Husqvarna T540XP Mark III Workshop Manual
  1. Manuals
  2. Brands
  3. Husqvarna Manuals
  4. Chainsaw
  5. T540XP Mark III
  6. Workshop manual
Husqvarna T540XP Mark III Workshop Manual

Husqvarna T540XP Mark III Workshop Manual

Hide thumbs Also See for T540XP Mark III:
Table of Contents

Advertisement

Quick Links

Download this manual
Workshop manual
T540XP Mark III
English
1790 - 001 - 19.04.2023

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the T540XP Mark III and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Husqvarna T540XP Mark III

Summary of Contents for Husqvarna T540XP Mark III

  • Page 1 Workshop manual T540XP Mark III English 1790 - 001 - 19.04.2023...

  • Page 2: Table Of Contents

    2.4 Symbols on the product......... 4 7.12 Lubrication system..........26 2.5 Cutting equipment safety........5 7.13 Air filter............... 27 7.14 Husqvarna connectivity device......28 3 Prepare and do servicing on the product 7.15 Carburetor............28 3.1 Maintenance schedule........... 6 7.16 Start/stop switch..........32 7.17 Fuel tank............

  • Page 3: Introduction

    1.5 Servicing tools The manual gives information about necessary servicing tools. Always use original tools from Husqvarna. 1790 - 001 - 19.04.2023 Introduction - 3...

  • Page 4: Safety

    2 Safety 2.1 Safety definitions • Wear protective gloves when you replace the crankshaft bearings. The crankcase halves are hot, Warnings, cautions and notes are used to point out risk of burn injuries. specially important parts of the manual. • Make sure that the chain brake is engaged when you remove the pressure spring on the chain brake.

  • Page 5: Cutting Equipment Safety

    Fuel. Chain oil. Both of the operator's hands must be used to operate the chainsaw. Never operate the chainsaw holding it with one hand only. Never let the guide bar tip come in contact with any object. Warning! Kickback may occur when the nose or tip of the guide bar touches an object, and cause a lightning fast reverse reaction, kicking the guide bar up and...

  • Page 6: Prepare And Do Servicing On The Product

    3 Prepare and do servicing on the product 3.1 Maintenance schedule Maintenance Before After 100 After 40 h operation Clean the external surfaces. After each operation. Clean the muffler, exhaust pipe and engine from dirt and unwanted lubricant. After each operation. Make sure that the saw chain does not move at idle speed.

  • Page 7: Servicing Data

    4 Servicing data 4.1 Servicing data ■ Lubricate with two-stroke oil. ● Lubricate with grease. ▲ Lubricate with chain oil. 13–15 Nm 13mm 2x 2.5–3.5 Nm 6x 2.0–3.0 Nm 3.0–4.0 Nm 4x 3.5–4.5 Nm 5.0–7.0 Nm 1.0–1.5 Nm 4x 2.0–3.0 Nm 1.0–1.5 Nm 3.0–4.0 Nm 5.0–6.0 Nm...
  • Page 8 2x 7.0–9.0 Nm 22.0– 25.0 Nm 12 mm 2x 6.0–8.0 Nm 2x 2.0–3.0 Nm 12.0–14.0 Nm 7x 7.0–9.0 Nm 16 mm 1.0–1.5 Nm 1.1–1.7 Nm 4x 7.0–9.0 Nm 2x 6.0–8.0 Nm 8 - Servicing data 1790 - 001 - 19.04.2023...

  • Page 9: Servicing Tools

    5 Servicing tools 5.1 Servicing tools 0. 3 1790 - 001 - 19.04.2023 Servicing tools - 9...
  • Page 10 Item Description Article num- Piston stop To lock the crankshaft. 521 54 83-01 Fuel filter hook To pull out the fuel filter from the tank. 502 50 83-01 Mandrel To remove the flywheel. 502 51 94-01 To do a check of the product and install updates to the firm- 598 07 28-02 ware.

  • Page 11: Function Overview

    For best results and performance use Husqvarna two- stroke oil. If Husqvarna two-stroke oil is not available, use a two- stroke oil of good quality for aircooled engines. Speak to your servicing dealer to select the correct oil.

  • Page 12: Repair Instructions

    7 Repair instructions 7.1 Product overview 1. Air filter cover 18. Muffler 2. Air filter 19. Clutch drum 3. Spark plug cap 20. Oil pump adjustment screw 4. Vibration element 21. Chain catcher 5. Air purge bulb 22. Chain brake and front hand guard 6.

  • Page 13: To Connect The Product To The

    7.3 To connect the product to the 7.4 Chain brake Note: It can be necessary to install firmware to a new 7.4.1 To remove the front handguard spare part. Make sure that you know the of the new spare parts before you connect the product to the . The WARNING: Make sure that the chain brake is found on the spare part.
  • Page 14 7.4.2 To install the front handguard 7.4.3 To disassemble and assemble the chain brake 1. Push the lever and install the front handguard. WARNING: Make sure that the chain brake spring does not eject and cause injury. Use protective goggles. 1.

