Ryobi Outdoor P540 User Manual
OPERATOR'S MANUAL
18 VOLT
CORDLESS CHAIN SAW
P540
BATTERIES AND CHARGERS
SOLD SEPARATELY
Your Cordless Chain Saw has been engineered and manufactured to Ryobi’s 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 buying a Ryobi product.
SAVE THIS MANUAL FOR FUTURE REFERENCE
TABLE OF CONTENTS
n Introduction ..................................................................................................................................................................... 2
�n General Safety Rules....................................................................................................................................................3-5
n Safety Rules for Charger ................................................................................................................................................. 6
�n Symbols........................................................................................................................................................................ 7-8
��n Features........................................................................................................................................................................... 9
��n Assembly....................................................................................................................................................................... 10
�n Operation.................................................................................................................................................................. 10-19
�n Maintenance.............................................................................................................................................................20-26
�n Troubleshooting ............................................................................................................................................................. 27
�n Parts Ordering / Service................................................................................................................................................ 28
INTRODUCTION
This tool 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.
2
GENERAL SAFETY RULES
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.
READ ALL INSTRUCTIONS
BASIC SAFETY PRECAUTIONS
n 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
combination of these persons may result from one-handed
operation. A chain saw is intended for two-handed use.
n 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 alcohol, drugs, or medication.
n Stay alert and pay attention to what you are doing. Use
common sense when using this unit.
n Keep all parts of your body away from the saw chain
when the unit is running.
n 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.
n Never let anyone use your chain saw who has not received
adequate instructions in its proper use. This applies to
rentals as well as privately owned saws.
n Before you start the unit, make sure the saw chain is not
contacting any object.
n Stop the chain saw before setting it down. Do not leave
the unit running unattended.
n To avoid accidental starting, never carry the unit with your
finger on the trigger.
n 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 periodically, and if damaged, have it replaced or repaired by an
authorized service dealer.
n Keep handles dry, clean, and free of oil and grease.
n Do not operate a chain saw that is damaged, improperly
adjusted, or not completely and securely assembled. 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.
n Check for damaged parts. Any part or guard that has been
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 conditions that may affect its operation. A guard or other part
that is damaged should be properly repaired or replaced
by an authorized service dealer unless otherwise indicated
elsewhere in this manual.
n All chain saw service, other than the items listed in the
operation and maintenance sections, should be performed
by your nearest Ryobi service dealer.
n Do not use in the rain, snow or wet conditions.
n Always maintain a proper stance.
n Do not adapt your powerhead to a bow guide or use it
to power any attachments or devices not listed for the
saw.
n Do not cut vines and/or small underbrush.
SAFETY APPAREL
n Wear snug fitting clothing. Always wear heavy, long pants,
overalls, jeans or chaps made of cut resistant material or
ones that contain cut resistant inserts. Wear non-slip safety
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.
n Wear eye protection which is marked to comply with ANSI
Z87.1 as well as hearing and head protection when operating this equipment.
3
GENERAL SAFETY RULES
KICKBACK
See Figures 1 - 2.
n 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.
n 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
and special guide bars that reduce the risks associated
with rotational kickback.
Use only the replacement guide bars and low kickback
chains specified by the manufacturer for the saw.
n With a basic understanding of kickback, you can reduce
or eliminate the element of surprise. Sudden surprise
contributes to accidents.
n Keep proper footing and balance at all times.
n Do not cut above shoulder height or overreach when cutting.
n Keep the SAFE-T-TIP® anti-kickback nose guard properly
mounted on the guide bar to prevent rotational kickback.
n Follow the sharpening and maintenance instructions for
the saw chain.
n 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.
ROTATIONAL
KICKBACK
BAR SHOWN WITHOUT SAFE-T-TIP® NOSE GUARD FOR
ILLUSTRATION PURPOSES ONLY.
