Husqvarna 540i XP Instruction manual

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.
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5.3 Chain tensioner
5.3.1 To disassemble and assemble the chain
tensioner
1. Remove the drive sprocket cover. Refer to
To
remove and install the drive sprocket cover on page
9 .
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.
A
B
C
D
E
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 rearward 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 forward until the holes align.
CLICK!
1430 - 001 - 05.05.2020 Repair instructions - 11

5.4.2 To remove and install the front handle
1. Remove the 2 screws (A) on the side of the front
handle.
A
B
2. Remove the 2 screws (B) at the bottom of the front
handle and remove the front handle.
3. Install in the opposite sequence.
CAUTION: Make sure to put the screws in
the correct position. A long screw below the
product can make a hole the oil tank.
5.4.3 To remove and install the handle insert
1. Remove the screw on the rear handle and carefully
remove the handle insert.
2. Install in the opposite sequence. Make sure that the
flange on the handle insert is installed correctly in
the hole when you install the handle insert.
5.4.4 To disassemble and assemble the crankcase
1. Move the front handguard rearward to release the
chain brake.
2. Remove the front handle. Refer to To remove and
install the front handle on page 12 .
3. Remove the handle insert. Refer to To remove and
install the handle insert on page 12 .
12 - Repair instructions 1430 - 001 - 05.05.2020

4. Remove the 10 screws.
5. Remove the left crankcase half.
6. Assemble in the opposite sequence.
CAUTION: Make sure that all parts are
installed correctly in the crankcase to
prevent damage to the cables.
5.4.5 To replace the guide bar bolt
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. Disassemble the crankcase. Refer to To
disassemble and assemble the crankcase on page
12 .
4. Remove the chassis. Refer to To remove and install
the chassis on page 19 .
5. Remove the guide bar bolt.
6. Put the new guide bar bolt through the hole in the
chassis.
7. Use a hammer and a mandrel to install the new
guide bar bolt.
8. Install the chassis. Refer to To remove and install
the chassis on page 19 .
9. Assemble the crankcase. Refer to To disassemble
and assemble the crankcase on page 12 .
10. Install the guide bar and the saw chain.
11. Install the drive sprocket cover. Refer to
To remove
and install the drive sprocket cover on page 9 .
5.5 Power trigger
5.5.1 To disassemble the power trigger
1. Disassemble the crankcase. Refer to To
disassemble and assemble the crankcase on page
12 .
2. Make a note of how the inner parts of the power
trigger handle are installed.
3. Remove the power trigger lockout.
4. Make sure that the power trigger lockout has no
defects. Replace the power trigger lockout if it has
defects.
1430 - 001 - 05.05.2020 Repair instructions - 13

5. Remove the power trigger.
6. Pull out the recoil spring from the power trigger.
7. Make sure that there is tension in the recoil spring.
Replace the recoil spring if it is necessary.
5.5.2 To assemble the power trigger
1. Make sure that there is tension in the recoil spring.
Replace the recoil spring if it is necessary.
2. Put the recoil spring in the power trigger.
3. Install the power trigger.
4. Make sure that the switch lever is above the switch
engage pin on the power trigger.
5. Make sure that the power trigger lockout has no
defects. Replace the power trigger lockout if it is
necessary.
6. Install the power trigger lockout.
14 - Repair instructions 1430 - 001 - 05.05.2020

7. Make sure that the edges of the power trigger and
the power trigger lockout are in the correct positions.
8. Assemble the crankcase. Refer to To disassemble
and assemble the crankcase on page 12 .
5.6 Front handguard
5.6.1 To remove and install the front handguard
1. Disassemble the crankcase. Refer to To
disassemble and assemble the crankcase on page
12 .
2. Remove the screw.
3. Carefully turn the front handguard to remove it from
the crankcase half.
4. Install in the opposite sequence.
5.7 Motor and control unit
5.7.1 To remove the motor, control unit and battery
connector
CAUTION: Do not pull the cables.
1. Remove the drive sprocket cover. Refer to To
remove and install the drive sprocket cover on page
9 .
2. Remove the drive sprocket. Refer to To remove and
install the drive sprocket on page 9 .
3. Remove the brake drum. Refer to To remove and
install the brake drum on page 9 .
4. Remove the worm gear. Refer to
To remove and
install the worm gear on page 10 .
5. Disassemble the crankcase. Refer to To
disassemble and assemble the crankcase on page
12 .
6. Disassemble the power trigger. Refer to To
disassemble the power trigger on page 13 .
7. Remove the user interface. Refer to To remove and
install the user interface on page 18 .
8. Make a note of how the cables and parts are
installed.
9. Remove the 2 screws on the battery connector.
10. Remove the 3 screws and the motor unit.
1430 - 001 - 05.05.2020 Repair instructions - 15

