Ryobi P540 User manual

Your chain saw has been engineered and manufactured to our high standard for dependability, ease of operation, and
operator safety. When properly cared for, it will give you years of rugged, trouble-free performance.
WARNING: To reduce the risk of injury, the user must read and understand the operator's manual before using
this product.
Thank you for your purchase.
OPERATOR’S MANUAL
18 VOLT CHAIN SAW
P540
P540A
P540B
SAVE THIS MANUAL FOR FUTURE REFERENCE
ACCEPTS ALL ONE+
BATTERY PACKS
BATTERIES AND CHARGERS
SOLD SEPARATELY

2
Introduction .......................................................................................................................................................................2
General Safety Rules.....................................................................................................................................................3-5
Specific Safety Rules.........................................................................................................................................................6
Symbols.........................................................................................................................................................................7-8
Features.............................................................................................................................................................................9
Assembly.........................................................................................................................................................................10
Operation................................................................................................................................................................... 10-18
Maintenance..............................................................................................................................................................19-25
Troubleshooting...............................................................................................................................................................26
Warranty ..........................................................................................................................................................................27
Parts Ordering / Service ....................................................................................................................................Back Page
TABLE OF CONTENTS
INTRODUCTION
This product has many features for making its use more pleasant and enjoyable. Safety, performance, and dependability
have been given top priority in the design of this product making it easy to maintain and operate.

3
GENERAL SAFETY RULES
READ ALL INSTRUCTIONS
BASIC SAFETY PRECAUTIONS
Do not operate a chain saw with one hand! Use a firm grip
with thumbs and fingers encircling the chain saw handles.
Serious injury to the operator, helpers, bystanders, or any
combinationofthesepersonsmayresultfromone-handed
operation. A chain saw is intended for two-handed use.
Always be aware of what you are doing when using the
chain saw. Use common sense. Do not operate the chain
saw when you are tired, ill, or under the influence of al-
cohol, drugs, or medication.
Stay alert and pay attention to what you are doing. Use
common sense when using this unit.
Keep all parts of your body away from the saw chain
when the unit is running.
Always carry the chain saw by the front handle with the
unit stopped and the guide bar and saw chain positioned
to the rear. When transporting your chain saw, use the
appropriate guide bar scabbard.
Neverlet anyoneuse yourchainsaw whohas notreceived
adequate instructions in its proper use. This applies to
rentals as well as privately owned saws.
Before you start the unit, make sure the saw chain is not
contacting any object.
Stop the chain saw before setting it down. Do not leave
the unit running unattended.
To avoid accidental starting, never carry the unit with your
finger on the trigger.
Maintain the unit with care. Keep the cutting edge sharp
and clean for best performance and to reduce the risk
of injury. Follow instructions for lubricating and changing
accessories. Inspect the battery charger cord periodi-
cally, and if damaged, have it replaced or repaired by an
authorized service dealer.
WARNING:
Do not attempt to operate this unit until you have read
thoroughly and understand completely all instructions,
safety information, etc. contained in this manual. Failure
to comply can result in accidents involving fire, electric
shock, or serious personal injury.
Keep handles dry, clean, and free of oil and grease.
Do not operate a chain saw that is damaged, improperly
adjusted,ornotcompletelyandsecurelyassembled.Chain
should stop turning when the trigger is released. If the
chain turns after the trigger has been released, have the
unit serviced by your nearest Ryobi service dealer.
Checkfor damaged parts.Any partor guardthathasbeen
damaged should be carefully checked to determine that
it will operate properly and perform its intended function.
Check for alignment of moving parts, binding of moving
parts, breakage of parts, mounting, and any other condi-
tions that may affect its operation. A guard or other part
that is damaged should be properly repaired or replaced
byanauthorizedservicedealerunlessotherwiseindicated
elsewhere in this manual.
All chain saw service, other than the items listed in the
operationandmaintenancesections,shouldbeperformed
by your nearest Ryobi service dealer.
Do not use in the rain, snow or wet conditions.
Always maintain a proper stance. Do not overreach.
Do not adapt your powerhead to a bow guide or use it
to power any attachments or devices not listed for the
saw.
Do not cut vines and/or small underbrush.
SAFETY APPAREL
Wear snugfitting clothing.Always wearheavy, longpants,
overalls, jeans or chaps made of cut resistant material or
onesthatcontaincutresistantinserts.Wearnon-slipsafety
footwear. Wear non-slip heavy duty gloves to improve
your grip and to protect your hands. Do not wear jewelry,
short pants, sandals, or go barefoot. Do not wear loose
fitting clothing, which could be drawn into the motor or
catch the chain or underbrush. Secure hair so it is above
shoulder level.
Wear eye protection which is marked to comply with ANSI
Z87.1 as well as hearing and head protection when oper-
ating this equipment.