Fig. 1
KICKBACK
DANGER ZONE
Fig. 2
PULL
PUSH
Fig. 3
4
GENERAL SAFETY RULES
IN THE CUTTING/WORK AREA
n Do not operate a chain saw in a tree, on a ladder, or scaf-
fold; this is extremely dangerous.
n 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.
n Never start cutting until you have a clear work area, secure
footing, and a planned retreat path from the falling tree.
Cluttered area invite injuries.
n Do not expose the chain saw to rain.
n Do not use the chain saw in damp or wet locations.
n Do not use the chain saw near flammable liquids, gases,
or in any type of explosive atmosphere.
n 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 balance.
n When cutting a limb that is under tension, be alert for
spring back so that you will not be struck when the tension in the wood fibers is released.
n Do not force the chain saw. The job can be performed
better and safer at the rate for which it was intended.
n 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.
n Do not use the chain saw for purposes not intended.
n 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.
n 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.
UNDERSTANDING YOUR CHAIN SAW SAFETY
DEVICES
See Figure 4.
SAFE-T-TIP® Anti-Kickback Nose Guard
The SAFE-T-TIP® prevents kickback from happening, because it covers the tip of the bar where kickback is generated. Never attempt any kind of cutting where the SAFE-TTIP® 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 (American National Standard for Power Tools - Gasoline-Powered
Chain Saws-Safety Requirements) when tested on the representative 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®.
SAFE-T-TIP®
Fig. 4
5
SAFETY RULES FOR CHARGER
BATTERY SAFETY
n 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.
n 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.
n 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.
MODEL BATTERY PACK (P100) CHARGER (P110)
P540 130255004 1423701, 140237023
or 140237021
n To reduce the risk of explosion and possible injury, Do
not place battery units or their batteries near fire or heat.
n Do not open or mutilate the battery pack. Released
electrolyte is corrosive and may cause damage to the
eyes or skin. It may be toxic if swallowed.
n A damaged battery pack is subject to explosion. To
avoid serious personal injury, properly dispose of a
damaged battery pack.
n Batteries vent hydrogen gas and can explode in the
presence of a source of ignition, 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.
n Do not charge unit in a damp or wet location. Following
this rule will reduce the risk of electric shock.
n For best results, your battery unit should be charged
in a location where the temperature is more than 50°F
(10°C) but less than 100°F (38°C). Do not store outside
or in vehicles.
n Under extreme usage or temperature conditions, bat-
tery 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.
n 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.
n 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.
CHARGER SAFETY
n Save these instructions. This manual contains impor-
tant Rules for Safe Operation and operating instructions for charger.
n Before using battery charger, read all instructions and
cautionary markings in this manual, on battery charger,
and product using battery charger.
n To reduce risk of injury, charge only nickel-cadmium
type rechargeable batteries. Other types of batteries
may burst, causing personal injury and damage.
n Do not expose charger to wet or damp conditions.
n Use of an attachment not recommended or sold by the
battery charger manufacturer may result in a risk of fire,
electric shock, or injury to persons.
n To reduce risk of damage to charger body and cord,
pull by charger plug rather than cord when disconnecting charger.
n Make sure cord is located so that it will not be stepped
on, tripped over, or otherwise subjected to damage or
stress.
n An extension cord should not be used unless abso-
lutely necessary. Use of improper extension cord could
result in a risk of fire and electric shock. If extension
cord must be used, make sure:
a. That pins on plug of extension cord are the same
number, size and shape as those of plug on charger.
b. That extension cord is properly wired and in good
electrical condition; and
c. That wire size is large enough for AC ampere rating
of charger as specified below:
Cord Length (Feet) 25' 50' 100'
Cord Size (AWG) 16 16 16
NOTE: AWG = American Wire Gage
n Do not operate charger with a damaged cord or plug.
