the “weak link”. We will tell you further how to repair a jigsaw with your own hands and reduce further wear of its parts.

Design and principle of operation of an electric jigsaw

To learn how to identify and troubleshoot a mechanism, you must first understand how it works. The numerous components of a jigsaw design may seem quite difficult to understand at first glance. In fact, the operating principle of this device is very simple, especially for those who know at least 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 electrical engineering.

The mechanism of any electric jigsaw is based on an electric motor, gearbox and rod. These are the main elements that force the file to make the necessary movements. Often a cooling fan and a pendulum mechanism are connected to the engine. The function of power supply and in some models of speed control is performed by a special start button with an electrical circuit. All of the above elements are compactly and securely placed in a plastic case, interacting with each other.

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 passes to the graphite brushes of the motor, causing the rotor to rotate around its axis. The torque is transmitted to a special “gearbox” mechanism, which converts the movement from rotational to reciprocating, directing it to the rod. The final unit is a fastening element that reliably connects the rod to the saw blade, forming a strong movable structure.

Types of faults

Prolonged or improper use of the tool can most likely cause it to break. A malfunction of the device occurs as a result of excessive contamination, wear of mechanism parts, or a short circuit of the electric motor. Repair of a jigsaw, depending on the nature of the breakdown, boils down to cleaning and lubricating the elements, or completely replacing them. Below, we will look at the most common types of breakdowns.

Mechanical problems

This category includes contamination, wear, or complete breakdown of mechanism parts. The engine of the tool is running, but it is not possible to obtain the required cut. There may be several reasons for mechanical breakdowns that require repair of jigsaws. Here are the most typical ones.

The jigsaw cuts crookedly
A significant deviation of the fork blade away from the intended line is often associated with the saw attachment mechanism or the rod. The reason for this may be severe contamination of the parts or their wear. To correct the situation, you need to remove the parts, clean them with a rag and put them back together. If the problem persists, the stem or fastener should be replaced.

Strong vibration and noise
Strange sounds, uncharacteristic of a running power tool, usually come from a faulty gearbox. This may be due to lack of lubrication, contamination or breakage of the gear teeth. To find out the exact cause and its further elimination, it is necessary to remove the side part of the case and visually inspect the mechanism for the presence of the above problems. In case of breakdown, the mechanism should be replaced with a similar one.

The jigsaw hits when cutting
Regular jolts of the tool during operation may be associated with the pendulum mechanism or the rod. The reason for this is mainly damage to parts, and in rare cases, severe contamination. To repair a jigsaw with a similar malfunction, it should be disassembled, the faulty unit should be identified and replaced with a similar one. If there is no obvious damage, all parts should be completely cleaned and lubricated.

Engine malfunctions

Oddly enough, numerous jigsaw breakdowns occur not only on moving parts, elements interacting with each other. Very often, a device stops functioning (partially or completely) due to damaged electronics. To identify such faults, you need a special “multimeter” device that determines the characteristics of the current in the device circuit. It is necessary for a complete diagnosis, although some problems can be identified without it.

Jigsaw won't turn on
The complete lack of vital activity of the tool is due to the lack of contact between the motor and the network. The reasons for this problem lie in the wiring or the start button. To identify a malfunction, it is necessary to completely inspect, or better yet, ring the instrument cable and internal wiring. The functionality of the button is checked by connecting the wiring directly to the motor. If the tool works when plugged into the network, then the problem lies there. The faulty contact must be replaced.

Doesn't cut under load
At first glance, the working tool is completely unable to cope with once simple tasks and slows down even on materials of small thickness. Significant loss of power is associated with engine damage. The jigsaw anchor, due to a short circuit, does not create a sufficient rotational impulse, creating the illusion of work. Typically, an instrument with such a breakdown sparks and emits a characteristic burning smell. To accurately determine the location of the short circuit, parts of the stator and rotor of the motor are alternately tested with a multimeter. The solution is to replace the damaged part or the entire motor.

Floating speed and burning smell
When, during operation, the tool periodically loses its strength, reducing its power and accompanied by a burning smell, it is worth paying attention to its wiring. To identify a weak contact, it is necessary to remove the housing cover and visually inspect all wires and their connections for defects. It is better to do this using a multimeter, paying attention to the start button and the motor windings. To restore the integrity of the circuit, the conductors should be replaced or the charred contacts should be cleaned.

Sparking brushes during operation
The abundant formation of sparks that occurs in the commutator area during operation of the tool can be associated not only with a malfunction of the engine, but also with a defect in the graphite brushes. In the modern world, this component is one of the most frequently replaced parts when repairing equipment, so many jigsaws have special grooves for quick and convenient removal. You can make the replacement yourself. It is enough to disconnect the old brushes from the contacts and connect new ones in their place.

Replacing the rod

The procedure for removing a damaged rod and installing a new one is quite trivial and boils down to a banal disassembly 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 faulty rod is removed and a new one is installed in its place. When installing, pay attention to the moving metal parts located on the base of the rod. They must be positioned in such a way that they fit into the grooves of the upper fastening and the metal frame that serves as the base of the rod. The assembled structure must be generously lubricated with a thick lubricant such as litol-24.

A more visual demonstration of replacing the rod can be seen in the video below about repairing a fiolent jigsaw with your own hands.

Replacing the saw holder

Replacing some types of fasteners is much easier than finding these parts. To perform a similar operation with block 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 using one or two screws, which makes it quite convenient to change them. In the case of some screw fasteners, replacement will require removing the rod to more conveniently and securely fix the holder.

