woodmizer D42 Guide

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.
February 1998
Form #916
!

ii D42doc061507 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 ...............................................................................................2-4
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....................................................................................3-4
3.4 Primary Fuel Filter .................................................................................3-6
3.5 Throttle Assembly ..................................................................................3-7
3.6 Muffler Assembly...................................................................................3-9
3.7 Drive Assembly ....................................................................................3-10
3.8 Radiator Assembly & D42 Engine Guards ..........................................3-11
3.9 Alternator Assembly.............................................................................3-13
3.10 Engine Pulley Guards ...........................................................................3-15
SECTION 4 ELECTRICAL WIRING DIAGRAMS, D42 4-1

About This Manual D42doc061507 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
!
Muffler
Radiator
Serial Number/Engine Type
A
lternator
Oil Filter Starter
Motor

Operation
Starting The Engine
1
1-1 D42doc061507 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.
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
SW-07 Setworks

Operation
Starting The Engine
Operation D42doc061507 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 cool engine idle for 2 minutes before apply-
ing load to prevent engine damage.
1. See the engine manufacturer’s manual for lubricating oil recommendations for specific
temperature ranges.
2. Use a 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 D42doc061507 Operation
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.

Maintenance
Safety
Maintenance D42doc061507 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 D42doc061507 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.
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-
8
8

Maintenance
Cooling System
Maintenance D42doc061507 2-3
2
tilled water).
FIG. 2-0
3h0963

Maintenance
Fuel Filter
2
2-4 D42doc061507 Maintenance
2.3 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
fuel pump bail until fuel begins to flow from the valve and is free of air bubbles. Tighten
the bleed screw. Inspect the water separator bowl periodically and drain the bowl as
required by turning the drain cap counterclockwise as viewed from the bottom.
FIG. 2-1
1500
Filter Cartridge
Water Drain
Bleed Screw
3H0463

Maintenance
Battery
Maintenance D42doc061507 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 D42doc061507 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. Release the blade tension and remove the blade from the sawmill if necessary. Turn the
key switch to OFF (0) and remove the key.
2. Remove the drive belt cover and alternator cover.
See Figure 2-2.
3. Use a belt tension gauge to measure the belt tension. Place the gauge on the belt at the
midpoint between the two pulleys. If the belt tension is less than 3/16” with 9 lb. of deflec-
tion, tighten the belt as described below.
4. Loosen the upper pivot, lower pivot and the adjustment bolt jam nut.
5. 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.
FIG. 2-2
AR
Belt Adjustment
Bolt
Jam Nut Upper Pivot
Lower
Pivot
3H0748-11

Maintenance
Radiator Fan Belt Adjustment
Maintenance D42doc061507 2-7
2
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.
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 2-3.
FIG. 2-3
AR

Maintenance
RPM Adjustments
2
2-8 D42doc061507 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 3200 RPM and low-end RPM should be 1500
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 clutch handle is
disengaged. Make sure the cable is not bent or kinked.
1. Use the bottom threaded cable mount to adjust the throttle cable. When the clutch handle
is disengaged, the throttle cable should be taut but the spring not extended. When the
clutch handle is engaged, the throttle spring should extend 1/8" to 1/4". Once the throttle
cable is adjusted properly, use the adjustments provided on the engine to adjust the
engine RPM (3200[+0, -100] high-end, 1500[±100] idle).
CAUTION! Do not extend the throttle spring over 1/4".
Excessive tension may cause the throttle cable to fail pre-
maturely.
See Figure 2-4.
FIG. 2-4
200
A
djust top nut, then
bottom nut up to loosen
throttle cable
A
djust bottom nut, then
top nut down to tighten
throttle cable
3H0748-1

Maintenance
RPM Adjustments
Maintenance D42doc061507 2-9
2
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.
4. Adjust the high-end RPM to 3200. To decrease speed, tighten the high-end adjustment
screw. To increase speed, loosen the high-end adjustment screw.
CAUTION! Do not adjust the high-end RPM above 3200.
Doing so may cause damage to the engine.
5. After the RPM settings are made, shut the engine off. Tighten the throttle cable by engag-
ing the clutch handle. 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. 2-5
High-End
Adjustment Scre
w
Idle
Adjustment Screw
3H0748-2

