Wood-mizer D42 Safety, Operation, Maintenance & Parts Manual
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Wood-mizer D42 Safety, Operation, Maintenance & Parts Manual

Wood-mizer D42 Safety, Operation, Maintenance & Parts Manual

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D42 Engine
Safety, Operation, Maintenance
& Parts Manual
LT40 Series MH
LT40 Series DH
Safety is our #1 concern! Read and understand
!
all safety information and instructions before oper-
ating, setting up or maintaining this machine.
February 1998
rev. E1.00
rev. E1.00
Form #916

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Summary of Contents for Wood-mizer D42

  • Page 1 D42 Engine Safety, Operation, Maintenance & Parts Manual LT40 Series MH rev. E1.00 LT40 Series DH rev. E1.00 Safety is our #1 concern! Read and understand all safety information and instructions before oper- ating, setting up or maintaining this machine.

  • Page 2: Table Of Contents

    Fuel Tank....................3-1 Engine Mount Assembly ................3-2 Engine Assembly..................3-4 Primary Fuel Filter .................3-6 Throttle Assembly ..................3-7 Muffler Assembly...................3-9 Drive Assembly ..................3-10 Radiator Assembly & D42 Engine Guards ..........3-11 Alternator Assembly................3-13 3.10 Engine Pulley Guards ................3-15 SECTION 4 ELECTRICAL WIRING DIAGRAMS, D42 D42doc061507...
  • Page 3 This manual is provided as a supplement to the equipment manufacturer’s manuals. This ® manual provides information specific to the use of this equipment on the Wood-Mizer sawmill. Refer to the sawmill operator’s manual and manufacturer's manual before attempting to operate this equipment.

  • Page 4: Operation

    Operation Starting The Engine SECTION 1 OPERATION Starting The Engine Control Lights See Figure 1-1. The following indicator lights are located on the sawmill control panel. Alternator Charge Indicator: Lights up if the alternator is not charging the battery. Engine Temperature Indicator: Lights up if the engine is overheating. A circuit breaker assembly in the engine harness will shut the engine off if the engine overheats.
  • Page 5 Operation Starting The Engine Engine Start DANGER! Always be sure the blade is disengaged and all persons are out of the path of the blade before starting the engine. Failure to do so will result in serious injury. DANGER! Operate your engine/machine only in well venti- lated areas.
  • Page 6 Operation Starting The Engine Engine Shutoff CAUTION! A minimum 2 minute idle time is recommended to allow the battery charge and the turbo-charger to cool down before the engine is shut off. Turn the key switch to the off (#0) position. D42doc061507 Operation...

  • Page 7: Maintenance

    Maintenance Safety SECTION 2 MAINTENANCE Refer to the manufacturer’s manual for maintenance intervals and procedures unless oth- erwise instructed in this manual. Follow the manufacturer’s recommendations for dusty conditions. IMPORTANT! This manual only provides information about additional procedures or procedures to be performed at dif- ferent time intervals than found in the manufacturer's manu- als.

  • Page 8: Cooling System

    Maintenance Cooling System Cooling System Clean the radiator fins every 8 hours of operation. Spray the radiator with water from a hose or compressed air to clean sawdust from the radiator fins. Do not use a pressure sprayer. CAUTION! Failure to keep the radiator fins clear of sawdust and/or dirt may cause the engine to overheat resulting in damage to the engine.
  • Page 9 Maintenance Cooling System tilled water). 3h0963 FIG. 2-0 Maintenance D42doc061507...

  • Page 10: Fuel Filter

    Maintenance Fuel Filter Fuel Filter See Figure 2-1. Replace the primary fuel filter cartridge every 1500 hours or one year of operation. After replacing the filter cartridge, loosen the air bleed screw and operate the 1500 fuel pump bail until fuel begins to flow from the valve and is free of air bubbles. Tighten the bleed screw.

  • Page 11: Battery

    Maintenance Battery Battery Check the battery electrolyte level every 50 hours of operation. See manufacturer’s man- ual for instructions. DANGER! Batteries expel explosive gases. Keep sparks, flames, burning cigarettes, or other ignition sources away at all times. Always wear safety goggles and a face shield when working near batteries.

  • Page 12: Alternator Belt

    Maintenance Alternator Belt Alternator Belt The belt tension should be checked after the first 100 hours of operation, when the bat- tery is not charging properly or when the alternator belt is squealing. If the battery contin- ues to not charge properly or the belt continues to squeal after the initial belt adjustment, replace the belt.

  • Page 13: Radiator Fan Belt Adjustment

    Maintenance Radiator Fan Belt Adjustment 6. After the alternator belt has been tensioned, tighten the adjustment bolt jam nut. Tighten the upper and lower pivots and replace the belt covers. Radiator Fan Belt Adjustment The fan belt tension should be checked after the first 100 hours of operation, when the engine is overheating or when the fan belt is squealing.

