Husqvarna 540i XP Gebrauchsanweisung

Workshop manual

540i XP®

English

1430 - 001 - 05.05.2020

Contents

1 Introduction

1.1 Document description............................................ 3

1.2 Target group...........................................................3

1.3 Revisions................................................................3

1.4 Safety..................................................................... 3

1.5 Servicing tools........................................................3

2 Safety

2.1 Safety definitions....................................................4

2.2 General safety instructions.....................................4

2.3 Symbols on the product......................................... 4

2.4 Special safety instructions......................................4

3 Servicing data

3.1 Servicing data........................................................ 5

4 Servicing tools

4.1 Servicing tools........................................................7

4.2 Electrical diagram...................................................8

5 Repair instructions

5.1 To clean and examine the product parts................9

5.2 Drive sprocket and guide bar................................. 9

5.3 Chain tensioner ................................................... 11

5.4 Crankcase............................................................ 11

5.5 Power trigger........................................................13

5.6 Front handguard...................................................15

5.7 Motor and control unit.......................................... 15

5.8 User interface.......................................................18

5.9 Chain oil tank....................................................... 18

5.10 Chain brake........................................................19

6 Troubleshooting

6.1 Diagnostic tools....................................................21

6.2 Troubleshooting of the product............................ 22

6.3 Troubleshooting of the battery and battery

charger....................................................................... 24

7 Technical data

7.1 Technical data......................................................26

21430 - 001 - 05.05.2020

1 Introduction

1.1 Document description

This manual gives a full description of how to do

maintenance and repair on the product. It also gives

safety instructions that the personnel must obey.

1.2 Target group

This manual is for personnel with a general knowledge

of how to do repair and do servicing. All personnel that

do repair or do servicing on the product must read and

understand the manual.

1.3 Revisions

Changes to the product can cause changes to the

maintenance work and spare parts. Separate

information is sent out for each change.

Read the manual together with all received information

about changes to maintenance and spare parts for the

product.

1.4 Safety

WARNING: All personnel that repair or do

servicing on the product must read and

understand the safety instructions in this

workshop manual.

1.5 Servicing tools

The manual gives information about necessary servicing

tools. Always use original tools from Husqvarna.

1430 - 001 - 05.05.2020 Introduction - 3

2 Safety

2.1 Safety definitions

Warnings, cautions and notes are used to point out

specially important parts of the manual.

WARNING: Used if there is a risk of injury or

death for the operator or bystanders if the

instructions in the manual are not obeyed.

CAUTION: Used if there is a risk of damage to

the product, other materials or the adjacent area

if the instructions in the manual are not obeyed.

Note: Used to give more information that is necessary in

a given situation.

2.2 General safety instructions

WARNING: Apply a new warning label if a

warning symbol on the product is damaged or

missing.

2.3 Symbols on the product

Fill with chain oil

Start/Stop

savE / Battery save mode

Warning lamp/Fault indicator

Indication of chain direction

Chain brake

2.4 Special safety instructions

2.4.1 To remove the battery

WARNING: Always remove the battery before

you do repairs or do servicing on the product.

WARNING: Do not put the battery back until the

product is assembled.

1. Press in the catches and remove the battery.

2.4.2 Cutting equipment safety

WARNING: Always remove the cutting

equipment before you do repairs or do servicing

on the product.

WARNING: Do not install the cutting equipment

until the product is assembled.

4 - Safety 1430 - 001 - 05.05.2020

3 Servicing data

3.1 Servicing data

▲ Lubricate with chain oil.

● Lubricate with grease.

