Husqvarna T540i XP Instruction manual

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
(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).
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
8 .
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 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 To
remove and install the drive sprocket cover on page
8 .
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
8 .
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
To
remove and install the drive sprocket cover on page
8 .
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
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.
B
A
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