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
LT60/70
LT60HD/70HD
LT80HD
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. A1.00-A3.00
rev. A1.00- A3.00
rev. A1.00-A3.00
Form #916

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Summary of Contents for Wood-mizer D42

  • Page 1 D42 Engine Safety, Operation, Maintenance & Parts Manual LT60/70 rev. A1.00-A3.00 LT60HD/70HD rev. A1.00- A3.00 LT80HD rev. A1.00-A3.00 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

    RPM Adjustments ..................2-8 SECTION 3 REPLACEMENT PARTS Fuel Tank....................3-1 Engine Mount Assembly ................3-2 Engine Assembly..................3-3 Primary Fuel Filter .................3-5 Acceleration/Brake Assembly ..............3-6 Muffler Assembly...................3-8 Radiator Assembly .................3-9 Alternator Assembly................3-10 Engine Guards ..................3-12 SECTION 4 ELECTRICAL WIRING DIAGRAMS, D42 D42doc102703 Table of Contents...
  • 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 to recover before the engine is shut off. Turn the key switch to the off (#0) position. D42doc102703 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: Fuel Filter

    Maintenance Fuel Filter Fuel Filter See Figure 2-1. Replace the primary fuel filter and prefilter cartridge every 200 hours. 1500 After replacing any of the two filter cartridges, loosen the air bleed screw on the main filter and turn the key switch on the control panel to #1 position and wait until fuel begins to flow from the valve and is free of air bubbles.
  • Page 10 Maintenance Fuel Filter See Figure 2-2. Inspect the water separator bowl on the prefilter periodically and drain the bowl as required by turning the drain cap counterclockwise as viewed from the bot- tom. FIG. 2-2 D42doc102703 Maintenance...

  • 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 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. If the engine continues overheat- ing or the belt continues to squeal after the initial belt adjustment, replace the belt.

  • 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 3000 RPM and low-end RPM should be 1150 RPM.
  • Page 15 Maintenance RPM Adjustments CAUTION! Do not adjust the high-end RPM above 3200. Doing so may cause damage to the engine. 2. After the RPM settings are made, shut the engine off. Tighten the throttle cable by engag- ing the blade switch. Check the throttle cable at the upper cable mounting bracket. The cable should be centered in the cable housing.
  • Page 16 Maintenance RPM Adjustments 2-10 D42doc102703 Maintenance...

  • Page 17: Replacement Parts

    Replacement Parts Fuel Tank SECTION 3 REPLACEMENT PARTS Fuel Tank 3H0780 DESCRIPTION (u 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

    Engine Mount Assembly Engine Mount Assembly 3H0902 DESCRIPTION (u Indicates Parts Available In Assemblies Only) PART # QTY. MOUNT WELDMENT, REAR D42 ENGINE 089468-1 MOUNT WELDMENT, FRONT D42 ENGINE 089459-1 BOLT, M10X1.25X25-8.8-A HEX HEAD FULL THREAD ZINC F81003-29 WASHER, 10.2 ZINC SPLIT...

  • Page 19: Engine Assembly

    (u Indicates Parts Available In Assemblies Only) PART # QTY. ENGINE, KUBOTA 1505TE 088022 Belt, Kubota Fan #16282-97010 028514 Filter, Kubota D42 Air B53/207(16617-11001) 088025 Filter, Kubota D42 Fuel D52/184(16616-43001) 088024 Filter, Kubota Oil #16271-32090 018050 Gasket Kit, Kubota Lower #07916-29265...
  • Page 20 Replacement Parts Engine Assembly Pump, Kubota Fuel Injector #16060-51010 028540 Pump, Kubota Fuel Transfer #16285-52032 028517 Pump, Kubota Water #16241-73032 028525 Radiator Parts (See Section 1.5) Sending Unit, Kubota Heat Senser #TM9A230RQCG 028510 Solenoid, Kubota Stop #17454-60010 028523 Switch, Kubota Oil Pressure #15841-39010 028547 Thermostat, Kubota #19434-73010 028546...

  • Page 21: Primary Fuel Filter

    Replacement Parts Primary Fuel Filter Primary Fuel Filter 3H0459PL DESCRIPTION (u Indicates Parts Available In Assemblies Only) PART # QTY. FILTER ASSEMBLY, STANDADYNE FUEL FPV-5,7 04WP40/3 088101 Filter, Standadyne Fuel Cartridge #31865 015898 FITTING, 8MM, FILTR FPV-5,7 088094 HOSE, 5/16” ID FUEL R80703-2 CLAMP, 11-17MM HOSE F81080-3...

