Husqvarna DM 220 Instruction manual

HUSQVARNA CONSTRUCTION PRODUCTS

Workshop manual

DM 220

2115 42 19-26

1. LITERATURE 3

2. COMPONENTS, WORK TIPS 4

3. WATER/DUST UNIT 6

4. DISMANTLING IN BASIC MODULES 7

5. GEAR HOUSING – INTERMEDIATE SHAFT 9

6. GEAR HOUSING – SPINDLE SHAFT 12

7. GEAR HOUSING – BEARING REPLACEMENT 14

8. CARBON BRUSHES 16

9. WIRING DIAGRAM – CABLING, 110 V 17

WIRING DIAGRAM – CABLING, 230 V 18

10. CIRCUIT BOARDS – CABLING 19

11. ROTOR 21

12. STATOR 23

13. TOOLS 24

HUSQVARNA

DM 220

CONTENTS Page

115 42 19-26

LITERATURE 1

Workshop manual

This workshop manual covers virtually all work

in the workshop that involves the DM220.

Some very simple and rather obvious repair

work has been omitted.

Disposition

Introductory sections entitled “Water/dust unit”

and “Dismantling in basic modules” show the

basic structure of the machine. This arrangement

means that mechanics who have no experience

of the machine must start with these chapters.

Later on, the manual describes in detail in the

various chapters how the work is to be executed

for the basic modules.

Arrangement – illustrations and text

In addition to graphics and illustrations, there

are sometimes two text columns. The left-hand

text column gives a brief explanation and is

intended for experienced mechanics, whereas

the right-hand column is a more detailed des-

cription and is intended for mechanics with less

experience of repair work for this type of

machine.

Contents

The manual is divided into numbered chapters

as well as chapter headings that are specied in

bold at the top of each page.

The list of contents also has page references to

the start of each chapter.

Spares

Spares DM 220

The folder includes all spares for Husqvarna

DM220.

The folder contains complete exploded

drawings for the whole machine where the

location, spares number and appearance of

each component is easy to identify.

HUSQVARNA CONSTRUCTION PRODUCTS

Workshop manual

DM 220

IPL, DM 220, 2011-03, 577 28 56-01

DM 220

Reservdelar

Spare parts

Ersatzteile

Pieces de rechange

Piezas de repuesto

Ricambi

Peças sobresselente

HUSQVARNA CONSTRUCTION PRODUCTS

577 28 56-01

“Dismantling in basic modules”

“Gear housing” (Example)

COMPONENTS, WORK TIPS

Components

1. Drill spindle

2. Water connection/dust extraction

3. Gear knob

4. Gear housing

5. Gear box cover

6. Electronic spirit level

7. Power indicator

8. Electric motor

9. Inspection cover for carbon brushes

10. Circuit breaker

11. Circuit breaker lock

12. Rear handle

13. Mains cable

14. Earth fault breaker

15. Stand mount and oil plug under

the cover

16. Front handle

17. Water hose (connects at 2)

18. Sleeve for dust extractor (connects at 2)

115 42 19-26

16 13

Two different types

DM 220 has been updated and the later building has the gearbox bolted from the

front for easier access.

The two different types will be called:

Type A

Type B

Two procedures differ between the types

• Dismantling of gear housing/gear box cover

• Adjusting the slip clutch

The difference between the types can be seen on the gear housing. On type B, the

screws attaching the Gear housing to the Gear box cover are visible.

Work tip

The easiest and most convenient way of executing

virtually all service work on the DM220 is with the

machine in a vertical position with the drill spindle

facing downwards.

Do it yourself

A xture for securing the machine in a vice is easily

made using a wood block and a pair of steel plates.

The wood block should be at an equal height to the

drill spindle, about

55 mm. Drill a hole with a diameter of 1 1/4 inches,

corresponding to around 32 mm, in the block.

The two steel plates secure the wood block horizon-

tally in the vice.