  • Page 14: Rpm Adjustments

    Maintenance RPM Adjustments RPM Adjustments WARNING! Remove the blade before performing any engine service. Failure to do so may result in serious injury. Check the RPM with a tachometer after the first 20 hours of operation and every 200 hours thereafter. High-end RPM should be 3200 RPM and low-end RPM should be 1500 RPM.
  • Page 15 Maintenance RPM Adjustments 2. Start the engine to measure the low-end RPM. Let idle for 10 minutes. 3. With the engine at idle, check the low-end RPM. Adjust to 1500. To decrease speed, loosen the idle adjustment screw. To increase speed, tighten the idle adjustment screw. See Figure 2-5.
  • Page 16 Maintenance RPM Adjustments See Figure 2-6. Upper Throttle Cable Mount Mounting Bolts Bracket Throttle Cable Throttle Cable Housing 3H0748-12 FIG. 2-6 CAUTION! Failure to properly center the throttle cable in the cable housing may result in premature cable wear. 2-10 D42doc061507 Maintenance...

  • Page 17: Replacement Parts

    Replacement Parts Fuel Tank SECTION 3 REPLACEMENT PARTS Fuel Tank 3H0780 DESCRIPTION Indicates Parts Available In Assemblies Only) PART # QTY. TANK ASSEMBLY, 5 GALLON GREEN DIESEL A12132 Tank, 5 Gallon Green Fuel P12166 Pickup, 9" Fuel P12172 Cap, 3/5 Gallon Fuel Tank P09683 Fitting, 1/4”...

  • Page 18: Engine Mount Assembly

    Replacement Parts Engine Mount Assembly Engine Mount Assembly DESCRIPTION Indicates Parts Available In Assemblies Only) PART # QTY. MOUNT WELDMENT, FRONT KUBOTA ENGINE 097154-1 MOUNT WELDMENT, REAR KUBOTA ENGINE 087945-1 VIBRATION ABSORBER, CLUTCH 090666-1 Bolt, M10X70-8.8 HEX HEAD, ZINC F81003-20 Washer, 3/8"...
  • Page 19 Replacement Parts Engine Mount Assembly BOLT M6x12-8.8-Fe/Zn5 F81001-7 WASHER, 10.2 SPLIT LOCK ZINC F81053-3 BOLT M10x1,25x25-8.8-A-Fe/Zn5 F81003-29 WASHER, 10.2 SPLIT LOCK ZINC F81055-2 BOLT, M8X45 - 8.8 HEX HEAD GRADE 5 F81002-14 WASHER, M8, FLAT ZINC F81054-1 Replacement Parts D42doc061507...

  • Page 20: Engine Assembly

    ENGINE, KUBOTA 1505TE 088022 Turbocharger, Kubota 097738 Belt, Kubota Fan 097739 Radiator Fan 097740 Filter, Kubota D42 Air B53/207 088025 Filter Cartridge, Kubota D42 Air 097741 Filter, Kubota D42 fuel 088024 Filter Cartdridge, Kubota Fuel D42 097742 Filter, Kubota Oil...
  • Page 21 Replacement Parts Engine Assembly Gasket, Kubota Valve Cover 097753 Gasket, Kubota Water Pump 097754 Gasket, Kubota Exhaust Manifold 097755 Glow Plug, Kubota 097756 Injector, Kubota Fuel 097757 Injection Sprayer, Fuel Kubota 097758 Motor, Kubota Starter 097759 Plug, Kubota Oil Drain 097760 Pump, Kubota Fuel Injector 097761...

  • Page 22: Primary Fuel Filter

    Replacement Parts Primary Fuel Filter Primary Fuel Filter 3H0459a DESCRIPTION Indicates Parts Available In Assemblies Only) PART # QTY. FILTER ASSEMBLY, STANDADYNE FUEL FPV-5,7 04WP40/3 088101 FITTING, 3.4/3, 8MM, FILTR FPV-5,7 088094 HOSE, 5/16” ID FUEL R80703-2 9 Ft CLAMP, 11-17MM HOSE F81080-3 BRACKET, DIESEL FUEL FILTER MOUNT 015905...

  • Page 23: Throttle Assembly

    Replacement Parts Throttle Assembly Throttle Assembly 3H0748-4 DESCRIPTION Indicates Parts Available In Assemblies Only) PART # QTY. CABLE, KUBOTA THROTTLE 015857 Spring, Throttle 016033 BOLT, 5/16-18 X 3/4” HEX HEAD F05006-5 NUT, 5/16-18 HEX SELF-LOCKING F05010-20 BRACKET, LOWER THROTTLE CABLE MOUNT 015853 BOLT, M10-1.5 X 25MM HEX HEAD FULL THREAD GRADE 5 F05009-52...
  • Page 24 Replacement Parts Throttle Assembly BOSS, 1/4 X 1/2 X .26” AL-BRONZE 016339 WASHER, .25ID X .62OD X .06THK, PLATED 016175 NUT, 1/4-20 NYLON LOCK F05010-69 NUT, 1/4-20 NYLON LOCK F05010-69 NUT, 5/16-18 SELF-LOCKING HEX F05010-20 BOLT, 5/16-18 X 1 1/4” HEX HEAD FULL THREAD F05006-18 NUT, 5/16-18 HEX LOCK F05010-6...