11. Disconnect the connector for the chain brake sensor
(A).
D
A
C
E
B
12. Remove the wire harness (B), the motor (C), the
control unit (D) and the battery connector (E ) from
the crankcase half.
13. Disconnect the user interface connector from the
control unit.
14. Remove the 3 screws and disconnect the motor
cables from the control unit.
15. Disconnect the communication cable (A) from the
control unit.
A
B
16. Remove the 2 screws (B) and the battery connector
from the control unit.
5.7.2 To install the motor, control unit and battery
connector
1. Install the battery connector cables with the 2
screws (A).
B
A
2. Connect the communication cable (B) to the control
unit.
3. Install the motor cables on the control unit with the 3
screws.
16 - Repair instructions 1430 - 001 - 05.05.2020

4. Connect the user interface connector to the control
unit.
5. Connect the connector for the chain brake sensor
(A).
C
A
B
D
E
6. Put the motor (B), the control unit (C), the battery
connector (D) and the wire harness (E) into the
crankcase half.
7. Make sure that the connection points on the wire
harness are in the correct positions.
CAUTION: Make sure that the wire harness
and the cables do not touch the fan.
8. Hold the battery connector in position and install the
2 screws.
9. Hold the motor in position and install the 3 screws.
10. Install the user interface. Refer to To remove and
install the user interface on page 18 .
11. Assemble the power trigger. Refer to To assemble
the power trigger on page 14 .
12. Assemble the crankcase. Refer to To disassemble
and assemble the crankcase on page 12 .
CAUTION: Make sure that all cables and
parts are installed correctly before you
assemble the crankcase.
13. Install the worm gear. Refer to To remove and install
the worm gear on page 10 .
14. Install the brake drum. Refer to To remove and
install the brake drum on page 9 .
15. Install the drive sprocket. Refer to To remove and
install the drive sprocket on page 9 .
16. Install the drive sprocket cover. Refer to To remove
and install the drive sprocket cover on page 9 .
1430 - 001 - 05.05.2020 Repair instructions - 17

5.8 User interface
5.8.1 To remove and install the user interface
1. Disassemble the crankcase. Refer to To
disassemble and assemble the crankcase on page
12 .
2. Disassemble the power trigger and the power trigger
lockout. Refer to
To disassemble the power trigger
on page 13 .
3. Disconnect the chain brake sensor.
4. Pull out the airflow cover and the user interface.
5. Disconnect the user interface.
6. Push out the clips and pull out the user interface
from the airflow cover.
7. Install in the opposite sequence.
5.9 Chain oil tank
5.9.1 To remove and install the chain oil tank
1. Empty the chain oil tank.
2. Disassemble the crankcase. Refer to
To
disassemble and assemble the crankcase on page
12 .
3. Remove the motor. Refer to To remove the motor,
control unit and battery connector on page 15 .
4. Remove the screw and pull out the chain oil tank
from the crankcase.
5. Remove the grommet (A) and pull out the oil hose
(B) and the oil filter (C).
A
B
C
6. Install in the opposite sequence. Make sure that you
push the oil hose into the dedicated slot in the
crankcase when you install the chain oil tank.
CAUTION: Make sure that the grommet is
attached correctly to the chain oil tank.
CAUTION: Make sure that the oil filter is at
the bottom of the chain oil tank when you
install the chain oil tank.
18 - Repair instructions 1430 - 001 - 05.05.2020

5.10 Chain brake
5.10.1 To remove and install the chassis
WARNING: Use protective glasses. The spring
can eject and cause injury.
1. Disassemble the crankcase. Refer to To
disassemble and assemble the crankcase on page
12 .
2. Remove the motor, control unit and the battery
connector. Refer to
To remove the motor, control
unit and battery connector on page 15 .
3. Remove the chain oil tank. Refer to To remove and
install the chain oil tank on page 18 .
4. Hold your thumb on the spring (A) and carefully pull
out the chain brake wheel (B).
A
C
B
D
5. Carefully remove the lever (C), the spring and the
spring retainer (D).
6. Remove the 6 screws and the chassis.
7. Install in the opposite sequence.
5.10.2 To remove and install the oil pump
1. Remove the chassis. Refer to To remove and install
the chassis on page 19 .
2. Remove the screw (A).
B
A
C
3. Remove the oil pump assembly (B) and the rubber
hose (C).
4. Remove the oil pump assembly from the rubber
hose.
5. Remove the rubber hose from the opening in the
chassis.
6. Install in the opposite sequence.
1430 - 001 - 05.05.2020 Repair instructions - 19

5.10.3 To disassemble and assemble the chain
brake
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 chassis. Refer to To remove and install
the chassis on page 19 .
4. Remove the 4 screws and carefully remove chain
brake cover.
WARNING: Use protective glasses. The
chain brake spring can eject and cause
injury.
5. Use a screwdriver to carefully remove the spring.
6. Assemble in the opposite sequence.
5.10.4 To remove and install the chain brake
sensor
1. Disassemble the crankcase. Refer to
To
disassemble and assemble the crankcase on page
12 .
2. Remove the motor, the control unit, and the battery
connector. Refer to
To remove the motor, control
unit and battery connector on page 15 .
3. Remove the support for the chain brake sensor (A).
A B
4. Pull out the chain brake connector (B).
5. Use a screwdriver to bend the clip (C) to the side
and push out the chain brake sensor (D).
C
D
6. Install in the opposite sequence. Make sure that the
cable, the support for the chain brake sensor and
chain brake connector are in the correct positions.
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