4
GENERAL SAFETY RULES
KICKBACK
See Figures 1 - 2.
WARNING: Kickback may occur when the moving chain
contacts an object at the upper portion of the tip of the
guide bar or when the wood closes in and pinches the
saw chain in the cut. Contact at the upper portion of the
tip of the guide bar can cause the chain to dig into the
object and stop the chain for an instant. The result is
a lightning fast, reverse reaction which kicks the guide
bar up and back toward the operator. If the saw chain
is pinched along the top of the guide bar, the guide bar
can be driven rapidly back toward the operator. Either of
these reactions can cause loss of saw control which can
result in serious injury. Do not rely exclusively upon the
safety devices built into the saw. As a chain saw user,
you should take several steps to keep your cutting jobs
free from accident or injury.
The following precautions should be followed to mini-
mize kickback:
1. Always grip the saw firmly with both hands. Hold the
saw firmly with both hands when the unit is running.
Place your right hand on the rear handle and your left
hand on the front handle with your thumbs and fingers
encircling the chain saw handles. A firm grip together
with a stiff left arm will help you maintain control of
the saw if kickback occurs.
2. Make sure that the area in which you are cutting is free
from obstructions. Do not let the nose of the guide bar
contact a log, branch, fence, or any other obstruction
that could be hit while you are operating the saw.
3. Always cut with the unit running at full speed. Fully
squeeze the throttle trigger and maintain a steady
cutting speed.
4. Use replacement parts such as low kickback chain,
SAFE-T-TIP®anti-kickback nose guards, chain brakes
andspecialguidebarsthatreducetherisks associated
with rotational kickback.
Use only the replacement guide bars and low kickback
chains specified by the manufacturer for the saw.
With a basic understanding of kickback, you can reduce
or eliminate the element of surprise. Sudden surprise
contributes to accidents.
Keep proper footing and balance at all times.
Do not cut above shoulder height or overreach when cutting.
Keep the SAFE-T-TIP®anti-kickback nose guard properly
mounted on the guide bar to prevent rotational kickback.
Follow the sharpening and maintenance instructions for
the saw chain.
Push and Pull - This reaction force is always opposite to
the direction the chain is moving where wood contact is
made. Thus, the operator must be ready to control the
PULL when cutting on the bottom edge of the bar, and
PUSH when cutting along the top edge. See Figure 3.
KICKBACK
DANGER ZONE
Fig. 2
ROTATIONAL
KICKBACK
BAR shOwN wIThOuT sAfE-T-TIp®NOsE GuARD fOR
ILLusTRATION puRpOsEs ONLy.
Fig. 1
push Fig. 3
puLL

5
GENERAL SAFETY RULES
IN THE CUTTING/WORK AREA
Do not operate a chain saw in a tree, on a ladder, or scaf-
fold; this is extremely dangerous.
Keep ALL children, bystanders, visitors, and animals out
of the work area while starting or cutting with the chain
saw.
NOTE: The size of the work area depends on the job
being performed as well as the size tree or work piece
involved. For example, felling a tree requires a larger work
area than making bucking cuts.
Neverstart cuttinguntilyouhavea clearwork area,secure
footing, and a planned retreat path from the falling tree.
Cluttered area invite injuries.
Do not expose the chain saw to rain.
Do not use the chain saw in damp or wet locations.
Do not use the chain saw near flammable liquids, gases,
or in any type of explosive atmosphere.
Use extreme caution when cutting small size brush and
saplings, because slender material may catch the saw
chain and be whipped toward you or pull you off bal-
ance.
When cutting a limb that is under tension, be alert for
spring back so that you will not be struck when the ten-
sion in the wood fibers is released.
Do not force the chain saw. The job can be performed
better and safer at the rate for which it was intended.
Always use the right product for your application. The
chain saw should be used for cutting wood only. Never
use the chain saw to cut plastic, masonry or non-wood
building materials.
Do not use the chain saw for purposes not intended.
Store idle chain saw when not in use. Chain saw should
be stored in a dry and high or locked area out of the reach
of children. When storing chain saw, remove battery and
place the scabbard on the bar and chain or store the chain
saw in a carry case.
Remove the battery pack from the chain saw before
cleaning, servicing, storing, removing material from the
unit, changing accessories such as the bar and chain, or
when not in use.
sAfE-T-TIp®
Fig. 4
UNDERSTANDING YOUR CHAIN SAW SAFETY
DEVICES
See Figure 4.
SAFE-T-TIP®Anti-Kickback Nose Guard
The SAFE-T-TIP®prevents kickback from happening, be-
cause it covers the tip of the bar where kickback is gener-
ated. Never attempt any kind of cutting where the SAFE-T-
TIP®would have to be removed from the bar tip.
LOW KICKBACK SAW CHAIN
The rakers (depth gauges) ahead of each cutter can minimize
the force of a kickback reaction by preventing the cutters
from digging in too deeply at the kickback zone. Only use
replacement chain that is equivalent to original chain or has
been certified as low kickback chain per ANSI B175.1.
Low kickback saw chain is chain that has met the kickback
performance requirements of ANSI B175.1 - 1991 (Amer-
ican National Standard for Power Tools - Gasoline-Powered
Chain Saws-Safety Requirements) when tested on the rep-
resentative sample of chain saws below 3.8 c.i.d. specified
in ANSI B175.1 - 1991.
As saw chains are sharpened during their useful life, they
lose some of the low kickback qualities and extra caution
should be used.
GUIDE BARS
Generally, guide bars with small radius tips have somewhat
lower kickback potentials.
When making a replacement, be sure to order one of the
Ryobi bars listed for the saw in this operator's manual. The
proper size SAFE-T-TIP®nose guard comes installed on the
bar. Use only guide bars that have a provision for mounting
the SAFE-T-TIP®.

