woodmizer D42 Guide

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.
February 1998 Form #916
!

2 D42doc102703 Table of Contents
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 Fuel Filter ...............................................................................................2-3
2.4 Battery ....................................................................................................2-5
2.5 Alternator Belt........................................................................................2-6
2.6 Radiator Fan Belt Adjustment................................................................2-7
2.7 RPM Adjustments ..................................................................................2-8
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 .................................................................................3-5
3.5 Acceleration/Brake Assembly................................................................3-6
3.6 Muffler Assembly...................................................................................3-8
3.7 Radiator Assembly .................................................................................3-9
3.8 Alternator Assembly.............................................................................3-10
3.9 Engine Guards......................................................................................3-12
SECTION 4 ELECTRICAL WIRING DIAGRAMS, D42 4-1

About This Manual D42doc102703 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

Operation
Starting The Engine
1
1-1 D42doc102703 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 D42doc102703 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 D42doc102703 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 D42doc102703 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 dur-
ing and following operation. Contact with hot engine com-
ponents 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 D42doc102703 Maintenance
2.2 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.
8

Maintenance
Fuel Filter
Maintenance D42doc102703 2-3
2
2.3 Fuel Filter
See Figure 2-1. 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. 2-1
1500

Maintenance
Fuel Filter
2
2-4 D42doc102703 Maintenance
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

Maintenance
Battery
Maintenance D42doc102703 2-5
2
2.4 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
2-6 D42doc102703 Maintenance
2.5 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 2-3.
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. 2-3
AR
Jam
Nut
Belt Adjustment
Bolt
5709
Left
Pivot
Right
Pivot

Maintenance
Radiator Fan Belt Adjustment
Maintenance D42doc102703 2-7
2
2.6 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 2-4.
FIG. 2-4
AR

Maintenance
RPM Adjustments
2
2-8 D42doc102703 Maintenance
2.7 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.
Before checking the RPM, make sure belt and brake strap tensions are correct (See Saw-
mill Maintenance). Also check oil, fuel, and coolant levels.
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". .
CAUTION! Do not extend the throttle spring over 1/4".
Excessive tension may cause the throttle cable to fail pre-
maturely.
See Figure 2-5. Use the adjustments shown below to adjust the engine RPM (3000[+0,
-50] high-end, 1150[±50] idle).
FIG. 2-5
200
Right
Adjustment
Bolt
Left
Adjustment
Bolt

Maintenance
RPM Adjustments
Maintenance D42doc102703 2-9
2
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. 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.
See Figure 2-6.
CAUTION! Failure to properly center the throttle cable in
the cable housing may result in premature cable wear.
FIG. 2-6
Mounting Bolts
Upper Throttle
Cable Mount
Bracket
Throttle Cable
Housing
Throttle Cable
3H0748-12

Maintenance
RPM Adjustments
2
2-10 D42doc102703 Maintenance

Replacement Parts
Fuel Tank
Replacement Parts D42doc102703 3-1
3
SECTION 3 REPLACEMENT PARTS
3.1 Fuel Tank
REF DESCRIPTION (uIndicates Parts Available In Assemblies Only) PART # QTY.
TANK ASSEMBLY, 5 GALLON GREEN DIESEL A12132 1
1Tank, 5 Gallon Green Fuel P12166 1 u
2Pickup, 9" Fuel P12172 2
3Cap, 3/5 Gallon Fuel Tank P09683 1
4Fitting, 1/4” NPT Male Quick Disconnect 015583 1
5Fitting, Female Quick Disconnect Barb 015582 1
6Fitting, 1/4" NPT Plastic Female Disconnect P12175 1
7Fitting, 1/4” Barb Plastic Male Disconnect P12176 1
8 HOSE, 1/4” ID FUEL P642 7.17 Ft
9 HOSE, 5/16” ID FUEL 016338 9 Ft.
10 CLAMP, 7/32 - 1/2 HOSE P649 6
ADDITIVE, DIESEL FUEL 16OZ BOTTLE 004878 1
1 Stanadyne Performance Formula helps eliminate contaminants and water in fuel, prevents gelling in cold weather, and improves
lubrication of fuel system parts. 16 oz. bottle treats 60 gallons of diesel fuel.
1
1
2
2
4
3
10
5
10
9
8
3H0780
6
7