(x3) 3.5 Nm T27

2.5 - 3 Nm T27

(x2) 1 - 2 Nm T20

(x4) 1 - 2 Nm T20

(x6) 2 - 2.5 Nm T27

(x1) 4 Nm T27

(x1) 3 Nm T27

(x1) 7 - 8 Nm T27

(x2) 1.8 - 2.2 Nm T27

(x5) 2.2 Nm T27

1430 - 001 - 05.05.2020 Servicing data - 5

(x1) 1 Nm T20

(x1) 4 Nm T27

(x4) 3 - 4 Nm T27

(x10) 2.5 - 3 Nm T27

(x2) 4 Nm T27

6 - Servicing data 1430 - 001 - 05.05.2020

4 Servicing tools

4.1 Servicing tools

CST

INSTRUCTION

321

Posi-

tion

Description Use Article No.

1 Diagnostic tool kit To do a check of the product and install updates to the firm-

ware.

583 89 71-01

2 Adapter cable for battery

products

To do a check of battery products with the diagnostic tool kit. 581 19 23-01

3 T-handle Torx, T20 To loosen or remove Torx screws. 588 59 85-01

3 T-handle Torx, T27 To loosen or remove Torx screws. 502 71 27-03

1430 - 001 - 05.05.2020 Servicing tools - 7

4.2 Electrical diagram

Battery

White

Red

Blue

J10

J12

Grey

Yellow

Pink

1 1

2 2

Red

White

Black

Grey

White

Blue

Yellow

Grey

Green

Black

Orange

Red

Pink

1 2 3 4 5 6 7 8 9

Trigger

White

Blue

Grey

Green

Black

Orange

Red

123 4 56789

1 2 3 4 5 6 7 8 9

White

Black

1 2 3

Switch

Motor

8 - Servicing tools 1430 - 001 - 05.05.2020

5 Repair instructions

5.1 To clean and examine the product parts

• Clean and examine all parts fully. You find more

instructions in the chapter for each part if special

tools or procedures are necessary.

• Replace damaged or defective parts.

• Always use original spare parts.

5.2 Drive sprocket and guide bar

5.2.1 To remove and install the drive sprocket

cover

1. Loosen the nut (A) and remove the drive sprocket

cover (B).

Note: The nut is attached to the drive sprocket

cover.

2. Install in the opposite sequence.

5.2.2 To remove and install the drive sprocket

1. Remove the drive sprocket cover. Refer to

remove and install the drive sprocket cover on page

2. Remove the guide bar and the saw chain.

3. Hold the drive sprocket with adjustable pliers and

remove the screw (A).

4. Remove the small washer (B), the large washers (C)

and the drive sprocket (D).

5. Install in the opposite sequence.

CAUTION: The concave side of the large

washers must point in the direction of the

drive sprocket.

5.2.3 To remove and install the brake drum

1. Remove the drive sprocket. Refer to

To remove and

install the drive sprocket on page 9

2. Move the front handguard rearward to release the

chain brake.

3. Remove the brake drum.

4. Examine the brake drum for damage. Replace the

brake drum if it is damaged.

5. Install in the opposite sequence.

1430 - 001 - 05.05.2020 Repair instructions - 9

5.2.4 To remove and install the worm gear

1. Remove the brake drum. Refer to

To remove and

install the brake drum on page 9

2. Remove the worm gear.

3. Examine the worm gear for wear and damage.

Replace the worm gear if it is damaged.

4. Install in the opposite sequence. Make sure that the

flat surfaces in the worm gear are aligned with the

flat surfaces on the motor axle.

5.2.5 To remove and install the spiked bumper

1. Remove the drive sprocket cover. Refer to

remove and install the drive sprocket cover on page

2. Remove the guide bar and the saw chain.

3. Remove the 2 screws and the spiked bumper.

4. Examine the spiked bumper for wear and damage.

Replace the spiked bumper if it is damaged.

5. Install in the opposite sequence.

5.2.6 To remove and install the chain catcher

1. Remove the drive sprocket cover. Refer to

remove and install the drive sprocket cover on page

2. Remove the guide bar and the saw chain.

3. Remove the screw and the chain catcher.

4. Examine the chain catcher for wear and damages.

Replace the chain catcher if it is worn or damaged.

5. Install in the opposite sequence.

10 - Repair instructions 1430 - 001 - 05.05.2020

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