It is even easier to drill a hole in the work bench.

Warning

A workshop often has a range of electrical tools at the workplace. It is not uncommon for the

wrong contact to be connected to the mains – perhaps to the very machine you are working with!

A simple way of highlighting this and preventing unintentional connections is to tape over the

contact pin.

Note: A machine that has been dismantled must not be connected to the

mains supply. Functional tests must not, and do not need to be made on a

dismantled machine that is connected to the mains.

COMPONENTS, WORK TIPS

WATER/DUST UNIT

Function

Water supply or dust extraction

Drilling with the DM220 can be performed either with water cooling or dry

with dust extraction.

Construction

1. For connecting, you either use the water hose or the sleeve for dust

extractor. The casing is rotatable with the front handle. The casing is held in

place by a plastic ring in the casing’s outer ring that locks the unit.

2. Two O-ring seals between the casing and the gear housing.

3. The seal between the rotating spindle shaft and gear housing consists of a

cylinder which has radial seals at both ends. The cylinder is locked against

rotation to the gear housing.

4. The holes in the drilling spindle lead out to the drill attachment.

Service

The casing seals, consisting of two O-rings, can be replaced from the outside of

the machine. To replace the cylinder (3), that seals between the spindle shaft and

gear housing, you must rst remove the spindle shaft from the gear housing.

Replacing the seals

Remove the casing

1. The outer ring has a break slot for dismantling. Break

up the ring a little with a screwdriver.

2. Continue to break up the ring all around until it

releases its grip. Pull off the outer ring, the casing and

the inner ring.

Replace O-rings

3. Remove the O-rings and clean. Lubricate the new

O-rings and t these.

Replace the plastic retaining ring

Always replace with new plastic rings once it has

been dismantled. The outer ring has a break slot for

removing the plastic ring.

Press the new plastic ring in the outer ring. Lubricate

the inside of the plastic ring.

Fit the casing

Assemble the inner ring, casing, and t the outer ring

dog to the inner ring.

Fit the outer ring by tapping around the outside, then

insert this in to its locking groove in the gear housing.

Separation

Gear housing/motor housing

The handle halves must be removed so that the screws

that hold the electric motor to the gear housing can be

accessed.

1. Remove the two screws holding the inspection cover

for the carbon brushes. Remove the cover.

2. Remove the three screws connecting the handle

halves and the two screws that hold the handle half to

the motor.

3. Lift off the handle half.

4. Turn the machine and remove the two screws that

hold the other handle half.

DISMANTLING BASIC MODULES 4

1 2

3 4

1 2

Gear housing/electric motor

Virtually all service work requires the separation of the

gear housing from the electric motor. The process of

dismantling the machine in to its basic components is

described in this chapter.

Pull the connector for the power cables out of its

compartment. An earth wire runs from the gear hou-

sing, under the stator, to the connector.

1. Locate the yellow/green earth wire that runs under

the stator.

2. Remove the earth wire from the connector.

DISMANTLING BASIC MODULES

Gear housing/gear box cover

Remove the stand mount. It sits with a press t in the

gear housing and gear box cover.

Use a brass mandrel and angle this as shown in the

gure to the left. Knock with a small metal hammer

alternately on both sides so that the stand mount

gradually lifts equally on both sides.

Four screws connect the electric motor to the gear

housing.

1. Remove the two screws at the location of the

connector for the cables.

2. Remove the two screws on the opposite side, under

the position of the circuit board.

3. Remove the cover for the stand mount.

4. Pull out the carbon brushes and lock them with the

spring to the side of the carbon brush.

5. Lift off the electric motor housing. Note the earth

wire in the gear housing.

If you need to use a puller to press the bearing from

its seat, you must rst remove the magnetic sensor at

the centre of the shaft.

1-5-

4-8-

2-6-

3-7-

Lift off the air line for the fan. Store this in conjunction

with the rotor as it can easily be overlooked when re-as-

sembling.