Replacement Parts
Engine Mount Assembly
3
3-2 D42doc102703 Replacement Parts
3.2 Engine Mount Assembly
REF DESCRIPTION (u Indicates Parts Available In Assemblies Only) PART # QTY.
1 MOUNT WELDMENT, REAR D42 ENGINE 089468-1 1 u
2 MOUNT WELDMENT, FRONT D42 ENGINE 089459-1 1 u
3 BOLT, M10X1.25X25-8.8-A HEX HEAD FULL THREAD ZINC F81003-29 16
4 WASHER, 10.2 ZINC SPLIT F81055-2 16
5 NUT, M16-8 HEX NYLON ZINC LOCK F81036-2 4
6 WASHER, 17 ZINC FLAT F81058-1 4
7 BOLT, M10X25 8.8 HEX HEAD FULL THREAD F81003-31 16
8 WASHER, 10.5 ZINC FLAT F81055-1 32
9 NUT, M10-8-B HEX NYLON ZINC LOCK F81033-1 16
10 BOLT, M16X90-8.8 HEX HEAD ZINC F81006-17 4
11 SHOCK ABSORBER MEGI-LAGER 742 062 S1 STEEL, RUBBER 088570 4
1
2
3
4
3
4
5
6
7
8
7
8
89
1
0
10
9
3H0902
11

Replacement Parts
Engine Assembly
Replacement Parts D42doc102703 3-3
3
3.3 Engine Assembly
REF DESCRIPTION (u Indicates Parts Available In Assemblies Only) PART # QTY.
ENGINE, KUBOTA 1505TE 088022 1
Belt, Kubota Fan #16282-97010 028514 1
Filter, Kubota D42 Air B53/207(16617-11001) 088025 1
1Filter, Kubota D42 Fuel D52/184(16616-43001) 088024 1
2Filter, Kubota Oil #16271-32090 018050 1
Gasket Kit, Kubota Lower #07916-29265 028519 1
Gasket Kit, Kubota Upper #16285-99352 028572 1
Gasket, Kubota Exhaust #15263-12370 028513 1
Gasket, Kubota Fuel Injector #15841-53622 028516 1
Gasket, Kubota Fuel Transfer Pump #16264-52140 028518 1
Gasket, Kubota Head #16292-03310 028571 1
Gasket, Kubota Muffler #15263-12371 028549 1
Gasket, Kubota Oil Drain Plug #15451-96670 028543 1
Gasket, Kubota Stop Solenoid #16299-60150 028544 1
Gasket, Kubota Thermostat #15313-7320 028545 1
Gasket, Kubota Valve Cover #16241-14520 028524 1
Gasket, Kubota Water Pump #16259-73430 028526 1
Glow Plug, Kubota #16851-65510 028562 1
Injector, Kubota Fuel #16032-53000 028515 1
3Motor, Kubota Starter #37560-63010 028522 1
4Plug, Kubota Oil Drain #16541-33750 028542 1
3
2
1
4
6
5
7
3H0748-10

Replacement Parts
Engine Assembly
3
3-4 D42doc102703 Replacement Parts
5Pump, Kubota Fuel Injector #16060-51010 028540 1
6Pump, Kubota Fuel Transfer #16285-52032 028517 1
Pump, Kubota Water #16241-73032 028525 1
7Radiator Parts (See Section 1.5)
Sending Unit, Kubota Heat Senser #TM9A230RQCG 028510 1
Solenoid, Kubota Stop #17454-60010 028523 1
Switch, Kubota Oil Pressure #15841-39010 028547 1
Thermostat, Kubota #19434-73010 028546 1
HARNESS ASSEMBLY, KUBOTA DIESEL ENGINE 024594 1
Breaker Assembly, Water Temp Max Circuit 024453 1
Socket, Glow Plug Relay w/Fuse Holder 024554 1
Fuse Link, 50 Amp 024597 1
Relay, Glow Plug 088143 1
RELAY, 40A, 12V 021238 1