  • Page 15: Chain Catcher

    5. Remove the chain brake spring. 7.4.4 To clean and examine the chain brake a) Hold one hand on the chain brake spring. Use 1. Carefully clean and examine all parts of the chain the other hand to push a small screwdriver in brake.

  • Page 16: Muffler

    7.6 Muffler 7.5.2 To replace the spiked bumper 1. Remove the clutch cover. 7.6.1 To remove and install the muffler 2. Remove the 2 screws, the chain catcher and the WARNING: Do not touch a hot muffler. Risk of spiked bumper. burn injuries.

  • Page 17: Handles

    4. Remove the screw and pull out the spark arrester 7.7.2 To remove and install throttle trigger and screen. throttle trigger lockout To remove 1. Remove the right handle half. Refer to and install the right handle half on page 17 . 2.
  • Page 18 6. Install in the opposite sequence. 3. Remove the throttle wire from the wire bracket and the carburetor. 7.7.3 To remove and install the front handle To remove 1. Remove the right handle half. Refer to and install the right handle half on page 17 . 2.

  • Page 19: Starter

    7.8 Starter 5. Remove the screw (A) and remove the pulley (B). 7.8.1 To disassemble the starter unit WARNING: Use protective glasses. The recoil spring can eject from the starter pulley and cause injury. 1. Loosen the 4 screws that hold the starter housing. 2.

  • Page 20: Ignition System

    11. Pull the starter rope until 1 cm of the spring guide Note: If the starter rope is broken in the starter rope is shown. At the same time, assemble the starter handle, push the starter handle cover down. Use handle cover.
  • Page 21 7. Remove the start/stop switch. Refer to and install the start/stop switch on page 32 . damage to the ignition system. Only use spark plugs recommended by Husqvarna, refer to the To remove and 8. Remove the carburetor. Refer to operator's manual.
  • Page 22 7.9.4 To install the ignition module 3. Put a air gap gauge between the ignition module and the flywheel. Tighten the screw to the correct 1. Install the the ignition cable. Make sure that the Servicing tools on page 9 . torque.

  • Page 23: Flywheel

    11. Install the starter unit and the air conductor. Refer to 9. Remove the flywheel nut. To disassemble the starter unit on page 19 . 12. Install the clutch cover. 7.10 Flywheel 7.10.1 To remove the flywheel 1. Remove the starter unit (A). 10.
  • Page 24 13. Remove the mandrel and the flywheel. 6. Make sure that you install the springs in the correct position, as shown in the illustration. 7.10.2 To install the flywheel 1. Clean the crankshaft. 2. Put the flywheel on the crankshaft. Turn the flywheel until the key goes into the key slot on the shaft.

  • Page 25: Centrifugal Clutch

    7.11 Centrifugal clutch 11. Install in the opposite sequence. 7.11.2 To clean and examine the centrifugal clutch 7.11.1 To remove and install the centrifugal clutch 1. Measure the diameter of the clutch shoes across the 1. Disengage the chain brake. full clutch hub.

  • Page 26: Lubrication System

    4. Lubricate the needle bearing with a grease gun. Use 5. Remove 4 screws, the chain guide plate (A), the engine oil or a bearing grease of high quality. muffler cover (B) and the cover for the pump housing (C). 6.

  • Page 27: Air Filter

    7.12.2 To disassemble and examine the lubrication b) Turn the adjustment screw counterclockwise to increase the chain oil flow. system To remove 1. Remove the lubrication system. Refer to and install the lubrication system on page 26 . 2. Remove the pin (A), the adjustment screw (B) and the spring (C).

  • Page 28: Husqvarna Connectivity Device

    Device. ® 7.14.1 To install the Husqvarna Connectivity Device ® Do the steps that follow to install the Husqvarna Connectivity Device. For more information about ® the Husqvarna Connectivity Device, refer to www.husqvarna.com. 1. Remove the screw and open the plastic cover.
  • Page 29 ® 3. Remove the service connector (A). 7. Loosen the connector for the Husqvarna Connectivity Device. 8. Remove the carburetor. 4. Remove the screw that hold the choke assembly (B). 5. Remove the 2 screws on the carburetor. 9. Disconnect the throttle wire.
  • Page 30 10. Disconnect the connectors on the carburetor. 3. Remove the 4 screws (A) and the 4 washers (B). 11. Remove the suction hose (C) from the carburetor. 12. Install in the opposite sequence. 7.15.2 To disassemble the carburetor To remove and 1.
  • Page 31 8. Remove the screw (R) and the throttle plate (S). 7.15.3 To clean and examine the carburetor 1. Clean all parts in clean gasoline. Use compressed air to dry the gasoline. Point the air through all channels in the carburetor housing and make sure that the channels are not blocked.

  • Page 32: Start/Stop Switch

    7.16 Start/stop switch 3. Connect the pressure tester to the fuel inlet on the carburetor. Increase the pressure to 50kPa. Refer to Servicing tools on page 9 . 7.16.1 To remove and install the start/stop switch To remove 1. Remove the right handle half. Refer to and install the right handle half on page 17 .

