Husqvarna T540i XP Gebrauchsanweisung

Workshop manual

T540i XP®

English

1204 - 001 - 03.12.2019

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 T540i XP.........................................5

4 Servicing tools

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

5 Repair instructions

5.1 To clean and examine the product parts................8

5.2 Drive sprocket and guide bar................................. 8

5.3 Chain tensioner ..................................................... 9

5.4 Crankcase............................................................ 10

5.5 Power trigger........................................................11

5.6 Front hand guard..................................................13

5.7 Motor and control unit.......................................... 13

5.8 User interface.......................................................16

5.9 Chain oil tank....................................................... 17

5.10 Chain brake........................................................17

6 Troubleshooting

6.1 Diagnostic tools....................................................20

6.2 Troubleshooting of the product............................ 21

6.3 Troubleshooting of the battery and battery

charger....................................................................... 23

7 Technical data

7.1 Technical data......................................................25

21204 - 001 - 03.12.2019

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.

1204 - 001 - 03.12.2019 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 1204 - 001 - 03.12.2019

3 Servicing data

3.1 Servicing data T540i XP

▲ Lubricate with chain oil.

● Lubricate with grease.

(x4) 3.5 Nm T27

2.5 - 3 Nm T27

(x2) 1 - 2 Nm T20

(x4) 1 - 2 Nm T20

(x6) 6 - 8 Nm T27

(x1) 4 Nm T27

(x1) 3 Nm T27

(x1) 6 - 8 Nm T27

(x2) 1.8 - 2.2 Nm T27

1204 - 001 - 03.12.2019 Servicing data - 5

(x1) 1 Nm T20

(x1) 2.5 - 3 Nm T27

(x1) 2 - 2.5 Nm T27

(x1) 2.5 - 3 Nm T27

(x2) 3 Nm T27

(x10) 2.5 - 3 Nm T27

6 - Servicing data 1204 - 001 - 03.12.2019

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. 412 36 49-01

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

1204 - 001 - 03.12.2019 Servicing tools - 7

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 8

2. Remove the brake drum.

3. Examine the brake drum for damage. Replace the

brake drum if it is damaged.

4. Install in the opposite sequence.

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 8

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.

8 - Repair instructions 1204 - 001 - 03.12.2019

CAUTION: 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.

5.3 Chain tensioner

5.3.1 To disassemble and assemble the chain

tensioner

1. Remove the drive sprocket cover. Refer to

remove and install the drive sprocket cover on page

2. Remove the 2 screws and the chain tensioner cover.

3. Remove the chain tensioner (A), shaft (B),

adjustment screw (C), washer (D) and O-ring (E)

from the drive sprocket cover.

1204 - 001 - 03.12.2019 Repair instructions - 9

4. Assemble in the opposite sequence.

5.4 Crankcase

5.4.1 To remove and install the air intake cover

1. Remove the screw.

2. Push the air intake cover to the rear and carefully

pull out the air intake cover.

3. Install in the opposite sequence.

Note: Push the air intake cover against the

crankcase until you hear a click. Push the air intake

cover to the left until the holes align.

CLICK!

5.4.2 To remove and install the handle insert

1. Remove the rear screw on the top handle and the

handle insert.

2. Install in the opposite sequence.

CAUTION: Make sure that the flange (A) on

the handle insert is installed in the notch (B)

on the throttle trigger lockout.

5.4.3 To disassemble and assemble the crankcase

1. Remove the handle insert. Refer to

To remove and

install the handle insert on page 10

2. Move the front hand guard rearward to release the

chain brake.

3. Unfold the rope eyelet.

10 - Repair instructions 1204 - 001 - 03.12.2019

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