woodmizer D42 Guide

D42 Engine
Safety, Operation, Maintenance
& Parts Manual
L T 7 0 S / M M H r e v . C 2 . 0 0
LT70S/M DH rev.C7.02
LT70L DH rev.B7.02
Safety is our #1 concern! Read and understand all
safety information and instructions before operating,
setting up or maintaining this machine.
Form #916_80
!

2 D42doc063022
Table of Contents Section-Page
SECTION 1 OPERATION 1-1
1.1 Starting The Engine................................................................................1-1
SECTION 2 MAINTENANCE 2-1
2.1 Safety......................................................................................................2-1
2.2 Cooling System ........................................................................................... ............. 2-2
2.3 Air Filter & Pre-Cleaner.............................................................................. ............. 2-3
2.4 Engine Oil & Filter...................................................................................... ............. 2-4
2.5 Fuel Filter .................................................................................................... ............. 2-5
2.6 Battery ......................................................................................................... .............2-7
2.7 Alternator Belt............................................................................................. ............. 2-8
2.8 Radiator Fan Belt Adjustment..................................................................... ............. 2-9
2.9 RPM Adjustments ....................................................................................... ........... 2-10
2.10 Centrifugal Clutches Maintenance .............................................................. ........... 2-13
SECTION 3 REPLACEMENT PARTS 3-1
3.1 Fuel Tank .................................................................................................. ............. 3-1
3.2 Engine Mount Assembly ............................................................................. ............. 3-2
3.3 Engine Assembly......................................................................................... ............. 3-3
3.4 Primary Fuel Filter ...................................................................................... ............. 3-6
3.5 Acceleration/Brake Assembly ..................................................................... ............. 3-7
3.6 Muffler Assembly........................................................................................ ............. 3-9
3.7 Radiator Assembly ...................................................................................... ........... 3-10
3.8 Alternator Assembly.................................................................................... ........... 3-12
3.9 Engine Guards ............................................................................................. ........... 3-14

About This Manual D42doc063022 iii
ABOUT THIS MANUAL
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.
IMPORTANT! Read the sawmill operator’s manual and
engine manufacturer’s manual for instructions and safety
precautions before operating this equipment.
The information and instructions given in this manual do not amend or extend the limited
warranties for the equipment given at the time of purchase.
ENGINE COMPONENTS
!
Serial Number
Radiator
Oil Filter
Starter Motor
Mufler
3h0901
Radiator
Mufler
Serial Number
Starter Motor
Oil Filter

Operation
Starting The Engine
1
1-1 D42doc121820 Operation
SECTION 1 OPERATION
1.1 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. Turn the
key switch off and allow the engine to cool for a period of time before restarting. If the
overheating condition persists, stop operating the engine until the condition is corrected.
The engine will automatically switch to low idle if an overheating condition occurs.
Key Switch Indicator: Lights up when the key is in either the on or accessory (#1 or #3)
position.
Oil Indicator: Lights up if the oil pressure is too low.
Glow Plug Indicator: Lights up after the key has been turned to the on (#1) position.
FIG. 1-1

Operation
Starting The Engine
Operation D42doc121820 1-2
1
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. The exhaust gases of your engine can cause
nausea, delirium and potentially death unless adequate
ventilation is present.
DANGER! Never operate an engine with a fuel or oil leak.
The leaking fuel or oil could potentially come in contact with
hot surfaces and ignite into flames.
WARNING! Be sure the power feed switch is in the neutral
position before turning the key switch to the on (#1) or
accessory (#3) position. This prevents accidental carriage
movement which may cause serious injury or death.
WARNING! Do not operate engine without proper and
operational spark arrester/muffler. Sparks emitted from the
engine exhaust could ignite surrounding materials, causing
serious injury or death.
CAUTION! Do not crank starter for more than 7 seconds at
one time during starting attempts. Damage to the engine
may result.
CAUTION! Let engine idle for 2 minutes before applying
load to prevent engine damage.
1. See the engine manufacturer’s manual for lubricating oil recommendations for specific
temperature ranges.
2. Use the best quality diesel fuel for below freezing starting.
3. Turn the key switch on the control panel to the on (#1) position.
4. Wait until the glow plug indicator goes out.
5. Turn the key switch to the start (#2) position and release.