If damaged, have replaced immediately by a qualified
serviceman.
n Do not operate charger if it has received a sharp blow,
been dropped, or otherwise damaged in any way; take
it to a qualified serviceman.
n Do not disassemble charger; take it to a qualified
serviceman when service or repair is required. Incorrect
reassembly may result in a risk of electric shock or fire.
n To reduce risk of electric shock, unplug the charger
from outlet before attempting any maintenance or
cleaning. Turning off controls will not reduce this risk.
n Disconnect charger from power supply when not in
use.
n Risk of electric shock. Do not touch uninsulated por-
tion of output connector or uninsulated battery terminal.
n Save these instructions. Refer to them frequently and
use them to instruct others who may use this unit. If
you loan someone this unit, loan them these instructions also.
6
SYMBOLS
Important: Some of the following symbols may be used on your tool. Please study them and learn their meaning. Proper
interpretation of these symbols will allow you to operate the tool better and safer.
SYMBOL NAME EXPLANATION
V Volts Voltage
A Amperes Current
Hz Hertz Frequency (cycles per second)
W Watt Power
min Minutes Time
Alternating Current Type or a characteristic of current
Direct Current Type or a characteristic of current
n
Class II Construction Designates Double Insulated Construction tools
.../min Revolutions or Reciprocation Per Minute Revolutions, strokes, surface speed, orbits etc.
Safety Alert Symbol Indicates danger, warning or caution. It means
Wet Conditions Alert Do not ex pose to rai n or use in damp
Read Your Operator’s Manual Your manual contains special messages to bring
Wear Eye, Hearing, and Head Protection Wear eye protection which is marked to comply
Wear Safety Footwear Wear non-slip safety footwear when using this
Wear Gloves Wear non-slip, heavy-duty protective gloves when
0
No Load Speed Rotational speed, at no load
per minute
attention!!! Your safety is involved.
locations.
attention to potential safety concerns, machine
damage as well as helpful operating and servicing
information. Please read all the information carefully to avoid injury and machine damage.
with ANSI Z87.1 as well as hearing and head protection when operating this equipment.
equipment.
handling the pruner.
Keep Children and Pets Away Danger- Keep children and pets away.
Beware of Kickback DANGER! Beware of kickback.
7
SYMBOLS
Important: Some of the following symbols may be used on your tool. Please study them and learn their meaning.
Proper interpretation of these symbols will allow you to operate the tool better and safer.
SYMBOL NAME EXPLANATION
SAFE-T-TIP The SAFE-T-TIP® nose guard on your bar nose
prevents rotational kickback.
Bar nose contact Avoid bar nose contact.
Holding saw Hold saw properly with both hands.
WARNING:
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 tool operation, always wear safety goggles
or safety glasses with side shields and a full face shield when needed. We recommend Wide
Vision Safety Mask for use over eyeglasses or standard safety glasses with side shields. Always
wear eye protection which is marked to comply with ANSI Z87.1.
The purpose of safety symbols is to attract your attention to possible dangers. The safety symbols, and the explanations
with them, deserve your careful attention and understanding. The safety warnings do not by themselves eliminate
any danger. The instructions or warnings they give are not substitutes for proper accident prevention measures.
SYMBOL 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. It may also be used to alert against unsafe practices that may cause property
damage.
NOTE: Advises you of information or instructions vital to the operation or maintenance of the equipment.
SAVE THESE INSTRUCTIONS
NOTE: Save these instructions. Refer to them frequently and use them to instruct others who may use this unit. If you loan
someone this unit, loan them these instructions also.
8
FEATURES
PRODUCT SPECIFICATIONS
Motor......................................................................................................................................................................18 Volt DC
Bar Length......................................................................................................................................................................10 in.
Charger Input .......................................................................................................................................120 V, 60 Hz, AC only
Charge Rate .................................................................................................................................................................1 Hour
Replacement Bar Part Number ..................................................................................................... 671256002 or 671667002
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.
SCABBARD
CHAIN OIL
TANK CAP
REAR
HANDLE
BAR
SAFE-T-TIP
®
CHAIN
HAND GUARD
FRONT HANDLE
TRIGGER RELEASE
BUTTON
BATTERY PACK
(NOT INCLUDED)
BATTERY PACK
(NOT INCLUDED)
HEX KEY
HEX KEY
STORAGE AREA
9
TRIGGER
Fig. 5
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