Drain the oil

Remove the drain plug and drain the gearbox oil.

(Relling: Volume 0.25 litre. Oil quality: Mobil Lube

1 SHC 75W-90, Shell Spirax ASX 75W-90 or equivalent

quality.)

Type A

Four screws connect the gear housing to the gear box

cover, two on the inside of the fan and two on the out-

side next to the oil plug.

Note that the screws on the fan have O-rings that seal

the gear box oil.

Type B

Four screws on the gear housing connect it to the gear

box cover

Pull the gear box cover, together with the rotor, from

the gear housing. Remove the rotor from one side as

described in the “ROTOR” chapter.

M5 x 60 mm M5 x 50 mm

OIL

GEAR HOUSING – INTERMEDIATE SHAFT 5

Function

The gear housing contains a transmission that reduces the high speed of the

electric motor to a lower speed on the spindle shaft. The transmission is built

on two shafts, the intermediate shaft (A) and spindle shaft (B).

The electric motor powers the top gear wheel on the intermediate shaft.

This gear wheel has a slip clutch to the intermediate shaft to protect the

operator in the event of jamming.

The transmission has three gear selection positions that are controlled by

the knob (C). Change gear when the motor is idle.

Service work

The work procedure dictates that the complete intermediate shaft must always

be dismantled rst.

However, the spindle shaft with attendant components, is dismantled into

individual parts from the gear housing. Following dismantling of the compo-

nents, the actual spindle shaft can be removed from the gear housing.

Dismantling –

intermediate shaft

1. Position the puller under the

two upper gear wheels.

2. Prepare for dismantling as per

the illustration. Press the shaft

up using the puller.

Dismantling – intermediate

shaft

To dismantle you need a small standard

puller with long shanks, two spacers

(wooden blocks, at least 15 mm/.6 in.

high) and a bridge between them, e.g. a

rough metal object.

1. Position the puller under the two

upper gear wheels.

2. Prepare for dismantling as per the

illustration. Press the shaft up using the

puller.

The motor shaft drives the helical drive.

There is a slip clutch between the drive

and the intermediate shaft.

The helical drive has a slip

clutch on the intermediate shaft.

Slip clutch

Use special tool 510 22 11-01 to lock the

shaft.

Remove the nut.

Slip clutch

Remove the nut.

510 22 11-01

Torque: 16 Nm, 12 lbf∑ft

Spring washers

The spring washers provide the braking

force to the clutch when the nut is tted

and tightened with the correct torque.

To function properly it is vital that

the washers are installed correctly and

that they are intact.

Remove the spring washers

Lift up the three spring washers and at

washer under them.

Rem. For practical work, lift the gear

wheel up from the shaft and turn to

empty the washers.

Remove the friction washer

Remove the friction washer from the

gear wheel. Replace the washer if it is

damaged or has signicantly reduced

functionality.

Lift off the gear wheel

Check the condition of the gear wheel

and that the centre bushing is not loose

on the shaft.

The bushing is located with a light

press t in the gear wheel.

Remove the friction washer

Remove the friction washer from the

gear wheel. Replace the washer if it is

damaged or has signicantly reduced

functionality.

GEAR HOUSING – INTERMEDIATE SHAFT

Type A

Adjusting the slip clutch

Mount the intermediate shaft’s helical

drive wheel in a vice with soft bre jaws.

Start by screwing in the nut to the

mechanical stop position. Now unscrew

the nut 45°. The clutch must have a

slipping torque of at least 16 Nm. If the

value is not reached, the spring and

friction washers must be replaced.

If the slip clutch is higher than 16 Nm,

adjust the value to the correct level.

510 22 11-01

–

IMPORTANT

When reassembling the spring

washers and friction washer,

lubricate with gearbox oil.

This is important to ensure

the correct slipping torque

when adjusting the slip clutch.

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