  • Page 25: Muffler Assembly

    Replacement Parts Muffler Assembly Muffler Assembly 80_103 DESCRIPTION Indicates Parts Available In Assemblies Only) PART # QTY. MUFFLER, KUBOTA ENGINE 088100 BOLT, M8X40-8.8 HEX HEAD FULL THREAD ZINC F81002-15 WASHER, 8.2 ZINC SPLIT LOCK F81054-4 NUT, M8 HEX WELD F81032-3 Replacement Parts D42doc061507...

  • Page 26: Drive Assembly

    Replacement Parts Drive Assembly Drive Assembly 3H0748-9B DESCRIPTION Indicates Parts Available In Assemblies Only) PART # QTY. SHAFT, KUBOTA POWER 087953 SHEAVE, 5V X 4.46” POLY V (GAS/DIESEL) 085921 BUSHING, SH X 1 7/16” 085714 BELT, 3BX72 014085 BRACKET, DRIVE BELT SUPPORT 016364 BOLT, 3/8-16 X 1”...

  • Page 27: Radiator Assembly & D42 Engine Guards

    Replacement Parts Radiator Assembly & D42 Engine Guards Radiator Assembly & D42 Engine Guards DESCRIPTION Indicates Parts Available In Assemblies Only) PART # QTY. RADIATOR, KUBOTA D42 ENGINE 097148 RADIATOR GUARD, KUBOTA D42 ENGINE 097201-1 BOLT M6X16 8.8 FE/ZN5 F81001-15...
  • Page 28 Replacement Parts Radiator Assembly & D42 Engine Guards RADIATOR JOINT, METAL-RUBBER 088183 NUT, M8,HEXAGON,NYLON LOCK ZINC F81032-2 FRONT RADIATOR BRACKET, PTD 097154-1 BOLT M10-1.5X50MM H/H PART/THR G5 ZINC F81003-29 WASHER, M10 SPLIT LOCK ZINC F81055-2 BOLT, M6X12MM HEX HEAD ZINC...

  • Page 29: Alternator Assembly

    Replacement Parts Alternator Assembly Alternator Assembly 13 14 3H0748-7C DESCRIPTION Indicates Parts Available In Assemblies Only) PART # QTY. WIRE ASSEMBLY, 61/140 AMP ALTERNATOR PLUG 015969 ALTERNATOR ASSEMBLY, 140 AMP 023730 Alternator, 140 Amp 023695 Pulley, 140 Amp Alternator 023694 BRACKET, ALTERNATOR SUPPORT 015923 WASHER, 10.5 SAE FLAT...
  • Page 30 Replacement Parts Alternator Assembly WASHER, 8.2 SPLIT LOCK F81054-4 WASHER, 8.4 SAE FLAT F81054-1 WASHER, 10.2 SPLIT LOCK F81055-2 WASHER, 6.5 SAE FLAT F81053-11 BOLT, M10 X 1.25 X 25MM HEX HEAD F81003-29 BELT, 6PK1080 FIBERGLASS ALTERNATOR 088181 GUARD WELDMENT, ALTERNATOR BELT 093470-1 BOLT, M6X12-8.8 HEX HEAD F81001-7...

  • Page 31: 3.10 Engine Pulley Guards

    Replacement Parts Engine Pulley Guards 3.10 Engine Pulley Guards 3H0748-8C DESCRIPTION Indicates Parts Available In Assemblies Only) PART # QTY. GUARD WELDMENT, KUBOTA ENGINE PULLEY 095086-1 BOLT, M6x12-8.8 HEX HEAD F81001-7 WASHER, 6,5 ZINC F81053-11 Replacement Parts D42doc061507 3-15...

  • Page 32: Electrical Wiring Diagrams, D42

    Electrical Information SECTION 4 ELECTRICAL WIRING DIAGRAMS, D42 IMPORTANT! When using a sawmill with the rewired con- trol panel it is very important not to switch between saw head forward/backward movement until the saw head stops. Failure to do so may result in serious sawmill dam- age.
  • Page 33 PCB1 BROWN Power Feed PCB VIOLET +12V SOL3 SOL2 SOL4 SOL5 SOL1 SW 07 Fwd/Rev Switch Up/Down Switch OUT2 ENKODER MSK320 OUT1 GND W1 W2 Blade Guide Feed Rate Pot Switch Hourmeter Board Return FIG. 4-1 D42 CONTROL BOX DIAGRAM).
  • Page 36 FIG. 4-4 D42 CONTROL BOX DIAGRAM (VARIABLE REVERS MOVEMENT SPEED).
  • Page 37 M otor 2 1 AW G Bl a c k Fus e Bo x S O L10 Ne g ative Co n tac t H y d ra u lic M ills O n ly FIG. 4-5 D42 HYDRAULIC DIAGRAM.
  • Page 38 Component List It e m Mf g . P a r t N o . Mf g . Woo d -M iz e r De s c ri p t i o n Pa r t N o . 023 73 0 W o o d - M iz e r 0 23 73 0 A lter n a to r, 14 0 A m p...

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