LITERATURE 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.
COMPONENTS, WORK TIPS 7. Power indicator 14. Earth fault breaker Components 1. Drill spindle 8. Electric motor 15. Stand mount and oil plug under the cover 2. Water connection/dust extraction 9. Inspection cover for carbon brushes 16. Front handle 3. Gear knob 10.
COMPONENTS, WORK TIPS 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 fixture for securing the machine in a vice is easily made using a wood block and a pair of steel plates.
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.
DISMANTLING BASIC MODULES 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. 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.
DISMANTLING BASIC MODULES 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.
GEAR HOUSING – INTERMEDIATE SHAFT 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.
GEAR HOUSING – INTERMEDIATE SHAFT Spring washers The spring washers provide the braking force to the clutch when the nut is fitted and tightened with the correct torque. To function properly it is vital that the washers are installed correctly and that they are intact.
GEAR HOUSING – INTERMEDIATE SHAFT 510 22 11-01 Type B Adjusting the slip clutch Mount the intermediate shaft’s helical drive wheel in the service tool. Tighten the service tool in a vice. Start by tightening the nut to the mecha- –...
GEAR HOUSING – SPINDLE SHAFT Spindle shaft The spindle shaft is driven by the intermediate shaft which in turn is dri- ven by the electric motor. The complete spindle shaft contains a number of moving parts, including axially moving gear wheels for the gear function. The transmission in this machine is rarely the cause of any problems.
GEAR HOUSING – SPINDLE SHAFT Remove the wedge. A small pair of lock ring pliers is needed to remove the lock ring, manufacture: Milbar/Imperial IR-15R or equivalent Start by turning the lock ring to ensure the opening is accessible by pliers in the gear wheel.
GEAR HOUSING – BEARING REPLACEMENT Bearings The bottom bearings in the spindle shaft are press-fitted in the gear housing and on the shaft. The retaining rings on the shaft and in the gear housing secure the bearing. The black seal cylinder has radial seals at both ends, on the bearing and the tool holder.
GEAR HOUSING – BEARING REPLACEMENT Tools Dismantling The following tools are required for removing the gear housing’s bearing: 1. Internal bearing extractor to grip behind the bearings. 2. Use a counter stay device where there is a counterhold. 3. A slide hammer is an alternative to the counter stay device if there is no counterhold available.
CARBON BRUSHES Replacing the carbon brushes The two carbon brushes transfer electric current to the motor’s rotor. A cable from the stator is connected to the screw in the holder. The carbon brush’s line is connected to the same screw. The carbon brushes are wear parts that must be checked regularly.
GREY Stator Circuit board GREY WHITE Rotor GREY GREEN BLUE Stator GREY Circuit breaker BLACK GREEN/YELLOW Gear housing BLACK BLACK BROWN Earth fault breaker BLUE WHITE GREEN/YELLOW Wiring in the handle 110 V Mains cable/terminal block Terminal block a Earth wire. Yellow/green wire. b Connect to the circuit breaker, pos.
GREY Stator Circuit board GREY WHITE Rotor GREY GREEN BLUE Stator GREY Circuit breaker BLACK SILVER BLACK Capacitor BLACK GREEN/YELLOW GREEN/YELLOW WHITE Gear housing BLACK BLACK BROWN Earth fault breaker BLUE BLACK WHITE GREEN/YELLOW Wiring in the handle 230 V Mains cable/terminal block Terminal block a Earth wire.
Circuit board The circuit board is divided into two interconnected units that cannot be shared. The unit on the right has two functions. It senses the motor’s speed and also has a function that acts as an electronic spirit level “Level guiding sys- tem”.
CIRCUIT BOARD – CABLING Circuit board wiring A Black cable with a small flat pin connector. Connects to the circuit breaker at position 2a according to the wiring diagram and illustration below. B Black, long cable that runs through the handle. Connects to the terminal at position c according to pages 15 and 16.
ROTOR Functional test Preparations Remove the screws on the right handle half to access the screws that hold the electronics box above the speed sensor. Remove the box and refit the screws, as these also hold the carbon brush holders. Connect a measurement cable to each carbon brush and connect to the measurement instrument.
ROTOR Gear box cover side – Gear box cover side – bearing bearing replacement replacement Remove the circlip and wavy Remove the circlip with circlip pliers and washer. the wavy washer under this. Remove the bearing with a Use a counter stay device to pull out the counter stay device.
STATOR Functional test Breaks in the stator winding are detected easily with the following functionality check. In general, short-circuited windings can also be identified, particularly if the short circuit eliminates current in several winding turns. If the short circuit only eliminates a few turns, the measurement is unlikely to record this. A fault like this has hardly any noticeable effect on the performance of the motor either.
TOOLS = Service operation The tools listed below are available from Husqvarna. The special tools below are needed for service work to DM 220 but are not sold by Husqvarna. 510 22 11-01 Lock ring pliers Special socket Make: Milbar/Imperial IR-15R.
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