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

ASSEMBLY

UNPACKING

This product has been shipped completely assembled.

n Carefully remove the tool and any accessories from the

box. Make sure that all items listed in the packing list are
included.

n Inspect the tool carefully to make sure no breakage or

damage occurred during shipping.

n Do not discard the packing material until you have care-

fully inspected and satisfactorily operated the tool.

n If any parts are damaged or missing, please call

1-800-525-2579 for assistance.

PACKING LIST

Cordless Chain Saw with Scabbard

Wrench

Bar and Chain Oil

Lanyard (not included in combo)

Operator’s Manual

Warranty Registration Card

WARNING:

If any parts are missing do not operate this tool until the
missing parts are replaced. Failure to do so could result
in possible serious personal injury.

WARNING:

Do not attempt to modify this tool or create accesso­ries not recommended for use with this tool. 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
tool when assembling parts.

OPERATION

WARNING:

Do not allow familiarity with tools 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 tools. Failure to do so could re­sult in objects being thrown into your eyes, resulting in
possible serious injury.

WARNING:

Do not use any attachments or accessories not recom­mended by the manufacturer of this tool. The use of at­tachments or accessories not recommended can result
in serious personal injury.

APPLICATIONS

You may use this tool for the following purposes:

n Limbing and pruning branches from trees.

n Felling small trees up to 5 in. (127 mm) diameter.

n Bucking the fallen tree into shorter lengths.

CAUTION:

To prevent damage to the battery pack, remove the
battery pack from the charger immediately if no LED
comes on. Return the battery pack and charger to your
nearest service center for checking or replacing. Also,
if you are removing the battery pack from the charger
and no LEDs are on, return both the battery pack and
the charger to your nearest service center. Do not insert
another battery pack into the charger. A damaged charger
may damage a battery pack.

10

OPERATION

LED FUNCTIONS OF CHARGER
LED WILL BE ON TO INDICATE STATUS OF

CHARGER AND BATTERY PACK:

See Figure 6.

n Red LED on = Fast charging mode.
n Green LED on = Fully charged and in maintenance charge

mode.

n Green LED on = When battery pack is inserted into

charger, indicates hot battery pack or that battery pack
is out of normal temperature range.

n Yellow and Green LEDs on = Deeply discharged or

defective battery pack.

n No LED on = Defective charger or battery pack.

CHARGING THE BATTERY PACK

The battery pack for this tool has been shipped in a low
charge condition to prevent possible problems. Therefore,
you should charge it until the green LED on the front of the
charger comes on.

NOTE: Batteries will not reach full charge the first time they
are charged. Allow several cycles (operation followed by
recharging) for them to become fully charged.

CHARGING A COOL BATTERY PACK

If battery pack is within normal temperature range, the red
LED on charger will come on.

NOTE: If the charger does not charge the battery pack
under normal circumstances, return both the battery pack and
charger to your nearest Ryobi Authorized Service Center for
electrical check.

n Charge the battery pack only with a recommended

charger.

n Make sure the power supply is normal household

voltage, 120 volts, 60 Hz, AC only.

n Connect the charger to the power supply.

n Place the battery pack in the charger aligning raised rib

on the battery pack with the groove in the charger.

n Press down on the battery pack to be sure contacts on

the battery pack engage properly with contacts in the
charger.

n Normally the red LED on charger will come on. This

indicates the charger is in fast charging mode.

n Red LED should remain on for approximately 1 hour

then the green LED will come on. Green LED on
indicates battery pack is fully charged and charger is
in maintenance charge mode.

NOT E: Th e gre en LE D wi l l rem ain on unt il th e

battery pack is removed from the charger or charger is
disconnected from the power supply.

n If both yellow and green LEDs come on, this indi-

cates a deeply discharged or defective battery pack.
Allow the battery pack to remain in the charger for 15
to 30 minutes. When the battery pack reaches normal
voltage range, the red LED should come on. If the
red LED does not come on after 30 minutes, this may
indicate a defective battery pack and should be
replaced.

n After normal usage, a minimum of 1 hour of charging time

is required to fully recharge battery pack.

n The battery pack will become slightly warm to the

touch while charging. This is normal and does not
indicate a problem.

n Do not place the charger and battery pack in an area of

extreme heat or cold. They will work best at normal room
temperature.

NOTE: The charger and battery pack should be placed

in a location where the temperature is more than 50°F
but less than 100°F.

n When batteries become fully charged, unplug the

charger from power supply and remove the battery
pack.