Operation
Starting The Engine
1
1-3 D42doc121820 Operation
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.

Maintenance
Safety
Maintenance D42doc070721 2-1
2
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. Refer to the manufacturer's manual for complete
maintenance instructions.
2.1 Safety
Use caution when performing maintenance or service to the engine.
DANGER! Always be aware of and take proper protective
measures against rotating shafts, pulleys, fans, etc. Always
stay a safe distance from rotating members and make sure
that loose clothing or long hair does not engage rotating
members resulting in possible injury.
DANGER! Engine components can become very hot during
operation. Avoid contact with any part of a hot engine. The
exhaust components of your engine are especially hot
during and following operation. Contact with hot engine
components can cause serious burns. Therefore, never
touch or perform service functions on a hot engine. Allow
the engine to cool sufficiently before beginning any service
function.
WARNING! Remove the blade before performing any
engine service. Failure to do so may result in serious injury.
WARNING! Always wear proper and necessary safety
equipment when performing service functions. Proper
safety equipment includes eye protection, breathing protec-
tion, hand protection and foot protection.
This symbol identifies the interval (hours of operation) at which each maintenance pro-
cedure should be performed. "AR" signifies maintenance procedures which should be
performed as required.
!
0

Maintenance
Cooling System
2
2-2 D42doc070721 Maintenance
2.2 Cooling System
Clean the radiator fins every 40 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.
CAUTION! Do not spray the radiator with water when the
engine is hot.
CAUTION! Do not open the radiator cap or reservoir cap
when the engine is hot.
Every 8 hours of operation check the coolant level on the coolant reservoir. When engine
is cold the coolant level should be above the LOW level.
For the aluminium radiator use only glycol solution (1l. of glycol concentrate for 1l. of dis-
tilled water).G11 Specifications.
FIG. 2-1
40
8

Maintenance
Air Filter & Pre-Cleaner
Maintenance D42doc070721 2-3
2
2.3 Air Filter & Pre-Cleaner
WARNING! Always wear proper and necessary safety
equipment when performing service functions. Proper
safety equipment includes eye protection, breathing
protection, hand protection and foot protection.
Service the pre-cleaner every four hours of operation. Service by gently shaking excess
sawdust and debris from the foam piece.
Clean the air filter (air cleaner element) and pre-cleaner (element wrapper) every 40
hours of operation. See the engine manual for further instructions.
Replace the air filter (cleaner) every 200 hours of operation.
Replace the pre-cleaner (element wrapper) every 2000 hours of operation.
4
40
200
2000

Maintenance
Engine Oil & Filter
2
2-4 D42doc070721 Maintenance
2.4 Engine Oil & Filter
Check the oil level every 8 hours of operation. Add oil as necessary. See the engine
manual for oil viscosity and grade recommendations.
IMPORTANT! During initial break-in, change the oil and the
oil filter after the first 50 hours and every 200 hours
thereafter. Continue to check oil level every 8 hours of
operation and refill as necessary.
NOTE: Engine in factory is filled with 10W/40 Shell Helix HX7, semi-synthetic oil. The
recommended oil level is 5 liter.
8
200

Maintenance
Fuel Filter
Maintenance D42doc070721 2-5
2
2.5 Fuel Filter
See Figure 2-2. Replace the primary fuel filter and prefilter cartridge every 200 hours.
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. Turn the key to #0 position. Tighten the
bleed screw.
FIG. 2-2
200

Maintenance
Fuel Filter
2
2-6 D42doc070721 Maintenance
See Figure 2-3. 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. 2-3

Maintenance
Battery
Maintenance D42doc070721 2-7
2
2.6 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. Failure to do so will cause
serious injury.1
WARNING! Battery posts, terminals and related accesso-
ries contain lead and lead compounds, chemicals known to
the State of California to cause cancer and reproductive
harm. Wash hands after handling.
1. Battery Council International, copyright 1987
50

Maintenance
Alternator Belt
2
2-8 D42doc070721 Maintenance
2.7 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.
1. Turn the key switch to OFF (#0) and remove the key.
2. Remove the alternator cover.
See Figure 2-4.
3. Loosen the left pivot, right pivot and jam nut.
4. Turn the belt tension adjustment bolt clockwise to tighten the belt, counterclockwise to
loosen the belt. Adjust the bolt until the proper belt tension is achieved.
CAUTION! Do not overtighten the alternator belt. Damage
to the alternator will occur.
5. After the alternator belt has been tensioned, tighten the jam nut. Tighten the left and right
pivots and replace the belt covers.
FIG. 2-4
AR
Jam
Nut
Belt Adjustment
Bolt
5709
Left
Pivot
Right
Pivot