The video below about repairing a jigsaw with your own hands clearly demonstrates the process of replacing the shoe-type fastening.

If things are relatively simple with simple saw holders, then replacing a quick-clamping one can cause some difficulties, especially for an inexperienced craftsman. Let's start with the fact that these types of fastenings, according to the location of the levers, are divided into radial, lateral 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 yourself, but it would be best to buy it assembled, along with the rod.

Replacing brushes

Due to abrasion or burning of contacts, jigsaw brushes very often become the main contenders for replacement. In some models of power tools, this operation does not require removing the housing and occurs simply by 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 gain access to the electric motor. To do this, we disassemble the housing or remove a certain part of it. Next, in the collector area, we look for brushes and study the principle of their fastening. On different models of instruments, the fastening of these elements can vary significantly. In some places they are pressed against metal plates, in others they are latched with special levers, and sometimes they are even held in place by the body of the instrument. The replacement process itself is not some incredibly complicated DIY jigsaw repair. It is enough to carefully remove the defective brushes and replace them with new, identical ones. This process is clearly demonstrated in the following video.

Replacing the start button

If you choose the latter option, all the difficulty will be in the search, since the trigger must be absolutely identical to the standard one. Perhaps you will be lucky and the necessary element will be found in the nearest store. It all depends on the location and model of the instrument. The installation process is exactly the same as removal, only in reverse order. We connect the wires to the contacts and tighten the device body.

If you want to repair the jigsaw button yourself, we recommend that you watch the video below, which demonstrates this process in great detail.

Tool prevention

The long service life and constant efficiency of the tool depend not only on the characteristics of its operation, but also on timely care of its mechanism. Regular preventative measures will significantly reduce the wear of parts, reducing the likelihood of serious breakdowns.

Carrying out such a procedure requires only a screwdriver, a piece of rag for cleaning and a little grease. The whole process takes no more than an hour and consists of disassembling the jigsaw and carefully cleaning its parts. The gearbox and rod assembly must be cleaned and lubricated most thoroughly. Prevention should be carried out as the tool becomes dirty, based on the frequency of its use.

Replacing jigsaw rod guide bushings.

When the listed signs are detected, you must immediately turn off the jigsaw, then inspect it to determine the malfunction. All types of such breakdowns can be divided into 2 large groups.

Electrical failures:

1. Factory defect in the form of rotor breakdown (cannot be repaired, you must contact a service center).
2. The stator or rotor becomes very hot during operation, and melting of the insulation is observed. The reason is dust, contamination, improper load.
3. The brushes wear out (replacement is being carried out).
4. If the speed controller does not work, it needs to be replaced. It is best to contact a specialist.

Failures of the mechanical part of the jigsaw:

The internal structure of a jigsaw.

1. The gear has worn or deformed teeth. It is possible to repair a jigsaw; a complete replacement of the gear is required; in the future, it is necessary to carefully monitor the loads and the correct choice of blade.
2. The rod breaks and there are kinks on it. It is necessary to repair the jigsaw by replacing the rod, and then choose the right files according to the type of material. For example, for wood or metal, use only specially designed devices.
3. The balancers that guide the rollers are worn out. The balancers need to be replaced, and the loads need to be monitored in the future.
4. If the bearings are worn out, they are replaced. It is best to contact a specialist.

Other types of breakdowns may also occur. For example, if there is a strong impact, the case may crack. Do not drop the jigsaw; in this case, other parts may be damaged. It is best not to fix engine breakdowns yourself, but to immediately contact a service center. You can handle replacing worn parts yourself. To do this, the manufacturer provides instructions; following them, you can easily cope with the work yourself.

Breakage of the support roller and fixation unit: prevention, repair

Main characteristics of household jigsaws.

How to repair if problems are found? The support roller may break if the load on it is too great, i.e. cutting technology is broken. The file is attached specifically to this roller; if it is broken, the file will not be able to be used. To prevent damage from happening:

1. Use only high-quality hacksaw blades.
2. Do not use dull files.
3. Hacksaw blades should be selected only in full accordance with their intended purpose. For example, for metal, only the blade that is intended specifically for this material is used.

If the roller is not replaced when it breaks, 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 repair itself is not too complicated. The support roller with signs of damage must be removed and then replaced with a new one that matches the jigsaw model used.

The working blade fixing unit usually breaks when it gets covered in large quantities of dust. During operation, dust is not uncommon, so for prevention it is regularly necessary to clean the surface of the fastener. Over time, the situation will get worse and the equipment may completely fail. The repair usually consists of completely replacing the retainer.

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

It consists of performing a number of actions:

1. The unit must be constantly cleaned and then lubricated.
2. During operation, you should use a dust collector, which will prevent large amounts of dust from getting onto the tool.

Other breakdowns

Repairs may be required in other cases. Breakdowns may be due to physical wear and tear of the equipment.