BATTERY PACK

CHARGER

P110

YELLOW

LIGHT

n RED LIGHT “ON” INDICATES FAST CHARGING MODE
n YELLOW AND GREEN LIGHTS “ON” INDICATES

CONTROL CHARGE OR POSSIBLE FAULTY BATTERY

n GREEN LIGHT “ON” INDICATES FULLY CHARGED

GREEN

LIGHT

RED LIGHT

Fig. 6

11

OPERATION

CHARGING A HOT BATTERY PACK

When using the tool continuously, the batteries in the battery
pack will become hot. You should let a hot battery pack cool
down for approximately 30 minutes before attempting to
recharge. When the battery pack becomes discharged and
is hot, this will cause the green LED to come on instead of
the red LED. After 30 minutes, reinsert the battery pack in
the charger. If the green LED continues to remain on, return
battery pack to your nearest Ryobi Authorized Service Center
for checking or replacing.

NOTE: This situation only occurs when continuous use of
the tool causes the batteries to become hot. It does not
occur under normal circumstances. Refer to “CHARGING
A COOL BATTERY PACK” for normal recharging of batter­ies. If the charger does not charge your battery pack under
normal circumstances, return both the battery pack and
charger to your nearest Ryobi Authorized Service Center
for electrical check.

TO INSTALL BATTERY PACK

See Figure 7.

n Place the battery pack in your chain saw. Align raised

rib on battery pack with groove in chain saw’s battery
port.

n Make sure the latches on each side of the battery pack

snap in place and that battery pack is secured in chain
saw before beginning operation.

CHAIN OIL SYSTEM

See Figure 8.

n Use Homelite Bar and Chain Oil. It is formulated to

perform over a wide temperature range with no dilution
required.

NOTE: Do not use dirty, used or otherwise contaminated

oils. Damage may occur to the bar or chain.

n Carefully pour the bar and chain oil into the tank.

n Check and fill the oil tank when battery is recharged, or

as needed.

n Depress the oil tank cap several times to pump the oil to

the chain before starting the saw.

n Depress the oil tank cap every 20-30 seconds while cut-

ting to keep the chain lubricated.

NOTE: It is normal for oil to seep from the saw when not
in use. To prevent seepage, empty the oil tank after each
use. When storing the unit for a long period of time (three
months or longer) be sure the chain is lightly lubricated; this
will prevent rust on the chain and bar sprocket.

TO REMOVE BATTERY PACK

See Figure 7.
Locate latches on side of battery pack and depress both

sides to release the battery pack from the chain saw.

CAUTION:

When placing battery pack in your chain saw, be sure
raised rib on battery pack aligns with groove in chain
saw's battery port and latches snap in place properly.
Improper assembly of battery pack can cause damage
to internal components.

CAUTION:

Remove battery pack from unit. Fill oil tank with Homelite
Bar and Chain Oil before starting the chain saw. Failure
to lubricate the chain will cause damage to the bar and
chain.

BATTERY

PORT

LATCHES

BATTERY

PACK

Fig. 7

Fig. 8

12

OPERATION

STARTING AND STOPPING THE CHAIN SAW

See Figure 9.

WARNING:

Keep body to the left of the chain line. Never straddle
the saw or chain, or lean over past the chain line.

STARTING THE CHAIN SAW

n Place the chain saw on a flat bare surface and make sure

no objects or obstructions are in immediate vicinity which
could come in contact with the bar and chain.

n Press and hold the trigger release button. This makes the

trigger operational.

n Press and hold the trigger, release the trigger release

button and continue to squeeze the trigger for continued
operation.

STOPPING THE CHAIN SAW

n Release the trigger to stop the chain saw.

n Upon release of the trigger, the trigger release button will

be automatically reset to the lock position.

This cordless chain saw is not designed for cutting trees
larger than 5 in. (127 mm) in diameter.

This cordless chain saw is designed for limbing and pruning
type cutting, as well as cutting trees up to 5 in. (127 mm) in
diameter only.

Do not attempt to make any cut that would require removal
of the SAFE-T-TIP®.

TRIGGER RELEASE

BUTTON

TRIGGER

TRIGGER RELEASE

BUTTON

PREPARATION FOR CUTTING

PROPER GRIP ON HANDLES

See Figures 10 - 12.

Refer to “Important Safety Instructions” earlier in this manual
for appropriate safety equipment.

n Wear non-slip gloves for maximum grip and protection.

n Hold the saw firmly with both hands. Always keep your

left hand on the front handle and your right hand on the
rear handle so that your body is to the left of the chain
line.

TRIGGER

Fig. 9

13

OPERATION

WARNING:

Never use a left-handed (cross-handed) grip, or any
stance which would place your body or arm across the
chain line.

n Maintain a proper grip on the saw whenever the unit is

running. The fingers should encircle the handle and the
thumb is wrapped under the handlebar. This grip is least
likely to be broken (by a kickback or other sudden reaction
of the saw). Any grip in which the thumb and fingers are
on the same side of the handle, is dangerous because a
slight kick of the saw can cause loss of control.

WARNING:

Do not operate the throttle trigger with your left hand
and hold the front handle with your right hand. Never
allow any part of your body to be in the chain line while
operating a saw.