6
BATTERY SAFETY
Battery operated units do not have to be plugged into an
electrical outlet; therefore, they are always in operating
condition. Be aware of possible hazards even when unit
is not operating.
Remove the battery pack from the chain saw before
cleaning, servicing, storing, removing material from the
unit, changing accessories such as the bar and chain, or
when not in use.
A battery pack must be recharged only with the speci-
fied charger for the battery pack. A charger that may be
suitable for one type of battery pack may create a risk
of fire when used with another battery pack. Use battery
pack only with charger listed.
To reduce the risk of explosion and possible injury, Do not
place battery units or their batteries near fire or heat.
Do not open or mutilate the battery pack. Released elec-
trolyte is corrosive and may cause damage to the eyes
or skin. It may be toxic if swallowed.
Do not crush, drop or damage battery pack. Do not
use a battery pack or charger that has been dropped or
received a sharp blow. A damaged battery is subject to
SPECIFIC SAFETY RULES
explosion. Properly dispose of a dropped or damaged
battery immediately.
Batteries can explode in the presence of a source of ig-
nition, such as a pilot light. To reduce the risk of serious
personal injury, never use any cordless product in the
presence of open flame. An exploded battery pack can
propel debris and chemicals. If exposed, flush with water
immediately.
Do not charge unit in a damp or wet location. Following
this rule will reduce the risk of electric shock.
For best results, your battery unit should be charged in
a location where the temperature is more than 50°F but
less than 100°F. Do not store outside or in vehicles.
Under extreme usage or temperature conditions, battery
pack leakage may occur. If liquid comes in contact with
your skin, wash immediately with soap and water, then
neutralize with lemon juice or vinegar. If liquid gets into
your eyes, flush them with clean water for at least 10
minutes, then seek immediate medical attention.
Do not dispose of batteries in a fire. The cell may explode.
Batteries should be recycled, consult your local waste
authority for information regarding available recycling
and/or disposal options.
When battery pack is not in use, keep it away from other
metal objects like: paper clips, coins, keys, nails, screws,
or other small metal objects that can make a connection
from one terminal to another. Shorting the battery pack
terminals together may cause sparks, burns, or a fire.
MODEL BATTERY PACK CHARGER (P113)
P540
P540A
P540B
(P104 Li-ion)
130429001, 130429002
130155001
(P100 Ni-Cd)
130255004, 130224028
140501001
140501005
BATTERY PACK CHARGER (P110)
(P100 Ni-Cd)
130255004, 130224028
1423701, 140237021,
140237023