Replacement of certain spare parts is required in the following cases:

1. Gearbox parts are damaged. Such breakdowns are possible due to the fact that dust particles and small debris get inside the gearbox through the ventilation holes. As a result, the equipment begins to get very hot during operation. The repair is extremely simple; you need to use dust collectors or a powerful vacuum cleaner, which will remove all the dust through the ventilation holes. Cleaning should be done regularly, as failure to do so will result in damage to the gearbox and will require replacement.
2. There is a bend or break in the support rod. This occurs if the equipment was handled carelessly or dropped. If such a defect is observed, then the support rod must be replaced; such a fracture can subsequently lead to failure of the entire device.
3. If the jigsaw collet is used incorrectly, the teeth may break off. This occurs when the hacksaw blade is inserted and not fully tightened. The repair consists of completely replacing the collet.
4. The worm gear may be worn. This happens when you start using a jigsaw before its engine reaches full power. What is the right thing to do? You must first wait until the engine reaches full power, and only after that bring it to the workpiece, and not vice versa. The repair consists of replacing the helical gear or armature transmission of the device.

Jigsaws are usually easy to repair. The job is to replace a worn part. To extend the service life of equipment, it is necessary to follow operating rules and carry out preventive maintenance. For more complex breakdowns, it is better to immediately contact a specialist.

Among the hand tools used in the household, the most popular is the jigsaw. 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 maintenance and repair if necessary.

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

The design of electric jigsaws and their malfunctions

The design of jigsaws from different companies differs little. It consists of a body, a sole, a saw blade, a cutting tool mechanism, a gearbox and an electric motor that drives the working part of the tool.

The difference in models from one manufacturer or another lies in the design features of some components. It is natural that the malfunctions and the reasons for their occurrence are also identical.

Knowledge of the most common failures of power tools and preventive measures to prevent them will help both the novice master and the experienced professional.

Typical failures of electric jigsaws include:

1. Sawing curvature.
2. Change in shape or destruction of the support roller.
3. Breakage of the cutting tool mounting unit.
4. Damage to the gear wheels of the gearbox.
5. Destruction or bending of the support rod.
6. Broken teeth on the jigsaw collet.
7. Early wear of the armature worm gear.

Typical power tool failures and measures to prevent them

The jigsaw is designed to perform rough curved cuts, so there is no point in talking about ideal sawing. Although this indicator is also different in hand tool models from different manufacturers. When using cheap models, they don’t pay much attention to this, and the cut turns out completely crooked. You need to deal with this in service centers, but you can try to get rid of the curvature at home.

The support roller may break if poor quality saw blades or dull tools are used. Use of cutting tools in inappropriate load conditions. The result may be jamming or cutting of the support roller.

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

As a rule, almost all models of jigsaws are equipped with a tool-free saw blade fixation unit. This simplifies the process of changing cutting tools. But operating the mechanism in conditions of constant dustiness leads to wood shavings getting into it, and this leads to failure of the device.

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

Failure of gearbox elements is a consequence 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 careless use of the power tool. This can happen when it falls or an unintentional collision of the jigsaw body, directly the support rod, with protruding elements of the surfaces being processed.

The destruction of a tooth on the collet of an electric jigsaw can only occur through the fault of the performer. This is caused by an attempt to inadvertently tighten a cutting blade that is not fully inserted.

The armature worm gear will not last long if you start the cutting process before the tool motor reaches optimal power. To extend the service life of the mechanism, do not start work before reaching full engine speed.

Jigsaw Interskol: correction of sawing curvature

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

Replacing the quick-release saw blade mount

This is the curvature of the saw. What is the problem, and is it possible to get rid of it? The culprit was the quick-release fastening of the file. The fact is that it is designed for saw blades of maximum thickness. All cutting tools of smaller thickness simply dangle in the mount.

How to get out of this situation? You need to replace the quick-release mount with a simple device with regular bolts. It's not difficult to make. You need to take a square rod, cut two blanks, drill holes in them and connect them with two M5 bolts and nuts. The procedure for attaching the saw blade will become somewhat more complicated, but the tool will produce an even cut.

Refinement of jigsaw design

In addition, you can modify the design of the tool itself and limit the movement of the file in the transverse plane.

To do this you need:

• take sheet aluminum and cut the plate to the size of the jigsaw sole;
• In the front part of the workpiece, it is necessary to make a cut to the size of the working area of ​​the cutting tool. File all edges, make bevels on the inner longitudinal edges of the cutout;
• You need to cut a plate from plexiglass 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 jigsaw base. Drill holes and make chamfers for installing countersunk screws;
• A piece of plexiglass must be inserted into an aluminum plate, having first made a cut at its location.

Now, during operation, the saw blade will be limited in transverse movement almost in the cutting zone, which will give it even greater straightness.

Jigsaw Diold: a budget option for the household

Another, no less popular manufacturer of domestic power tools is the Smolensk company Diold. Jigsaws are distinguished by their low price and fairly decent quality. For home work, this is a completely suitable budget option.

Support roller repair

It also has points that are worth paying attention to. The first is the support roller. Over time, which is about a year, it begins to lose its round shape. The reason is the material of the roller or the technology of its manufacture. It lacks hardness.

Its repair consists of replacement. Still, it is better not to reinvent the wheel, but to purchase an original roller from the manufacturer or take the tool to a service center, especially if it is under warranty.

If this option is not suitable or is not feasible, then you can revive the jigsaw using improvised means. To do this you will need a regular M5 bolt with a nut. In this case, the bolt will serve as an axis, so the thread on it needs to be ground off, and the nut with a roller, in which a groove needs to be cut along the generatrix according to the thickness of the saw blade.

It is ideal to do this on a lathe, but you can also use a tool that you have on hand, for example, a drill and an angle grinder disc. The disk must be clamped in a vice, the bolt and nut must be clamped into a drill and a groove must be cut. The repair option is not ideal, but it has the right to life, since it has been tested in practice.