Fig. 10

CHAIN LINE

Fig. 11

Fig. 12

14

OPERATION

PROPER CUTTING STANCE

See Figure 13.

n Weight should be balanced with both feet on solid

ground.

n Keep left arm with elbow locked in a "straight arm" posi-

tion to withstand any kickback force.

n Your body should always be to the left of the chain line.

n Thumb should be on underside of handlebar.

BASIC CUTTING PROCEDURE

Practice cutting a few small logs using the following tech­nique to get the "feel" of using the saw before you begin a
major sawing operation.

n Take the proper stance in front of the wood with the saw

off.

n Squeeze the trigger and let the chain accelerate to full

speed before entering the cut.

n Begin cutting with the saw against the log.

n Keep the unit running the entire time you are cutting,

maintain a steady speed.

n Allow the chain to cut for you; exert only light downward

pressure. If you force the cut, damage to the bar, chain,
or unit can result.

n Release the trigger as soon as the cut is completed, al-

lowing the chain to stop. If you run the saw without a
cutting load, unnecessary wear can occur to the chain,
bar, and unit.

n Do not put pressure on the saw at the end of the cut.

CHAIN LINE

STRAIGHT ARM

POSITION

Fig. 13

n Always cut with both feet on solid ground to prevent be-

ing pulled off balance.

n Do not cut above chest height, as a saw held higher is

difficult to control against kickback forces.

n Do not fell trees near electrical wires or buildings. Leave

this operation for professionals.

n Cut only when visibility and light are adequate for you to

see clearly.

TREE FELLING

Unusual Hazardous Tree Felling Conditions

Do not fell trees during periods of high wind or heavy precipi­tation. Wait to do your cutting until the hazard has ended.

WORK AREA PRECAUTIONS

n Cut only wood or materials made from wood, no sheet

metal, no plastics, no masonry, no non-wood building
materials.

n Never allow children to operate the saw. Allow no person

to use this chain saw who has not read this Operator's
Manual or received adequate instructions for the safe
and proper use of this chain saw.

n When felling a tree, keep everyone - helpers, bystanders,

children, and animals - a safe distance from the cutting
area. During felling operations, the safe distance should
be a least twice the height of the largest trees in the felling
area. During bucking operations, keep a minimum distance
of 15 feet (4.5 m) between workers.Trees should not be
felled in a manner that would endanger any person, strike
any utility line or cause any property damage. If the tree
does make contact with any utility line, the utility company
should be notified immediately.

WARNING:

Do not cut down trees having an extreme lean or large
trees that have rotten limbs, loose bark, or hollow trunks.
Have these trees pushed or dragged down with heavy
equipment, then cut them up.

WARNING:

Do not cut trees near electrical wires or buildings.

WARNING:

Check the tree for damaged or dead branches that could
fall and hit you during felling.

15

OPERATION

WARNING:

Periodically glance at the top of the tree during the
backcut to assure the tree is going to fall in the desired
direction.

WARNING:

If the tree starts to fall in the wrong direction, or if the
saw gets caught or hung up during the fall, leave the saw
and save yourself!

n Felling a tree - When bucking and felling operations are

being performed by two or more persons, at the same
time, the felling operation should be separated from the
bucking operation by a distance of at least twice the
height of the tree being felled. Trees should not be felled
in a manner that would endanger any person, strike any
utility line or cause any property damage. If the tree does
make contact with any utility line, the utility company
should be notified immediately.

n Before any cuts are started, pick your escape route (or

routes in case the intended route is blocked); clear the
immediate area around the tree and make sure there are
no obstructions in your planned path of retreat. Clear path
of safe retreat approximately 135° from planned line of
fall. The retreat path should extend back and diagonally
to the rear of the expected line of fall. See Figure 14.

n Before felling is started, consider the force and direction

of the wind, the lean and balance of the tree, and the lo­cation of large limbs. These things influence the direction
in which the tree will fall. Do not try to fell a tree along a
line different from its natural line of fall.

n The chain saw operator should keep on the uphill side

of the terrain as the tree is likely to roll or slide downhill
after it is felled.

n Remove dirt, stones, loose bark, nails, staples, and wire

from the tree where felling cuts are to be made.

n Notched Undercut. Cut a notch about 1/3 the diameter

of the tree, perpendicular to the direction of fall. Make the
cuts of the notch so they intersect at a right angle to the
line of fall. This notch should be cleaned out to leave a
straight line. To keep the weight of the wood off the saw,
always make the lower cut of the notch before the upper
cut. See Figure 15.