  • Page 22: Acceleration/Brake Assembly

    Replacement Parts Acceleration/Brake Assembly Acceleration/Brake Assembly 80_102 DESCRIPTION (u Indicates Parts Available In Assemblies Only) PART # QTY. ACCELERATION/BRAKE ASSEMBLY, D42 088936 Grommet, 20/13 Rubber 086188 Fitting, M6 Straight Grease 086280 Bolt, M10x1.25x25-8.8-A Hex Head Full Thread Zinc F81003-29 Washer, 10.5 Zinc Flat...
  • Page 23 Replacement Parts Acceleration/Brake Assembly Pin, 3.2x25 Zinc Cotter F81043-4 Pin, B 6X35/30 Clevis W/Head Zinc F81045-4 Washer, 6.4 Zinc Flat F81053-1 Pin, 1.6x16 Zinc Cotter F81040-1 Plate, Brake Strap Mount 088946-1 Actuator, LA1 S12-17A-08-01 Linear 089428 Strap, K140ER Clutch/Brake 088935 Bolt, M5x16 -8.8 Hex Head Full Thread Zinc F81000-20 Washer, 5.3 Zinc Flat...

  • Page 24: Muffler Assembly

    Replacement Parts Muffler Assembly Muffler Assembly 80_103 DESCRIPTION (u 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 D42doc102703 Replacement Parts...

  • Page 25: Radiator Assembly

    Replacement Parts Radiator Assembly Radiator Assembly DESCRIPTION (u Indicates Parts Available In Assemblies Only) PART # QTY. RADIATOR ASSEMBLY, D42 A21/349(16292-72001) 088023 GUARD, KUBOTA RADIATOR FRONT 087967-1 BRACKET, RADIATOR MOUNT 088083-1 GUARD, KUBOTA RADIATOR REAR 088126-1 BOLT, M6X12-8.8 HEX HEAD FULL THREAD ZINC F81001-7 WASHER, 6.5 FLAT ZINC...

  • Page 26: Alternator Assembly

    Replacement Parts Alternator Assembly Alternator Assembly 80_104 DESCRIPTION (u Indicates Parts Available In Assemblies Only) PART # QTY. ALTERNATOR, 190A (FOR LT60) 089466 BELT, 6PK 775 ALTERNATOR 089465 PLATE, D190 ALTERNATOR BELT TENSIONER 088933-1 WASHER, SPECIAL 088932-1 BOLT, M10X90-8.8-B HEX HEAD ZINC F81003-66 BOLT, M10X80-8.8 HEX HEAD ZINC F81003-51...
  • Page 27 Replacement Parts Alternator Assembly BOLT, M10 SPECIAL 089472-1 BOLT, M8X90-8.8 HEX HEAD FULL THREAD ZINC F81002-16 WASHER, 8.4 ZINC FLAT F81054-1 BLOCK, ALTERNATOR BELT TENSIONER 089473-1 GUARD, 190A ALTERNATOR 089491-1 BOLT, M8X20-8.8-B HEX HEAD FULL THREAD ZINC F81002-4 WASHER, 8.4 ZINC FLAT F81054-1 NUT, M8-8-B HEX NYLON ZINC LOCK F81032-2...

  • Page 28: Engine Guards

    Guard, Left Side Painted 088985-1 Guard Weldment, Front Upper Painted 089496-1 Guard, Front Lower Painted 088988-1 Guard Weldment, Rear Painted 088980-1 Guard, D42 Main Drive Belt Side Painted 088983-1 Bolt, M6x12-8.8 Hex Head Full Thread Zinc F81001-7 3-12 D42doc102703 Replacement Parts...
  • Page 29 Replacement Parts Engine Guards Washer, 6.4 Zinc Flat F81053-1 BOLT, M10X25-8.8 HEX HEAD FULL THREAD ZINC F81003-11 WASHER, 10.5 ZINC FLAT F81055-1 NUT, M10-8-B HEX NYLON ZINC LOCK F81033-1 Replacement Parts D42doc102703 3-13...
  • Page 30 Replacement Parts Engine Guards 3-14 D42doc102703 Replacement Parts...

  • Page 31: 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 32 D42 (Overhead View) 089428 Radiator Auto Clutch 14 AWG Black 14 AWG White 14 AWG Red 12 AWG Black 6 AWG Red 16 AWG Yellow 16 AWG White 16 AWG Green 16 AWG Gray FIG. 4-1 D42 WIRING DIAGRAM (LT60/70/80 SAWMILLS).
  • Page 33 FIG. 4-2 D42 CONTROL BOX DIAGRAM).
  • Page 35 FIG. 4-4 D42 CONTROL BOX DIAGRAM (VARIABLE REVERS MOVEMENT SPEED).
  • Page 36 Mo tor M otor 1 M otor 2 1 AW G Bl a c k Fus e Bo x S O L10 Ne gative Co n tac t H y drau lic M ills O nly FIG. 4-5 D42 HYDRAULIC DIAGRAM.
  • Page 37 D42doc102703 Electrical Information...

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