Start Button Maintenance

Another nuance in using a Diold jigsaw is that wood dust gets 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 is to periodically, at least once a year, clean the contacts.

Jigsaw Metabo: ideal in quality, but difficult to repair

One of the best jigsaws on the world market are models from the German company Metabo. Everything about it is good. High power, aluminum body, pendulum device. In addition, the tool is equipped with electronics that allow you to configure the jigsaw to individual programs for each type of cut. And the cut is simply perfect both in quality and straightness. The Metabo power tool is the best jigsaw to date.

But not eternal. Breakdowns happen here too. The reasons can be very different. But as practice has shown, the weak point is the mechanics. After significant loads, and in particular, sawing metal, it may fail.

As a rule, the axle on the bearing bracket, lever and rod do not support. To restore the instrument, it is better to purchase all original spare parts and carry out the assembly at a service center by specialists.

When assembling a Metabo jigsaw yourself, you must apply Castrol LMX lubricant to all rubbing surfaces with the addition of RiMET grease in a 3:1 ratio.

Jigsaw Fiolent: main reasons for failure

Let's consider another budget option for a jigsaw - the Crimean Fiolent. This is a completely acceptable model both in price and quality. There are two problems with using a jigsaw. This is a possible failure of the rod due to incorrect handling of the tool and insufficient or improper lubrication.

Replacing the rod

In the first case, to avoid this damage, it is enough to handle the tool carefully and carefully. But if this happens, you will have to replace the damaged rod. To do this you need:

1. Remove the housing cover by unscrewing the 4 screws.
2. Remove the rectangular washers and retaining guides from the rod.
3. Unscrew the 4 bolts and remove the mechanism cover. Below it is the flywheel and the rod itself.
4. Unscrew 2 screws each, remove the lower and upper rod holders. The latter has a spring, so you need to remove it carefully.
5. Remove the damaged rod with guide washers.
6. Lubricate the flywheel and eccentric with special gearbox lubricant.
7. Place the guide washers on the new rod and install it in place.
8. Attach the saw blade holder to the lower part of the rod.
9. Install the upper and lower holders, screw on the mechanism cover and install washers and retaining guides.
10. Insert the cutting tool and test the jigsaw at idle and under load. If the check does not reveal any deviations, install the housing cover.

Tool lubrication

In the second case, everything is much more serious. It would seem that what is so difficult about lubrication? But due to the fact that the tool constantly operates in extreme conditions, wood dust cannot be avoided getting inside the device; service work has to be carried out according to the intensity of use, 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 you, for example, limited yourself to only dismantling the rod, now we disassemble the tool completely and smear all the rubbing surfaces of the parts.

For lubrication, the manufacturer offers Litol 24, but it will not work in a jigsaw gearbox due to its thick consistency, so it is usually lubricated with oils. You can combine Litol 24 with graphite-containing lubricant Feol 2U in a ratio of 3:1.

Finalization of the design

However, it should be taken into account 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 the left-hand transmission. As the rotor rotates, the lubricant mixture is captured by the teeth and fed to the rotor as if through a screw. The oil separator installed inside the electric motor housing does not perform its functions. In theory, it should reject 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 modification needs to be done. Or rather, place the oil sump not inside, but outside the electric motor housing. At the same time, in order for the oil separator snail to work and reject oil, it is turned over.

One more nuance. The diameter of the mounting hole is Ø 9 mm, and the diameter of the outer part of the oil separator is Ø 9.2 mm - it will ideally block the passage for the lubricant mixture. But when installing it, you need to apply a certain force and an attachment in the form of a pipe of a suitable size.

In addition, it is advisable to install a dust shield on the rear armature bearing. It will protect it from wood dust and extend its service life.

After this, you need to assemble the lubricated jigsaw and test it for functionality. After operating for 10 hours, you need to check the tool for grease getting into the motor housing. If everything is done correctly, then this option is excluded.

Bosch jigsaw: high price and expensive repairs

And of course, Bosch. Power tools from this manufacturer are distinguished by high quality components, assembly and a long service life, provided they are treated with care. It also has a drawback - the price. Moreover, both the product as a whole and spare parts are expensive.

It should be noted that Bosch tools practically do not break, but there are some nuances that appear during long-term use. For example, wear of the electric motor brushes, failure of the speed controller or saw blade fastening device. There are even more complicated accidents, failure of the rod or armature, but this is most likely due to incorrect handling.

As in the case of Metabo, Bosch jigsaws are best repaired at service centers. They will install original spare parts and provide a guarantee for the repairs performed. But this is an expensive pleasure.

After reading the article, the user gained theoretical knowledge about failures in the operation of jigsaws. 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.

After the electric drill and grinder, the jigsaw takes third place in the arsenal of every home craftsman. This versatile tool frees you from exhausting work and turns work into pleasure. The use of a jigsaw improves the quality of the cut and the speed of processing the part. If you know how to use a tool, it becomes a reliable assistant at a construction site and in the countryside, but this does not mean that sooner or later it will not need repairs. Fortunately, many problems can be corrected with your own hands.

Jigsaw device, application, additional features

A jigsaw is a tool designed for sawing materials using a special blade, which is driven by a reciprocating mechanism.

