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

3
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)

4
COMPONENTS, WORK TIPS
2
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
14
1
4
8
9
3
6
15
5
10
2
12
16 13
11
17
18
7
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
5
2

6
WATER/DUST UNIT
3
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.
4
3
2
1
1
3
4
2

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.
7
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.

8
DISMANTLING BASIC MODULES
4
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.
3
5
4
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
2
1
A

GEAR HOUSING – INTERMEDIATE SHAFT 5
9
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.
B
A
C
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
1
2

Torque: 16 Nm, 12 lbf∑ft
10
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
5
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.