PLANNED LINE OF FALL

90°

SAFE

RETREAT

ZONE

PLANNED PATH OF SAFE RETREAT 135° FROM PLANNED LINE

OF FALL

SAFE

RETREAT

ZONE

90°

SAFE

RETREAT

ZONE

Fig. 14

NOTCH -

APPROX. 1/3

TRUNK

PLANNED

LINE OF FALL

135°

45°

45°

135°

HINGE

2 IN. (5 CM) OR 1/10 DIA

DIAMETER OF

16

BACK CUT

2 IN. (5 CM)

Fig. 15

OPERATION

n Felling Backcut. The backcut is always made level and

horizontal, and at a minimum of 2 inches (5 cm) above
the horizontal cut of the notch. See Figures 15 - 16.

n Never cut through to the notch. Always leave a band of

wood between the notch and backcut (approximately 2
inches (5 cm) or 1/10 the diameter of the tree). This is
called "hinge" or “hingewood.” It controls the fall of the
tree and prevents slipping or twisting or shoot-back of
the tree off the stump. See Figures 15 - 16.

n On large diameter trees, stop the back cut before it is

deep enough for the tree to either fall or settle back on
the stump. Then insert soft wooden or plastic wedges
into the cut so they do not touch the chain. The wedges
can be driven in, little by little, to help jack the tree over.

See Figure 17.

NOTE: When bucking or felling with a wedge, it may

be necessary to remove the SAFE-T-TIP® anti-kickback
device to allow the bar to be drawn through the cut.
After the cut is complete, the tip should be reinstalled
immediately.

n As tree starts to fall, stop the chain saw and put it down

immediately. Retreat along the cleared path, but watch
the action in case something falls your way. Be alert for
overhead limbs or branches that may fall and watch your
footing.

n Sometimes it is impossible to avoid pinching (with just

standard cutting techniques) or difficult to predict which
way a log will settle when cut. To avoid pinching while
cutting, rotate or move the log so that the pinch is elimi­nated.

NOTCH

BACK CUT

HINGE

Fig. 16

WARNING:

Never cut through to the notch when making a backcut.
The hinge controls the fall of the tree, this is the section
of wood between the notch and backcut.

BUCKING

See Figures 18 - 21.

Bucking is the term used for cutting a fallen tree to the de­sired log length.

n Always make sure your footing is secure and your weight

is distributed evenly on both feet.

n Cut only one log at a time.
n Support small logs on a saw horse or another log while

bucking.

n Keep a clear cutting area. Make sure that no objects

can contact the guide bar nose and chain during cutting,
this can cause kickback. To avoid the danger, keep the
SAFE-T-TIP® anti-kickback device attached while cutting.
Refer to “Precautions Against Kickback” earlier in this
manual.

n When bucking on a slope, always stand on the uphill side

of the log. To maintain complete control of the chain saw
when cutting through the log, release the cutting pressure
near the end of the cut without relaxing your grip on the
chain saw handles. Do not let the chain contact the ground.
After completing the cut, wait for the saw chain to stop
before you move the chain saw. Always stop the motor
before moving from tree to tree.

WEDGE

KICKBACK

Fig. 17

Fig. 18

Fig. 19

17

OPERATION

BUCKING LOGS UNDER STRESS

See Figures 20 - 21.

When the log is supported along its entire length, it should
be cut from the top or overbucking.

When the log is supported on one end, cut 1/3 the diameter
from the underside or underbucking. Then make the finishing
cut by overbucking to meet the first cut.

As the log is being cut, it will tend to bend. The saw can
become pinched or hung in the log if you make the first cut
deeper than 1/3 of the diameter of the log.

Give special attention to logs under stress to prevent the
bar and chain from pinching.

When bucking on a slope, always stand on the uphill side
of the log as shown in Figure 19. When “cutting through,”
to maintain complete control of the chain saw, release the
cutting pressure near the end of the cut without relaxing your
grip on the chain saw handles. Do not let the chain contact
the ground. After completing the cut, wait for the saw chain
to stop before you move the chain saw. Always stop the

motor before moving from tree to tree. See Figure 19.

TYPES OF CUTTING USED

See Figure 21.

LOG SUPPORTED AT ONE END:

LOAD

FINISHING CUT

1ST CUT

1/3 DIA

LOG SUPPORTED AT BOTH ENDS:

LOAD

1ST CUT 1/3 DIA

OVERBUCKING

Begin on the top side of the log with the bottom of the saw
against the log; exert light pressure downward. Note that

the saw will tend to pull away from you.

UNDERBUCKING

Begin on the under side of the log with the top of the saw
against the log; exert light pressure upward. During under­bucking, the saw will tend to push back at you. Be pre-

pared for this reaction and hold the saw firmly to maintain
control.

WARNING:

Never climb into a tree to limb or prune. Do not stand on
ladders, platforms, a log, or in any position which can
cause you to lose your balance or control of the saw.

FINISHING CUT

OVERBUCKING

UNDERBUCKING

Fig. 20

Fig. 21

18

OPERATION

2

4

1

3

LIMBING

See Figure 22.