Jigsaw device

1. An electronic unit that performs the functions of soft start and speed control.
2. Electric motor, usually of the commutator type. Driven by alternating mains current or direct battery current.
3. Start button with working position lock.
4. A gearbox that converts the rotation of the electric motor rotor into translational movement of the rod. At the end of the rod there is a socket for attaching a file.
5. Ventilation pipe for removal of sawdust and shavings during operation. The diameter of the nozzle matches the dimensions of the vacuum cleaner hose.
6. Support platform. The angle of inclination in the vertical axis is adjustable, making it possible to make cuts at any desired angle.
7. Pendulum device. Used for accelerated sawing of materials. Structurally, in addition to the movement of the saw in the vertical axis, vibrations are added in the horizontal plane. As a result, the cutting speed increases, although the quality may decrease.
8. Support roller. Serves to compensate for vibration and beating of the saw, and performs a stabilizing function.
9. The chuck into which the cutting blade is attached. Many modern models use a quick blade replacement system, which allows replacement without the use of additional tools.
10. Working rod. It is a metal rod that transmits movement from the gearbox to the saw blade.

The first prototype of an electric jigsaw was assembled by the Swiss engineer A. Kaufman, who in 1946 had the idea to replace the needle in a sewing machine with a saw blade. Scintilla AG adopted the original invention, and already in 1947 the Lesto jigsaw appeared on the market. After 7 years, the company was absorbed by Bosch, and the name of the tool was changed to Bosch jigsaw.

Electric jigsaws are divided into two types:

• stationary;
• manual.

The first ones are installed on a frame and, compared to manual ones, have larger dimensions and productivity.

Stationary electric jigsaw "Corvette"

The second ones are lightweight and portable, widely used in construction and households. Manual ones can be mains or battery-powered, depending on the type of power supply.

Portable hand jigsaw

Manual jigsaws have a number of advantages that have made the tool so popular among users.

1. Wide range of applications. The industry produces a huge number of different saw blades of various shapes, lengths and tooth shapes. Thanks to this, the jigsaw has become an almost universal tool that can be used to process any materials - from wood to plastic.
2. Modern jigsaws are capable of sawing wood up to a depth of 160 mm, non-ferrous metals up to 30 mm, steel up to 10 mm. These are very good indicators, especially considering that the seam remains even and corresponds to the specified dimensions.
3. Possibility of curved cuts with an internal radius of 12 mm.
4. Thanks to the design, in which the blade is fixed at only one end, you can cut anywhere. The thickness of the blade allows you to work with any materials without the risk of breaking the file. If there is a need to make a cut without touching the edge of the workpiece, it is enough to make a hole to insert the file. And the file can cut into some soft types of wood even without drilling.

We also list the disadvantages that are inherent in this tool.

1. Presence of idle speed. The file works only when moving upward, in the direction where the teeth are “aimed.” Reverse stroke is idle. This results in reduced productivity (compared to tools such as circular saws, band saws or chain saws).
2. Risk of injury during work. The canvas cannot be hidden; it is always in the open position. That is why it is necessary to be careful and not trust sawing to minor children.
3. The blade stroke is short, which makes it difficult to remove chips, especially when cutting thick workpieces. In an ordinary jigsaw, this stroke ranges from 16 to 24 mm. When processing wood parts, the sawing speed drops noticeably.
4. A jigsaw cannot achieve the same results as a hand tool. This is due to the fact that the file is attached to one end and cannot be as thin. As a result, the turning radius of a manual jigsaw is much smaller.

Equipment: types of replaceable files, their markings

In order to understand the great variety of files offered by manufacturers, you will have to take a closer look at their labeling. Fortunately, there are international standards, according to which each letter and number on the shank of the file conveys certain information.

The letters T and U indicate the shape of the file attachment. The first means that the mount is T-shaped, the second that it is U-shaped

Types of saw attachment: T-shank on the right, U-shank on the left

• 1-leaf length up to 75mm;
• 2-length up to 90mm;
• 3-length up to 150 mm;
• 7-length over 150 mm.

The following letters indicate tooth size:

• A - small tooth, inherent in all metal files;
• B - larger, usually this is the size they cut plywood, chipboard or fiberboard;
• C and D - files with large teeth, intended for preparatory cutting; the quality of the cut is low.

Additional information is contained in the letters written at the very end of the marking:

• F - bimetallic saws;
• R - saws that have a “reverse tooth pointing downwards;
• X - designation of a universal saw intended for sawing metal, wood and plastic;
• O - files for curved cutting, for example a circle, an oval, etc.;
• P - reinforced blades, the thickness of which is greater than standard, mainly for precise cutting.

In addition to this information, inscriptions are displayed on the blade that indicate the type of material for which the file is intended……..

And also - marking of the steel from which the blade is made:

• HM/TC - saw blades made of carbide materials;
• HSS - designation for tool or high-speed steel;
• BiM - bimetallic base material;
• HCS - marking of high carbon steel.

The choice of file directly depends on the material of the workpiece. The fabric should not be used for other purposes. This will negatively affect both the workpiece itself and the file.

Color coding of Bosch fabrics

Separately from all modifications, we can note a saw blade designed for cutting tiles and ceramic tiles. Instead of traditional teeth, there is a coating of tungsten carbide chips on its working edge. Such a file will not “master” wood or metal. But it will cope perfectly with the function of a tile cutter.

