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
1
4
7
3
6
9
2
5
8
Battery
White
Red
Blue
J8
J8
J7
J4
J3
J2
J5
J1
1
4
7
3
6
9
2
5
8
J10
J10
J12
Grey
2
J7
1
3
2
1
2
1
Yellow
Pink
1 1
2 2
Red
White
Black
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).
A
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
To
remove and install the drive sprocket cover on page
9
.
2. Remove the guide bar and the saw chain.
3. Hold the drive sprocket with adjustable pliers and
remove the screw (A).
A
B
D
C
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
To
remove and install the drive sprocket cover on page
9
.
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
To
remove and install the drive sprocket cover on page
9
.
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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