Limbing is removing branches from a fallen tree.

n Work slowly, keeping both hands on the chain saw with

a firm grip. Always make sure your footing is secure and
your weight is distributed evenly on both feet.

n Leave the larger support limbs under the tree to keep the

tree off the ground while cutting.

n Limbs should be cut one at a time. Remove the cut limbs

from the work area often to help keep the work area clean
and safe.

n Branches under tension should be cut from the bottom

up to avoid binding the chain saw.

n Keep the tree between you and the chain saw while limb-

ing. Cut from the side of the tree opposite the branch you
are cutting.

PRUNING

See Figure 23.

Pruning is trimming limbs from a live tree.

n Work slowly, keeping both hands on the chain saw with

a firm grip. Always make sure your footing is secure and
your weight is distributed evenly on both feet.

n Do not cut from a ladder, this is extremely dangerous.

Leave this operation for professionals.

n Do not cut above chest height as a saw held higher is

difficult to control against kickback.

n When pruning trees it is important not to make the finishing

cut next to the main limb or trunk until you have cut off
the limb further out to reduce the weight. This prevents
stripping the bark from the main member.

n Underbuck the branch 1/3 through for your first cut.

n Your second cut should overbuck to drop the branch

off.

n Now make your finishing cut smoothly and neatly against

the main member so the bark will grow back to seal the
wound.

WARNING:

If the limbs to be pruned are above chest height, hire a
professional to perform the pruning.

CUT LIMBS ONE AT A TIME AND LEAVE SUPPORT LIMBS

UNDER TREE UNTIL LOG IS CUT

Fig. 22

LOAD

FIRST CUT

1/3 DIAMETER

FINISHING CUT

SECOND CUT

Fig. 23

SPRINGPOLE

Fig. 24

WARNING:

Springpoles are dangerous and could strike the operator,
causing the operator to lose control of the chain saw. This
could result in severe or fatal injury to the operator.

SPRINGPOLES

See Figure 24.

A springpole is any log, branch, rooted stump, or sapling
which is bent under tension by other wood so that it springs
back if the wood holding it is cut or removed. On a fallen
tree, a rooted stump has a high potential of springing back
to the upright position during the bucking cut to separate
the log from the stump. Watch out for springpoles, they
are dangerous.

19

MAINTENANCE

R

E

C

Y

C

L

E

1

.

8

0

0

.

8

2

2

.

8

8

3

7

R B R C

N i

C d

™

WARNING:

When servicing, use only identical Ryobi replacement
parts. Use of any other parts may create a hazard or
cause product damage.

WARNING:

Always wear safety goggles or safety glasses with side
shields during power tool operation or when blowing
dust. If operation is dusty, also wear a dust mask.

WARNING:

To avoid serious personal injury, always remove the
battery pack from the tool when cleaning or performing
any maintenance.

BATTERIES

The battery pack for this tool is equipped with nickel-cadmium
rechargeable batteries. Length of service from each charging
will depend on the type of work you are doing.

The batteries in this tool have been designed to provide
maximum trouble-free life. However, like all batteries, they
will eventually wear out. Do not disassemble battery pack
and attempt to replace the batteries. Handling of these
batteries, especially when wearing rings and jewelry, could
result in a serious burn.

To obtain the longest possible battery life, we suggest the
following:

n Remove the battery pack from the charger once it is fully

charged and ready for use.

For battery storage longer than 30 days:

n Store the battery pack where the temperature is below

80°F.

n Store battery packs in a "discharged" condition.

GENERAL MAINTENANCE

Avoid using solvents when cleaning plastic parts. Most
plastics are susceptible to damage from various types of
commercial solvents and may be damaged by their use. Use
clean cloths to remove dirt, dust, oil, grease, etc.

WARNING:

Do not at any time let brake fluids, gasoline, petroleum­based products, penetrating oils, etc., come in contact
with plastic parts. Chemicals can damage, weaken or
destroy plastic which may result in serious personal
injury.

Only the parts shown on the parts list are intended to be
repaired or replaced by the customer. All other parts should
be replaced at a Ryobi Authorized Service Center.

BATTERY PACK REMOVAL AND
PREPARATION FOR RECYCLING

To preserve natural resources, please
re cycle or disp ose of ba tteri es
properly.

This product contains nickel-cadmium
batteries. Local, state or federal laws
may prohibit disposal of nickel-cadmium
batteries in ordinary trash.

Consult your local waste authority for information regarding
available recycling and/or disposal options.

WARNING:

Up on re moval, cover th e batt ery pa ck’s termi­nals with heavy-duty adhesive tape. Do not at­tempt to destroy or disassemble battery pack or
remove any of its components. Nickel-cadmium
batteries must be recycled or disposed of properly. Also,
never touch both terminals with metal objects and/or
body parts as short circuit may result. Keep away from
children. Failure to comply with these warnings could
result in fire and/or serious injury.