Blade designed for cutting ceramics

Installation and replacement of files is carried out with the electrical appliance unplugged, so that accidentally pressing a button does not cause harm to your hands. Depending on the jigsaw model, there may be screw and quick-release chucks. As a rule, most modern tools have a chuck for the T-shank of the file. The canvas is inserted into it by lightly pressing until the lock clicks into place. U-shaped models are equipped with a special screw clamp that requires hand tightening. Some experts consider this type of fastening more reliable. However, they can be found less and less often.

Fastening the blade with a screw clamp

How to check and set up a jigsaw before work, types of modes, speed switching, pendulum function

Before starting work, you need to check the functionality of the jigsaw, insert a file suitable for the given material, and set the mode that is optimal for solving the task. The best advisor in these matters will be the instruction manual included with the jigsaw. Depending on the model, there may be various nuances. However, the general process of preparing a jigsaw for work is as follows:

1. Installing the file into the rod lock.
2. Setting the speed of the saw using a switch on the handle.
3. Enable/disable pendulum mode.
4. Connecting power via a plug cord.
5. Press the start button, start the engine and start sawing.

If you need to change the speed or reduce/increase the pendulum frequency, you must remove your finger from the start button and wait until the engine stops completely. Only after this the desired mode is set.

Switching speeds and pendulum stroke without turning off the engine will very soon lead to gearbox failure and tool failure.

For those who are new to the operation of a jigsaw, it will be useful to know that high speeds are used for soft wood, but are not suitable for plastic (which can melt from friction of the blade) and for metal. It is best to start cutting with a medium mode, and then adjust it to specific needs - speed, cutting accuracy, etc. For particularly precise sawing, the pendulum device can be switched off completely.

What jigsaw accessories and tool improvements can you make yourself?

Of the most common home improvements for a jigsaw, two simple additions have worked well. Any user can do them independently.

1. Sanding attachment. If you often have to sand hard-to-reach surfaces, a file covered with sandpaper may come in handy. Using super glue, the sandpaper is attached to the file and after drying, this attachment can be used to sand wood, plastic, metal or ceramics. Depending on the needs, sandpaper of different calibers and grain sizes is used. To grind ceramics moistened with water, use moisture-resistant sandpaper.
   The nozzle is made using glue and sandpaper

   In some cases, an additional thickening is glued to the blade, and the grinding diameter increases. You can make such a device yourself at home; all you need is high-quality universal glue and sandpaper.

   The thickening on the nozzle is glued together from small wooden slats

2. Table for stationary installation of a jigsaw. This table allows you to use a jigsaw as a band saw. The tool is secured with the blade up, the workpiece rests on the table (instead of the platform). The device makes it possible to significantly improve the quality of the cut and user convenience.
   The table dimensions are selected based on the conditions in which the tool will be used.

The only drawback of this device is that when the saw moves upward, it lifts the part and therefore the workpiece must be held firmly in your hands. You can improve the design and add a pressure bar to the cutting unit.

Improved design of a homemade jigsaw table

This design makes it convenient to connect a vacuum cleaner to remove chips.

The vacuum cleaner is connected through a hole in the table wall

Video: how to upgrade a jigsaw

In order for the jigsaw to work for a long time and you can always rely on it, it is important to follow simple rules.

How to use: operating instructions and safety precautions

1. If the cutting speed needs to be increased, there is no need to put pressure on the jigsaw handle and “adjust” it. It is better to adjust the rotation mode of the motor and pendulum. The correct selection of the file is also important.
2. The workpiece must be securely mounted on the workbench. You should never saw while holding the workpiece suspended in your hands. Good fasteners will give good results - cutting accuracy, speed and quality of sawed edges.
3. Straight cuts are made using a ruler that is included with the jigsaw (linear clamp).
4. Round holes and curved lines on thin plywood or plastic are cut better when the jigsaw is secured with the blade up and the part is fed to the cutting tool. Smooth circles can be made using a circle cutter.
5. Making a cut on a thin metal surface is much more convenient if you put plywood under the sheet. This will prevent the edges of the metal from deforming.
6. If there is a noticeable decrease in sawing speed, it is recommended to immediately replace the saw blade. Prolonged use of a dull blade will cause engine overheating with all the ensuing consequences.
7. If the cut needs to be made at an angle, the support sole is shifted by the required number of degrees.
8. When working in cold weather, it is advisable to run the engine at idle speed for 1–2 minutes. After this, you can work in load mode.
9. Take breaks from work whenever possible. Stop for 5-10 minutes every half hour.

We also list the basic safety rules.

1. When working, it is recommended to wear work clothing that does not have fluttering hems or dangling sleeves. Hair must be tucked under a headdress. Body position is stable.
2. Do not slow down the movement of the saw with your hands or a clamp.
3. It is unacceptable to leave a switched on and working tool unattended.
4. Use the tool only for its intended purpose. Do not hammer nails with a saw.
5. If you discover damage to the housing or other functional breakdowns, you need to stop working and fix the problem.
6. The power cord can only be turned on and off when the engine is off.
7. Do not allow minor children to play with the instrument. Is it dangerous.

How to properly cut various materials with a jigsaw

With practice and experience comes knowledge. But at first, a novice user will need information on how and with what to cut different parts.