Maintenance
Radiator Fan Belt Adjustment
Maintenance D42doc070721 2-9
2
2.8 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.
1. Turn the key switch to OFF (#0) and remove the key.
2. Remove the radiator covers.
3. Loosen the jam nut ( shown below ).
4. Tension the fan belt properly by hand.
5. Tighten the jam nut and replace the radiator covers.
See Figure 2-5.
FIG. 2-5
AR

Maintenance
RPM Adjustments
2
2-10 D42doc070721 Maintenance
2.9 RPM Adjustments
WARNING! Remove the blade before performing any
engine service. Failure to do so may result in serious injury.
CAUTION! The engine RPM should be adjusted when the
engine is warmed up to its working temperature.
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.
Before checking the RPM, make sure belt and brake tensions are correct (See Sawmill
Maintenance). Also check oil, fuel, and coolant levels.
To adjust brake, set the turnbuckle so that the braking time is about 5-7 seconds.
Make sure the throttle cable does not affect the engine RPM when the blade switch is dis-
engaged. Make sure the cable is not bent or kinked.
1. When the blade switch is disengaged, the throttle cable should be taut but the spring not
extended. When the blade switch is engaged, the throttle spring should extend 1/8" to
1/4" (3-6 mm).
CAUTION! Do not extend the throttle spring over 1/4".
Excessive tension may cause the throttle cable to fail pre-
maturely.
200

Maintenance
RPM Adjustments
Maintenance D42doc070721 2-11
2
See Figure 2-6. Use the adjustments shown below to adjust the engine RPM (3000[±50]
high-end, 1150[±50] idle).
CAUTION! Do not adjust the high-end RPM above 3200.
Doing so may cause damage to the engine.
NOTE: When using the 097779 clutch (with reduced diam-
eter) for hardwood cutting, adjust the high-end RPM at
2900.
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. If necessary, loosen the upper bracket
mounting bolts and adjust the bracket so the cable housing is centered around the cable.
Retighten the upper cable bracket mounting bolts.
FIG. 2-6
Left Adjustment
Bolt
Right Adjustment
Bolt
Turnbuckle

Maintenance
RPM Adjustments
2
2-12 D42doc070721 Maintenance
See Figure 2-7.
CAUTION! Failure to properly center the throttle cable in
the cable housing may result in premature cable wear.
FIG. 2-7
Mounting Bolts
Upper Throttle
Cable Mount
Bracket
Throttle Cable
Housing
Throttle Cable
3H0748-12

Maintenance
Centrifugal Clutches Maintenance
Maintenance D42doc070721 2-13
2
2.10 Centrifugal Clutches Maintenance
Always shut off the engine and allow the sawmill to come to a complete stop before
performing any engine service.
Before replacing the extension springs clean the clutch with compressed air.
The extension springs should be replaced every 250h of operation. Check the clutch
linings and replace them if they are worn to a thickness smaller than 1.5 mm.
Idling r.p.m., brake strap tension and clutch braking time should be checked after every
extension springs replacement.
See Picture 2-8.
Clutch linings and extension springs replacement:
1. Remove retaining ring (Fig.2-7 pos.3) and the cover plate (Fig.2-7 pos.2).
2. Pull out the ilnings and flyweights (Fig.2-7 pos.1).
3. Remove worn linings from the flyweights.
4. Fit new linings and extension springs. The hook opening should be turned outside!
5. Install the cover plate and secure with retaining ring.
PIC. 2-8
250
1
2
3

Maintenance
Centrifugal Clutches Maintenance
2
2-14 D42doc070721 Maintenance
The Seeger-L-circlip is slightly conical in shape and applies a degree of pressure on the
plate. It must be fitted with the radial fingers of the cirlip pressing towars the cover ensur-
ing at the same time that the circlip is fully seated in the hub groove.
CAUTION! Clutches must be fully assembled with the drum
in position and cover plated fastened before the driving
machine is started.