20

MAINTENANCE

REPLACING BAR AND CHAIN

See Figures 25 - 29.

WARNING:

Remove the battery pack from the chain saw and make
sure the chain has stopped before you do any work on
the saw. Failure to do so may result in accidental starting
and possible serious injury

WARNING:

The safety instructions in this section are to protect the
user from serious personal injury.

SPROCKET

ADJUSTING

PIN

BAR

WASHER

CAUTION:

Always wear gloves when handling the bar and chain;
these components are sharp and may contain burrs.

WARNING:

Never touch or adjust the chain while the motor is running.
The saw chain is very sharp; always wear protective
gloves when performing maintenance to the chain to
avoid possible serious lacerations.

n Remove the battery pack before you do any work on the

chain saw.

n Remove the hex key from the storage area and use it to

remove the chain cover screw, washer and chain cover
from the chain saw.

n Remove the bar and chain from the mounting surface.

n Remove the old chain from the bar.

n Lay out the new saw chain in a loop and straighten any

kinks. The cutters should face in the direction of chain
rotation. If they face the opposite direction, turn the loop
over.

n Place the chain drive links into the bar groove. Position

the chain so there is a loop at the back of the bar. Hold
the chain in position on the bar and place the loop around
the sprocket of the chain saw. Fit the bar flush against
the mounting surface so that the bar stud is in the long
slot of the bar.

NOTE: When placing the bar on the bar stud, assure that

the adjusting pin is in the chain tension pin hole.

RECOMMENDED BAR AND CHAIN
COMBINATIONS

Bar Part Number - 10 in. (254 mm)

671256002 or 671667002

Chain Part Number

6958301 or 690583002

CHAIN TENSION

PIN HOLE

CHAIN DRIVE

LINKS

GROOVE

CHAIN

BAR

CHAIN

COVER

CHAIN

COVER

SCREW

Fig. 25

Fig. 26

CHAIN

TENSIONING

SCREW

Fig. 27

21

MAINTENANCE

n Replace the chain cover, washer and chain cover screw.

Tighten the chain cover screw finger tight only. The bar
must be free to move for tension adjustment.

n Remove all the slack from the chain by turning the chain

tensioning screw clockwise until the chain seats snugly
against the bar with the drive links in the bar groove.

n Lift the tip of the guide bar up to check for sag. Release

the tip of the guide bar and turn the chain tensioning
screw 1/2 turn clockwise. Repeat this process until sag
does not exist.

n Hold the tip of the guide bar up and tighten the bar mount-

ing screw securely.

n Chain is correctly tensioned when there is no sag on the

underside of the guide bar, the chain is snug, but it can
be turned by hand without binding.

NOTE: If chain is too tight, it will not rotate. Loosen the

chain cover screw slightly and turn tension adjuster 1/4
turn counterclockwise. Lift the tip of the guide bar up
and retighten chain cover screw securely. Assure that
the chain will rotate without binding.

n Place the hex key back into the storage area.

LIFT THE TIP OF
THE GUIDE BAR

UP TO CHECK FOR

SAG

Fig. 28

CHAIN TENSION

See Figures 30 - 31.

n Stop the engine before setting the chain tension. Make

sure the guide bar screw is loosened to finger tight, turn
the chain tensioner clockwise to tension the chain. Refer
to “Replacing the Bar and Chain” earlier in this manual
for additional information.

A cold chain is correctly tensioned when there is no slack

on the underside of the guide bar, the chain is snug, but
it can be turned by hand without binding.

n Chain must be re-tensioned whenever the flats on the

drive links hang out of the bar groove.

n During normal saw operation, the temperature of the chain

will increase. The drive links of a correctly tensioned warm
chain will hang approximately .050 in. (1.25 mm) out of
the bar groove.

NOTE: New chain tends to stretch, check chain tension
frequently and tension as required.

CAUTION:

Chain tensioned while warm, may be too tight upon
cooling. Check the “cold tension” before next use.

FLATS

APPROX. .050 (1.25

HEX KEY

Fig. 29

Fig. 31

Fig. 30

22

MAINTENANCE

CHAIN MAINTENANCE

See Figures 32 - 33.

CAUTION:

Remove the battery pack and make sure the chain has
stopped before you do any work on the saw.

TOP PLATE

RIVET HOLE

CUTTING

CORNER

SIDE PLATE

DEPTH GAUGE

Use only low-kickback chain on this saw. This fast-cutting
chain will provide kickback reduction when properly main­tained.