1. Wood, plywood and laminate are the main materials that a jigsaw is designed to cut. If the cut is rough, you can use high speeds and oscillations of the pendulum. This will increase speed, but reduce quality and accuracy. Precise sections, depending on the density of the material, are sawed at medium speeds, with the pendulum turned off. This is especially true for laminate if it is precisely adjusted. On a six-point scale - 5.6.
2. Metal parts, including pipes, are cut at low speeds without turning on the pendulum (or use the pendulum at low speed). 1.2 speed. Corrugated sheets and sheet iron are sawed at speed 1, making sure that the edges do not curl. For aluminum and other non-ferrous metals, the speed can rise to 3–4 levels.
3. Plastic and plexiglass can be cut at high speeds, but care must be taken to ensure that the material does not melt. 4–6 on a six-point scale.
4. Ceramic tiles, as well as other hard types of stone cladding, are processed at speed 4–5. The pendulum is installed in the initial positions.
5. Drywall can be cut at high speed and with maximum swing of the pendulum. A natural limitation is the level of dust. If cutting occurs indoors, the dust from cutting can be very high. And so the speed is reduced.

Laminate is cut at high speed with the pendulum mechanism turned off

Jigsaw maintenance and prevention

Like any technical device, a jigsaw needs preventative maintenance. After the warranty period has expired, you need to carry out several simple operations and the shelf life of the instrument will again be extended by a year or two, depending on the intensity of use.

1. Replace the graphite brushes on the motor commutator.
2. Inspect current-carrying conductors, including the power cord. If damage or wear is detected, replace it.
3. Clean the internal cavity of the tool from dust, debris and chips.
4. Replace the lubricant in the mechanical components - bearings and gearbox.

Today, rarely does anyone sharpen files themselves. Especially if the blade has triangular teeth, which have increased maneuverability and chip emission. It is impossible to sharpen such a tooth at home. Moreover, such attempts can lead to the jigsaw starting to beat and the vibration level to increase. Following this, the saw holder socket will break, which will lead to the appearance of play in the drive rod. A dull file is simply replaced. Fortunately, their prices are affordable.

How to disassemble a jigsaw, see the video below.

Video: Disassembling and lubricating a jigsaw

If you do not feel confident in your abilities, it is better to seek the help of specialists.

Do-it-yourself jigsaw repair: faults and their elimination

When starting a DIY repair, it is recommended to clear the desktop of foreign objects, make good lighting and prepare a camera or notebook for sketches. The jigsaw parts are cleaned with a clean rag and washed with an alcohol solution.

Problems with the electric motor, repair or replacement of the motor

The commutator type engine is quite reliable in operation and can last for many years without failure. However, he is afraid of overheating and sudden voltage changes. And if it happens that the motor fails, it is necessary to carry out correct diagnostics. To do this, we will use a multimeter - an electrical measuring device for determining the current, voltage and resistance in a circuit.

Device for determining current characteristics in a network

As you know, an engine consists of two main parts - a rotor and a stator. Each individual node is a coil that induces an electromagnetic field. If the insulation of the coils is broken, a short circuit (short circuit) occurs, which is called interturn. To identify exactly where the short circuit occurred, the resistance of the windings is checked. The multimeter contacts are installed on adjacent commutator lamellas, and the ohmmeter reading is recorded. If in any pair the resistance is significantly lower, it means that it is in this winding that the short circuit has occurred.

Sequential measurement of armature winding resistance

Replacing the armature or stator is possible provided that similar parts are commercially available. You need to buy parts from the exact company that manufactures the jigsaw.

To replace, you need a set of screwdrivers, you may need small wrenches and pliers. To replace the rotor, you will need to remove the bearing from the working shaft. But you can purchase a shaft assembly for replacement. If this is not possible, a special puller is used to remove the bearing.

Before disassembling the jigsaw, you must make sure that the tool is unplugged.

If a conductor breakdown is detected in the stator, it must be disconnected from the jigsaw body. Fastening is carried out using screws. When installing new windings, it is important to correctly connect them to the electrical circuit.

Measuring the resistance of the coils with a multimeter, the stator windings are ringed

Video: Prevention and repair of jigsaws

Self-prevention of the instrument does not take much time. However, without it, the service life of the jigsaw is reduced.

Mechanical faults, unreliable fastening of the file, chuck repair

The two main mechanical components that are prone to malfunction are the gearbox and the saw holder. Moreover, these breakdowns are interconnected. A broken socket for fastening the blade leads to rapid wear and breakage of the gearbox. Therefore, it is important to carefully monitor the condition of the cartridge. Different models use different file locks. Therefore, there are no universal recipes. One thing must always be remembered - if the file begins to hold poorly in the socket and flies out of it during operation, the saw holder cartridge must be replaced. How to do it? The video will tell.

Video: replacing the saw blade holder in a jigsaw

Other possible problems and their repair

Let's look at the typical types of breakdowns of an electric jigsaw.

