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.
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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
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(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
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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
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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.
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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
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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.
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4. Remove the 9 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.
5.4.4 To replace the guide bar bolt
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. Disassemble the crankcase. Refer to To
disassemble and assemble the crankcase on page
10 .
4. Remove the chassis. Refer to To remove and install
the chassis on page 17 .
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 17 .
9. Assemble the crankcase. Refer to To disassemble
and assemble the crankcase on page 10 .
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 8 .
5.4.5 To remove and install the front handle
1. Disassemble the crankcase. Refer to
To
disassemble and assemble the crankcase on page
10 .
2. Remove the 2 screws and the front handle.
3. Install in the opposite sequence.
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
10 .
2. Make a note of how the inner parts of the top handle
are installed.
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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.
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. Pull out the recoil spring from the power trigger.
3. Install the power trigger.
CAUTION: Make sure that the switch lever
is above the switch engage pin on the
power trigger.
Note: Make sure that the recoil spring is below the
plastic molding boss before you install the throttle
trigger lockout.
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4. Make sure that the power trigger lockout has no
defects. Replace the power trigger lockout if it is
necessary.
5. Install the power trigger lockout.
Note: Make sure that the edges (A) of the power
trigger and the power trigger lockout are in the
correct positions.
A
6. Assemble the crankcase. Refer to To disassemble
and assemble the crankcase on page 10 .
5.6 Front hand guard
5.6.1 To remove and install the front hand guard
1. Disassemble the crankcase. Refer to To
disassemble and assemble the crankcase on page
10 .
2. Remove the screw.
3. Carefully turn the front hand guard 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
8 .
2. Remove the drive sprocket. Refer to To remove and
install the drive sprocket on page 8 .
3. Remove the brake drum. Refer to To remove and
install the brake drum on page 8 .
4. Remove the worm gear. Refer to To remove and
install the worm gear on page 8 .
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5. Disassemble the crankcase. Refer to To
disassemble and assemble the crankcase on page
10 .
6. Disassemble the power trigger. Refer to To
disassemble the power trigger on page 11 .
7. Remove the user interface. Refer to To remove and
install the user interface on page 16 .
8. Make a note of how the cables and parts are
installed.
9. Remove the cable cover.
10. Remove the 2 screws on the battery connector.
11. Remove the 3 screws and the motor unit.
12. Remove the wire harness (A) motor (B), control unit
(C) and battery connector (D) from the crankcase
half.
C
A
B
D
13. Disconnect the user interface connector from the
control unit.
14. Remove the 3 screws and disconnect the motor
cables from the control unit.
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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.
4. Connect the user interface connector to the control
unit.
5. Put the motor (C), control unit (D), battery connector
(E) and wire harness (F) into the crankcase half.
D
F
C
E
CAUTION: Make sure that the connection
points on the wire harness (G) and the
motor cable holder (H) are in the correct
positions.
G
H
CAUTION: Make sure that the wire harness
and the motor cable holder does not touch
the fan.
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6. Hold the battery connector in position and install the
2 screws.
7. Hold the motor in position and install the 3 screws.
8. Install the cable cover.
CAUTION: Make sure that the battery
connector cables are in the correct position.
9. Install the user interface. Refer to To remove and
install the user interface on page 16 .
10. Assemble the power trigger. Refer to To assemble
the power trigger on page 12 .
11. Assemble the crankcase. Refer to To disassemble
and assemble the crankcase on page 10 .
CAUTION: Make sure that all cables and
parts are installed correctly before you
assemble the crankcase.
12. Install the worm gear. Refer to To remove and install
the worm gear on page 8 .
13. Install the brake drum. Refer to
To remove and
install the brake drum on page 8 .
14. Install the drive sprocket. Refer to To remove and
install the drive sprocket on page 8 .
15. Install the drive sprocket cover. Refer to To remove
and install the drive sprocket cover on page 8 .
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
10 .
2. Disassemble the power trigger and the power trigger
lockout. Refer to
To disassemble the power trigger
on page 11 .
3. Disconnect the chain brake sensor.
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4. Pull out and disconnect the user interface.
5. 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
10 .
3. Remove the motor. Refer to To remove the motor,
control unit and battery connector on page 13 .
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.
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.
CAUTION: Make sure that you push the oil
hose into the dedicated slot in the
crankcase when you install the chain oil
tank.
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
10 .
2. Remove the motor, control unit and the battery
connector. Refer to To remove the motor, control
unit and battery connector on page 13 .
3. Remove the chain oil tank. Refer to To remove and
install the chain oil tank on page 17 .
1204 - 001 - 03.12.2019 Repair instructions - 17

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 17 .
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.
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
8 .
2. Remove the guide bar and the saw chain.
3. Remove the chassis. Refer to To remove and install
the chassis on page 17 .
4. Remove the 4 screws and carefully remove chain
brake cover.
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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. Remove the chassis. Refer to
To remove and install
the chassis on page 17 .
2. Pull out the chain brake connector (A) and remove
the cable.
A
3. Use a screwdriver to bend the clip (B) to the side
and push out the chain brake sensor (C).
B
C
4. Install in the opposite sequence.
CAUTION: Make sure the cable and chain
brake connector are in the correct positions.
1204 - 001 - 03.12.2019 Repair instructions - 19

6 Troubleshooting
6.1 Diagnostic tools
6.1.1 Common service tool
The common service tool (CST) is used with a computer
(not included) for Husqvarna products.
The common service tool transmits data from the
product and battery to the computer, for example
product ID. There is also a diagnostic tool list and a list
of saved error codes. The common service tool is also
used to update the software in battery products.
6.1.2 To connect the common service tool (CST)
CAUTION: If you install firmware to a new spare
part, make sure that you know the Husqvarna
identification number (HID). The identification
number is found on the spare part.
1. Remove the battery from the product.
2. Connect the adapter cable (A) to the battery (B) and
to the battery slot connector (C) on the product.
B
C
A
D
3. Start the product.
4. Connect the cable (D) to the common service tool
(CST).
5. Obey the instructions on the common service tool
(CST) and in the related chapter in this manual.
CAUTION: Do not disconnect the product
until the update is completed.
WARNING: Do not push the power trigger.
The motor can operate when the product is
in servicing mode.
6.1.3 To do troubleshooting of the common service
tool
If there is no signal to the common service tool when it is
connected to the product, do the procedure that follows.
1. Make sure that the connectors on the battery and on
the product are clean and not damaged. Replace the
battery or control unit on the product if there is
damage.
2. Make sure that the cable to the common service tool
is clean and not damaged. Replace the cable if there
is damage.
3. Restart the computer.
4. Install the software again.
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