For smooth and fast cutting, chain needs to be maintained
properly. The chain requires sharpening when the wood chips
are small and powdery, the chain must be forced through the
wood during cutting, or the chain cuts to one side. During
maintenance of your chain, consider the following:

n Improper filing angle of the side plate can increase the

risk of a severe kickback.

n Raker (depth gauge) clearance.

n Too low increases the potential for kickback.

n Not low enough decreases cutting ability.

n If cutter teeth have hit hard objects such as nails and

stones, or have been abraded by mud or sand on the
wood, have service dealer sharpen chain.

NOTE: Inspect the drive sprocket for wear or damage when
replacing the chain. If signs of wear or damage are present
in the areas indicated, have the drive sprocket replaced by
a Ryobi Service dealer.

HOW TO SHARPEN THE CUTTERS

See Figures 34 - 35.

Be careful to file all cutters to the specified angles and to
the same length, as fast cutting can be obtained only when
all cutters are uniform.

n Wear gloves for protection. Properly tension the chain

prior to sharpening. Refer to “Chain Tension Section”
earlier in this manual. Do all of your filing at the mid-point
of the bar.

n Use a 5/32 in. diameter round file and holder.

n Keep the file level with the top plate of the tooth. Do not

let the file dip or rock.

n Using light but firm pressure, stroke towards the front

corner of the tooth.

n Lift file away from the steel on each return stroke.

n Put a few firm strokes on every tooth. File all left hand

cutters in one direction. Then move to the other side and
file the right hand cutters in the opposite direction. Oc­casionally remove filings from the file with a wire brush.

HEEL

GULLET

CHECK FOR WEAR

OR DAMAGE

LEFT HAND

CUTTERS

RIGHT HAND

CUTTERS

TOE

Fig. 32

Fig. 33

Fig. 34

Fig. 35

23

MAINTENANCE

WARNING:

Improper chain sharpening increases the potential of
kickback.

WARNING:

Failure to replace or repair damaged chain can cause
serious injury.

WARNING:

The saw chain is very sharp, always wear protective gloves
when performing maintenance to the chain.

TOP PLATE FILING ANGLE

See Figure 36.

n CORRECT 30° - File holders are marked with guide marks

to align file properly to produce correct top plate angle.

n LESS THAN 30° - For Cross Cutting.

n MORE THAN 30° - Feathered Edge Dulls Quickly.

SIDE PLATE ANGLE

See Figure 37.

n CORRECT - 80

eter file is used in file holder.

n HOOK - “Grabs” and dulls quickly. Increases potential

of KICKBACK.

Results from using a file with diameter too small, or file

held too low.

n BACKWARD SLOPE - Needs too much feed pressure,

causes excessive wear to bar and chain.

Results from using a file with diameter too large, or file

held too high.

o

Produced automatically if correct diam-

CORRECT TOP PLATE

FILING ANGLE

CORRECT SIDE

PLATE FILING

ANGLE

30°

80°

INCORRECT TOP PLATE FILING

ANGLE

LESS

THAN 30°

INCORRECT SIDE PLATE

FILING ANGLE

HOOK

RAKER CLEARANCE

.025 in. (0.6 mm)

MORE

THAN 30°

BACKWARD

SLOPE

Fig. 36

Fig. 37

Fig. 38

DEPTH GAUGE CLEARANCE

See Figure 38.

n The depth gauge should be maintained at a clearance of

.025 in. (0.6 mm). Use a depth gauge tool for checking
the depth gauge clearances.

n Every time the chain is filed, check the depth gauge clear-

ance.

24

MAINTENANCE

Use a Flat File and a Depth Gauge Jointer to lower all
gauges uniformly. Depth gauge jointers are available in
.020 in. to .035 in. (0.5 mm to 0.9 mm). Use a .025 in. (0.6
mm) depth gauge jointer. After lowering each depth gauge,
restore original shape by rounding the front. Be careful not
to damage adjoining drive links with the edge of the file.

See Figures 39 - 40.

Depth gauges must be adjusted with the flat file in the same
direction the adjoining cutter was filed with the round file.
Use care not to contact cutter face with flat file when ad­justing depth gauges.

GUIDE BAR MAINTENANCE

See Figure 41.
When the guide bar shows signs of wear, reverse it on the

saw to distribute the wear for maximum bar life. The bar
should be cleaned every day of use and checked for wear
and damage.

Feathering or burring of the bar rails is a normal process
of bar wear. Such faults should be smoothed with a file as
soon as they occur.

A bar with any of the following faults should be replaced.

n Wear inside the bar rails which permits the chain to lay

over sideways.

n Bent guide bar.

n Cracked or broken rails.

n Spread rails.

In addition, guide bars with a sprocket at their tip must be
lubricated weekly with a grease syringe to extend the guide
bar life. Using a grease syringe, lubricate weekly in the lu­bricating hole.

Turn the guide bar and check that the lubrication holes and
chain groove are free from impurities.

n Replace the SAFE-T-TIP® on the bar nose.