  • Page 33: Fuel Tank

    7.17 Fuel tank 9. Remove the tank unit. 7.17.1 To remove and install the tank unit 1. Drain the fuel tank. 2. Remove the clutch cover and front hand guard. To remove the front handguard on page 13 . Refer to To remove and 3.
  • Page 34 4. Remove the suction hose (B) and the return hose (C) from the air purge bulb. 5. Install in the opposite sequence. 7.17.6 Air pressure in the fuel tank The two-way tank valve has a controlled opening pressure in the two directions. The controlled opening prevents positive pressure or vacuum in the fuel tank, and fuel leakage.

  • Page 35: Vibration Damping System

    7.18 Vibration damping system 7.19 Cylinder and piston 7.18.1 To disassemble and assemble the vibration 7.19.1 To remove the cylinder and piston damping system To disassemble 1. Remove the starter unit. Refer to the starter unit on page 19 . To remove 2.
  • Page 36 8. Remove the 2 screws and the cover for the ignition 12. Remove the 2 screws. cable. 13. Remove the cylinder cover. 9. Remove the 2 screws and the ignition module. To remove and install 14. Remove the muffler. Refer to the muffler on page 16 .
  • Page 37 16. Put a cover on the crankcase opening. 7.19.2 To clean the cylinder and piston 1. Clean the piston crown. 17. Use pointed pliers to remove the snap ring (A). Keep your thumb on the snap ring to make sure that it 2.
  • Page 38 7.19.5 To examine the piston rings 1. Examine the piston rings for damage. 2. Replace damaged piston rings. 7.19.6 Piston damages Score marks on the piston Incorrect carburetor setting. Too high speed. Too low octane fuel. The fuel has a too low octane grade. Carbon build-up Incorrect carburetor setting.
  • Page 39 7.19.7 To install the cylinder and piston 8. Put a new cylinder base gasket on the crankcase. 1. Put a cover on the crankcase opening. 2. Lubricate the needle bearing (A) and put it into the connecting rod. Make sure the bearing moves freely in the connecting rod.
  • Page 40 13. Install the cylinder cover. 16. Install the cover for the ignition cable. 14. Install the 2 screws. 17. Install the spark plug. 18. Connect the spark plug cap to the spark plug. 19. Install the inlet pipe and make sure that the inlet plate (H) is in the correct position.

  • Page 41: Crankshaft And Crankcase

    22. Install the the lubrication system. Refer to 7. Loosen the screws on the muffler and attach the remove and install the lubrication system on page outlet cover with the muffler screws. Refer to 26 . Servicing tools on page 9 . To remove and 23.
  • Page 42 To replace the 6. Remove the chain catcher. Refer to 5. Remove the 2 seal rings. chain catcher on page 15 . To remove 7. Remove the centrifugal clutch. Refer to and install the centrifugal clutch on page 25 . To remove 8.
  • Page 43 7.20.3 To clean and examine the crankshaft and a) On the clutch side. crankcase CAUTION: Make sure that dirt and unwanted particles do not go into the crankcase and into the bearings. Clean all components and remove gasket particles from the mating surfaces of the crankcase halves.

  • Page 44: Guide Bar Bolts

    3. Install the 2 guide bushings in the crankcase half on 4. Hit the guide bar bolt until it fall into the oil tank. the flywheel side. 5. Remove the guide bar bolt from the oil tank. 4. Attach the gasket (A) to one of the crankcase half on the clutch side.

  • Page 45: To Repair A Damaged Thread

    3. Pull the steel wire to pull out the guide bar bolt. If you have a PL5 screw, use a 6.1 mm diameter drill bit. 2. Attach the thread insert with the sharp part of the thread insert first. 4. Make sure that the square head of the guide bar bolt is correctly attached in the oil tank.

  • Page 46: Troubleshooting

    8 Troubleshooting 8.1 Troubleshooting Symptom Possible causes Recommended step The product does not start. The air filter is dirty. Clean or replace the air filter. The choke is damaged or worn. Repair or replace the choke. Leakage or dirt in the fuel hose. Clean the or replace fuel hose.
  • Page 47 Symptom Possible causes Recommended step The engine rpm don not increase at The air filter is dirty. The air filter is dirty. full throttle. The tank valve is damaged. Replace the tank valve. Leakage or dirt in the fuel hose. Clean the or replace fuel hose.

  • Page 48: Technical Data

    9 Technical data 9.1 Technical data Husqvarna Engine Cylinder displacement, cm 39.1 Idle speed, rpm 3000 Maximum engine power acc. to ISO 8893, kW/hp @ rpm 1.9/2.6@10200 Ignition system Spark plug NGK CMR7H Electrode gap, mm 0.65 Fuel and lubrication system Fuel tank capacity, liter/cm 0.31/310...
  • Page 49 1790 - 001 - 19.04.2023 Technical data - 49...
  • Page 50 50 - Technical data 1790 - 001 - 19.04.2023...
  • Page 51 1790 - 001 - 19.04.2023 Technical data - 51...
  • Page 52 1142978-26 2023-05-04...

Table of Contents