7
SYMBOLS
Some of the following symbols may be used on this product. Please study them and learn their meaning. Proper
interpretation of these symbols will allow you to operate the product better and safer.
SYMBOL NAME DESIGNATION/EXPLANATION
V Volts Voltage
A Amperes Current
Hz Hertz Frequency (cycles per second)
W Watt Power
min Minutes Time
Alternating Current Type of current
Direct Current Type or a characteristic of current
n
o
No Load Speed Rotational speed, at no load
Class II Construction Double-insulated construction
.../min Per Minute Revolutions, strokes, surface speed, orbits etc., per minute
Wet Conditions Alert Do not expose to rain or use in damp locations.
Read The Operator’s Manual To reduce the risk of injury, user must read and understand
operator’s manual before using this product.
Wear Eye, Hearing, and
Head Protection
Wear eye protection which is marked to comply with ANSI Z87.1
as well as hearing and head protection when operating this
equipment.
Safety Alert Precautions that involve your safety.
SAFE-T-TIP Nose Guard The SAFE-T-TIP nose guard on the guide bar helps prevent
kickback.
Operate With Two Hands Hold and operate the saw properly with both hands.
One Handed Do not operate the saw using only one hand.
Kickback DANGER! Beware of kickback.
Bar Nose Contact Avoid bar nose contact.
Wear Gloves Wear non-slip, heavy-duty protective gloves when handling the
chain saw.
Wear Safety Footwear Wear non-slip safety footwear when using this equipment.
Keep Bystanders Away Keep all bystanders and animals at least 50 ft. away.

8
SYMBOLS
SERVICE
Servicing requires extreme care and knowledge and should
be performed only by a qualified service technician. For
service we suggest you return the product to your nearest
AUTHORIZED SERVICE CENTER for repair. When servic-
ing, use only identical replacement parts.
WARNING:
SAVE THESE INSTRUCTIONS
The following signal words and meanings are intended to explain the levels of risk associated with this product.
SYMBOL SIGNAL MEANING
DANGER: Indicates an imminently hazardous situation, which, if not avoided, will
result in death or serious injury.
WARNING: Indicates a potentially hazardous situation, which, if not avoided, could
result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation, which, if not avoided, may
result in minor or moderate injury.
CAUTION: (Without Safety Alert Symbol) Indicates a situation that may result in
property damage.
WARNING:
To avoid serious personal injury, do not attempt to use this
product until you read thoroughly and understand com-
pletely the operator’s manual. If you do not understand
the warnings and instructions in the operator’s manual,
do not use this product. Call Ryobi customer service for
assistance.
The operation of any power tool can result in foreign objects being thrown into your eyes, which can
result in severe eye damage. Before beginning power tool operation, always wear safety goggles,
safety glasses with side shields, or a full face shield when needed. We recommend Wide Vision Safety
Mask for use over eyeglasses or standard safety glasses with side shields. Always use eye protection
which is marked to comply with ANSI Z87.1.

9
FEATURES
PRODUCT SPECIFICATIONS
Motor......................................................................................................................................................................18 Volt DC
Bar Length......................................................................................................................................................................10 in.
Replacement Bar Part Number ......................................................................................................671256002 or 671834007
Replacement Chain Part Number ......................................................................................................6958301 or 690583002
NOTE: This saw was designed for occasional light duty use and has some limitations as to what it can cut.
Fig. 5
ChAIN OIL
TANK CAp
REAR
hANDLE
fRONT hANDLE
BAR
ChAIN
sAfE-T-TIp®
BATTERy pACK
(NOT INCLuDED)
hEX KEy hEX KEy
sTORAGE AREA
hAND GuARD
TRIGGER
sCABBARD
BATTERy pACK
(NOT INCLuDED)
TRIGGER RELEAsE
BuTTON

10
ASSEMBLY
UNPACKING
This product has been shipped completely assembled.
Carefully remove the product and any accessories from
the box. Make sure that all items listed in the packing list
are included.
Inspect the product carefully to make sure no breakage
or damage occurred during shipping.
Do not discard the packing material until you have care-
fully inspected and satisfactorily operated the product.
If any parts are damaged or missing, please call
1-800-860-5040 for assistance.
PACKING LIST
Chain Saw with Scabbard
Wrench
Bar and Chain Lubricant
Operator’s Manual
WARNING:
If any parts are damaged or missing do not operate this
product until the parts are replaced. Failure to heed this
warning could result in serious personal injury.
WARNING:
Do not attempt to modify this product or create acces-
sories not recommended for use with this product. Any
such alteration or modification is misuse and could result
in a hazardous condition leading to possible serious
personal injury.
WARNING:
To prevent accidental starting that could cause serious
personal injury, always remove the battery pack from the
product when assembling parts.
OPERATION
WARNING:
Do not use any attachments or accessories not recom-
mended by the manufacturer of this product. The use of
attachments or accessories not recommended can result
in serious personal injury.
APPLICATIONS
You may use this product for the following purposes:
Limbing and pruning branches from trees
Felling small trees up to 5 in. diameter
Bucking the fallen tree into shorter lengths
WARNING:
Do not allow familiarity with this product to make you
careless. Remember that a careless fraction of a second is
sufficient to inflict serious injury.
WARNING:
Always wear safety goggles or safety glasses with side
shields when operating power tools. Failure to do so
could result in objects being thrown into your eyes result-
ing in possible serious injury.