Table of possible problems with an electric jigsaw

Signs of breakdown	Probable causes of failure	Troubleshooting
The jigsaw doesn't cut at all	1. Damage to external wiring. 2. Damage to internal wiring. 3. The start button is damaged.	1. Check the power cord. If necessary, repair or replace. 2. Checking the wires inside the instrument. If a break or unstable contact is detected, the wire is restored and the terminals are cleaned. 3. Power is supplied from the network directly to the electronic unit, bypassing the button. If the engine runs, then the button needs to be replaced.
The jigsaw cuts crookedly (provided that the blade is in working order)	The blade fastening cartridge is damaged.	The saw holder cartridge is removed and cleaned. If the problem cannot be resolved, the cartridge must be replaced.
The jigsaw beats during operation (provided that the pendulum mechanism is turned off)	Clogged or worn rod or pendulum mechanism	The casing is opened and the pendulum and rod are inspected. If there is excessive contamination, the mechanisms are cleaned. If the damage is mechanical in nature, the worn part is replaced.
The jigsaw does not cut under load	The electric motor is damaged. Does not develop rated power due to short circuit	The housing is disassembled, the stator and rotor of the electric motor are sequentially called. If a short circuit is detected, the damaged coil or the entire motor assembly is replaced.
High level of vibration during operation, extraneous metallic noises	1. Clogging of the gearbox, lack of lubrication on the gears. 2. Damage to the gear wheels of the gearbox.	1. The jigsaw body is disassembled. Having gained access to the gearbox, inspection and cleaning are performed. Before assembly, all parts are lubricated. 2. If the gears are damaged, broken or chipped, it is necessary to remove them from the gearbox and replace them with new ones. Clean the gearbox cavity from debris and chips and lubricate it.
During operation, the smell of burnt wiring appears, the engine speed is unstable, “floating”	Damage to wiring or motor	The entire electrical circuit of the instrument is inspected. The motor windings are checked with a multimeter. If a defect in the wires or contacts is detected, the terminals are cleaned or the conductors are replaced.
Excessive sparking of brushes on the commutator during operation	Engine brush wear	The brushes are removed from the brush holder and replaced.

If the Start button is damaged, you can briefly get out of the situation by starting the jigsaw “directly”. To do this, the wires entering the button are connected to the outgoing ones. The tool will be turned on and off by the plug. This is not convenient, so it is better to immediately replace the start button.

If the tool is under warranty, do not rush and repair it yourself.

Opening the casing entails the loss of all manufacturer's warranty obligations.

Video: DIY jigsaw repair

Tool storage

In order for a tool to serve for a long time and properly, it is important not only to follow the rules of its operation, but also to store it correctly. The best option is to keep the jigsaw in a case from the manufacturer. This suitcase is convenient both for storing spare parts and for transportation. But the instrument is not always sold with a case. In this case, you need to know that a jigsaw, like any power tool, is afraid of water and excess air humidity. Therefore, it must be stored in a dry, well-ventilated place. A cardboard or wooden box will serve as protection from mechanical damage. If the warehouse is unheated, then in the cold season, before starting work, the tool must “thaw” in a warm room for 20–25 minutes. During this time, the gearbox lubrication will become elastic again.

Standard case for storing and transporting a Makita jigsaw

When using a jigsaw at home, you should not neglect the rules of personal safety. While working, you cannot be distracted, talk on the phone or do other things. To protect your eyes and respiratory system, it is recommended to use a respirator and safety glasses. The use of homemade attachments is justified when they do not pose a health hazard and have successfully passed preliminary tests.

Knowledge typical electrical tool faults Needed by both the home craftsman and the professional. The ability to correctly identify the source of the problem and quickly repair the instrument saves time and money. And knowledge of the reasons leading to failure allows you to act proactively, avoiding operating modes in which the tool will be damaged prematurely.

A jigsaw is a universal power tool suitable for working with various materials. It can work with wood, metal, plastic, etc. This versatility is ensured by the use of a huge variety of saw blades that are available for all occasions. During operation, the jigsaw and its components experience heavy mechanical loads. The experience of service centers in repairing power tools, as well as advice from professionals, helps to identify main faults of jigsaws And causes their occurrence.

Typical faults of jigsaws and their causes

1. Broken support roller. The saw blade attached to the jigsaw is its main working element, performing useful work. The jigsaw file is mounted on the support roller of the jigsaw, and this roller takes on the greatest load in the process of cutting the material.

Reasons why the support roller may be overloaded and fail prematurely:

• using a low-quality file;
• using an overly dull file;
• using a saw blade that does not correspond to the nature of the work being performed.

As a result of overheating, the roller may simply jam. In another case, the roller itself may be cut with a saw blade.

Methods to prevent this breakdown

• use only high-quality components;
• change blades in time, without waiting until they become very dull;
• use canvases that match the nature of the work being performed;
• work with a jigsaw carefully, avoiding excessive force when cutting, and follow the manufacturer’s recommendations.

Breakage of the blade fixing unit. Tool-free fixation of the saw blade is a convenient feature that is present in many models of jigsaws. Allows you to quickly change the cutting tip without wasting a lot of time. The problem is that this unit can fail due to the frequent entry of dust created by the jigsaw during operation.

Preventive measures

• periodically clean the blade holder from dust;
• lubricate it, if necessary, with lubricants such as WD-40;
• use the ability to connect a vacuum cleaner or dust collector to the jigsaw.

Damage to gearbox parts. The reason lies in the same dust, which can get inside the gearbox through the ventilation holes and lead to breakdowns. As in point 2, a vacuum cleaner or dust collector can help.

Broken or bent support rod. Breakdowns can be prevented by developing a culture of careful use of power tools. In particular, you should not drop the jigsaw; try to avoid collisions of the body and rod with protruding parts of the material being processed.

Broken teeth on a jigsaw collet. Occurs when you try to tighten a file that is not fully inserted. Nothing but attentiveness will help here.

Premature wear of the armature worm gear jigsaw and its main helical gear. Occurs when the cutting process itself begins before the engine has reached full speed. Warning: Do not bring the jigsaw blade close to the material being processed until the normal speed has been established.

By following these simple tips, you will extend the trouble-free operation of your jigsaw.