Husqvarna 540i XP Workshop Manual
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Husqvarna 540i XP Workshop Manual

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Workshop manual
®
540i XP
English
1430 - 001 - 05.05.2020

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Summary of Contents for Husqvarna 540i XP

  • Page 1 Workshop manual ® 540i XP English 1430 - 001 - 05.05.2020...

  • Page 2: Table Of Contents

    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............

  • Page 3: Introduction

    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...

  • Page 4: Safety

    2 Safety 2.1 Safety definitions WARNING: Do not put the battery back until the product is assembled. Warnings, cautions and notes are used to point out specially important parts of the manual. 1. Press in the catches and remove the battery. 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.

  • Page 5: Servicing Data

    3 Servicing data 3.1 Servicing data ● Lubricate with grease. ▲ Lubricate with chain oil. (x4) 1 - 2 Nm (x1) 7 - 8 Nm (x2) 1 - 2 Nm (x1) 4 Nm (x6) 2 - 2.5 Nm (x1) 3 Nm (x3) 3.5 Nm (x2) 1.8 - 2.2 Nm (x5) 2.2 Nm...
  • Page 6 (x2) 4 Nm (x1) 4 Nm (x10) 2.5 - 3 Nm (x1) 1 Nm (x4) 3 - 4 Nm 6 - Servicing data 1430 - 001 - 05.05.2020...

  • Page 7: Servicing Tools

    4 Servicing tools 4.1 Servicing tools INSTRUCTION Posi- Description Article No. tion Diagnostic tool kit To do a check of the product and install updates to the firm- 583 89 71-01 ware. Adapter cable for battery To do a check of battery products with the diagnostic tool kit. 581 19 23-01 products T-handle Torx, T20...

  • Page 8: Electrical Diagram

    4.2 Electrical diagram Trigger 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 Switch Yellow Pink 1 2 3 4 5 6 7 8 9 White Black White Grey Black Motor Blue 1 2 3 8 - Servicing tools...

  • Page 9: Repair Instructions

    5 Repair instructions 5.1 To clean and examine the product parts 3. Hold the drive sprocket with adjustable pliers and remove the screw (A). • Clean and examine all parts fully. You find more instructions in the chapter for each part if special tools or procedures are necessary.
  • Page 10 5.2.4 To remove and install the worm gear 3. Remove the 2 screws and the spiked bumper. To remove and 1. Remove the brake drum. Refer to install the brake drum on page 9 . 2. Remove the worm gear. 4.

  • Page 11: Chain Tensioner

    5.3 Chain tensioner 5.4 Crankcase 5.3.1 To disassemble and assemble the chain 5.4.1 To remove and install the air intake cover tensioner 1. Remove the screw. 1. Remove the drive sprocket cover. Refer to remove and install the drive sprocket cover on page 2.
  • Page 12 5.4.2 To remove and install the front handle 5.4.3 To remove and install the handle insert 1. Remove the 2 screws (A) on the side of the front 1. Remove the screw on the rear handle and carefully handle. remove the handle insert. 2.

  • Page 13: Power Trigger

    To remove and install 4. Remove the 10 screws. 8. Install the chassis. Refer to the chassis on page 19 . To disassemble 9. Assemble the crankcase. Refer to and assemble the crankcase on page 12 . 10. Install the guide bar and the saw chain. To remove 11.
  • Page 14 5. Remove the power trigger. 3. Install the power trigger. 6. Pull out the recoil spring from the power trigger. 4. Make sure that the switch lever is above the switch engage pin on the power trigger. 7. Make sure that there is tension in the recoil spring. Replace the recoil spring if it is necessary.

  • Page 15: Front Handguard

    5.7 Motor and control unit 7. Make sure that the edges of the power trigger and the power trigger lockout are in the correct positions. 5.7.1 To remove the motor, control unit and battery connector CAUTION: Do not pull the cables. 1.
  • Page 16 11. Disconnect the connector for the chain brake sensor 15. Disconnect the communication cable (A) from the (A). control unit. 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 12.
  • Page 17 4. Connect the user interface connector to the control 8. Hold the battery connector in position and install the unit. 2 screws. 5. Connect the connector for the chain brake sensor 9. Hold the motor in position and install the 3 screws. (A).

  • Page 18: User Interface

    5.8 User interface 4. Remove the screw and pull out the chain oil tank from the crankcase. 5.8.1 To remove and install the user interface 1. Disassemble the crankcase. Refer to disassemble and assemble the crankcase on page 12 . 2.

  • Page 19: Chain Brake

    5.10 Chain brake 5.10.2 To remove and install the oil pump To remove and install 1. Remove the chassis. Refer to 5.10.1 To remove and install the chassis the chassis on page 19 . WARNING: Use protective glasses. The spring 2.
  • Page 20 5.10.3 To disassemble and assemble the chain 3. Remove the support for the chain brake sensor (A). brake 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. To remove and install 3.

  • Page 21: Troubleshooting

    The motor can operate when the product is CAUTION: If you install firmware to a new spare in servicing mode. part, make sure that you know the Husqvarna identification number (HID). The identification number is found on the spare part.

  • Page 22: Troubleshooting Of The Product

    6.2 Troubleshooting of the product Symptom Possible cause Recommended step The product does not start. No LEDs Defective battery. Press the ON/OFF button to do a come on when you press the check of the battery. A minimum of 1 ON/OFF button.
  • Page 23 Symptom Possible cause Recommended step A warning sign on the user interface Defective signal between the battery Make sure that the power connectors flashes after start. and the product. between the battery and the product are clean and not damaged. Make sure that the small cables be- tween the connector and the control unit are not loose or damaged.

  • Page 24: Troubleshooting Of The Battery And Battery Charger

    6.3 Troubleshooting of the battery and battery charger Symptom Possible causes Recommended step No LEDs flash on the battery when Defective battery. Replace the battery. you press the start button. A warning sign shows a constant red Defective battery. Replace the battery. light on the battery when the start but- ton is pressed.
  • Page 25 Symptom Possible causes Recommended step A green lamp on the charger comes Defective Battery. Put the battery in a charger. If the on for approximately 5-10 seconds same problem occurs, replace the when the battery is attached. After battery. that a red warning sign flashes on the Defective charger.

  • Page 26: Technical Data

    7.1.1 Approved batteries and chargers Information about approved batteries and chargers is found in the Husqvarna accessories guide. Only use Husqvarna original batteries and chargers for this product. Noise emissions in the environment measured as sound power (L ) in conformity with EC directive 2000/14/EC.
  • Page 27 1430 - 001 - 05.05.2020 Technical data - 27...
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