NOTE: The locking tab fits in the recessed hole in the

bar.

n Tighten the screw with your finger.

n From the finger-tight position, tighten the screw an ad-

ditional 3/4 of a turn using a wrench.

DEPTH GAUGE JOINTER

FLAT FILE

Fig. 39

RESTORE ORIGINAL

SHAPE BY ROUNDING

THE FRONT

Fig. 40

REVERSING THE GUIDE BAR

See Figures 41 - 43.

n Remove the SAFE-T-TIP® mounting screw.

n Remove the SAFE-T-TIP® from the bar.

n Remove the chain from the bar and turn the bar over.

NOTE: Bottom of bar should not be on top.

n Replace the chain on the bar. Refer to “Assembling the

Bar and Chain” earlier in this manual for specific infor­mation.

LUBRICATING HOLE

Fig. 41

25

MAINTENANCE

CAUTION:

Remove the battery pack and make sure the chain has
stopped before you do any work on the saw.

WARNING:

Although the guide bar comes with a SAFE-T-TIP® anti­kickback device already installed, you need to check the
tightness of the mounting screw before each use.

SAFE-T-TIP® NOSE GUARD MAINTENANCE

See Figures 42 - 43.

Tighten the mounting screw of the nose guard as instructed
below. These are specially hardened screws. If the screw
cannot be installed tightly, replace both the screw and the
SAFE-T-TIP® before further operation. Do not replace with
an ordinary screw.

In addition to preventing chain contact with solid objects at
the nose of the bar, the SAFE-T-TIP® also helps keep the
chain away from abrasive surfaces such as the ground. Keep
it on the right hand side of the bar, where it will be between
the chain and the ground during flush with ground cutting.

The mounting screw requires a 5/16 in. wrench (or adjust­able wrench) to achieve the recommended tightness of 35
to 45 in. lb. (4-5 Nm). A tightness within this range can be
achieved by the following method.

n Tighten the screw with your finger.

n From the finger-tight position, tighten the screw an ad-

ditional 3/4 of a turn using a wrench.

MOUNTING SAFE-T-TIP® NOSE GUARD

See Figures 42 - 43.

n Mount the SAFE-T-TIP® on the bar nose.

NOTE: The tab fits in the recessed hole in the bar.

n Tighten the screw with your finger.

n From the finger-tight position, tighten the screw an ad-

ditional 3/4 of a turn using a wrench.

SAFE-T-TIP

TIGHTEN 3/4

OF A TURN

MOUNTING SCREW

LOCKING RIVET

®

Fig. 42

Fig. 43

TRANSPORTING AND STORING

See Figure 44.

n Do not store or transport the chain saw when it is running.

The chain saw should always be idle before storing or
transporting.

n Always place the guide bar scabbard on the bar and chain

before storing or transporting the chain saw. Use caution
to avoid the sharp teeth of the chain.

n Clean the chain saw thoroughly before storing. Store the

chain saw indoors, in a dry place that is locked and/or
inaccessible to children.

n Keep away from corrosive agents such as garden chem-

icals and de-icing salts.

Fig. 44

26

TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

Bar and chain running hot
and smoking.

Motor runs, but chain is
not rotating.

IF THESE SOLUTIONS DO NOT SOLVE THE PROBLEM CONTACT YOUR AUTHORIZED SERVICE DEALER.

1. Check chain tension for
over tight condition

2. Chain oil tank empty.

1. Chain tension too tight.

2. Check guide bar and chain
assembly.

3. Check guide bar and chain
for damage.

1. Tension chain. Refer to “Chain Tension”
earlier in this manual.

2. Check oil tank.

1. Retension chain, Refer to “Chain
Tension” earlier in this manual.

2. Refer to “Assembling the Bar and
Chain” earlier in this manual.

3. Inspect guide bar and chain for
damage.

27

OPERATOR'S MANUAL

18 VOLT

CORDLESS CHAIN SAW
P540

• SERVICE

Now that you have purchased your tool, should a need ever exist for repair parts or
service, simply contact your nearest Ryobi Authorized Service Center. Be sure to provide
all pertinent facts when you call or visit. Please call 1-800-525-2579 for your nearest Ryobi
Authorized Service Center. You can also check our web site at www.ryobitools.com for a
complete list of Authorized Service Centers.

• MODEL NO. AND SERIAL NO.

The model number of this tool will be found on a plate attached to the motor housing.
Please record the model number and serial number in the space provided below.

• HOW TO ORDER REPAIR PARTS

When ordering repair parts, always give the following information:

• MODEL NUMBER

• SERIAL NUMBER

RYOBI TECHNOLOGIES, INC.

1428 Pearman Dairy Road, Anderson, SC 29625

Post Office Box 1207, Anderson, SC 29622-1207

P540

Phone [phone]

www.ryobitools.com

983000-538

6-05