Maintenance
RPM Adjustments
2
2-10 D42doc061507 Maintenance
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
U
pper
Th
rott
l
e
Cable Mount
Bracket
Throttle Cable
Housing
Throttle Cable
3H0748-12

Replacement Parts
Fuel Tank
Replacement Parts D42doc061507 3-1
3
SECTION 3 REPLACEMENT PARTS
3.1 Fuel Tank
REF DESCRIPTION (Indicates Parts Available In Assemblies Only) PART # QTY.
TANK ASSEMBLY, 5 GALLON GREEN DIESEL A12132 1
1Tank, 5 Gallon Green Fuel P12166 1 
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 D42doc061507 Replacement Parts
3.2 Engine Mount Assembly
REF DESCRIPTION ( Indicates Parts Available In Assemblies Only) PART # QTY.
1 MOUNT WELDMENT, FRONT KUBOTA ENGINE 097154-1 1
2 MOUNT WELDMENT, REAR KUBOTA ENGINE 087945-1 1
VIBRATION ABSORBER, CLUTCH 090666-1 1
3Bolt, M10X70-8.8 HEX HEAD, ZINC F81003-20 1
4Washer, 3/8" I.D. X 2 1/4" O.D. X 3/16" THICK S12412-0 1
5Nut, M10-8-B Hex Nylon Lock F81033-1 1
6 BUSHING, MOTOR MOUNT VIBRATION P05032 1
7 PIN WELDMENT, KUBOTA ENGINE MOUNT PIVOT 087955-1 1
8 BOLT, M12 X 40-8.8 HEX HEAD F81004-4 1
9 WASHER, 13 FLAT ZINC F81056-1 1
BUSHING ASSEMBLY, MOTOR MOUNT 016380 3
10 Bushing, 2” OD x 2” 016378 1
11 Bearing, 1” x 1 1/4” x 2” 016379 1
12 CLAMP WELDMENT, MOTOR MOUNT 086200 1
13 BOLT, M10-1.5X25MM HH GR8.8 F81003-11 1
14 NUT, M10, NYLON HEX ZINC LOCK F81033-1 2
15 NUT, M12-8-B NYLON LOCK F81034-2 1

Replacement Parts
Engine Mount Assembly
Replacement Parts D42doc061507 3-3
3
16 BOLT M6x12-8.8-Fe/Zn5 F81001-7 4
17 WASHER, 10.2 SPLIT LOCK ZINC F81053-3 4
18 BOLT M10x1,25x25-8.8-A-Fe/Zn5 F81003-29 8
19 WASHER, 10.2 SPLIT LOCK ZINC F81055-2 8
20 BOLT, M8X45 - 8.8 HEX HEAD GRADE 5 F81002-14 4
21 WASHER, M8, FLAT ZINC F81054-1 4

Replacement Parts
Engine Assembly
3
3-4 D42doc061507 Replacement Parts
3.3 Engine Assembly
REF DESCRIPTION ( Indicates Parts Available In Assemblies Only) PART # QTY.
ENGINE, KUBOTA 1505TE 088022 1
1Turbocharger, Kubota 097738 1
Belt, Kubota Fan 097739 1
Radiator Fan 097740 1
Filter, Kubota D42 Air B53/207 088025 1
Filter Cartridge, Kubota D42 Air 097741 1
Filter, Kubota D42 fuel 088024 1
Filter Cartdridge, Kubota Fuel D42 097742 1
2Filter, Kubota Oil 097743 1
Gasket Kit, Kubota Lower 097744 1
Gasket Kit, Kubota Upper 097745 1
Gasket, Kubota Muffler 097746 1
Gasket, Kubota Fuel Injector 097747 1
Gasket, Kubota Fuel Transfer Pump 097748 1
Gasket, Kubota Head 097749 1
Gasket, Kubota Oil Drain Plug 097750 1
Gasket, Kubota Stop Solenoid 097751 1
Gasket, Kubota Thermostat 097752 1
1
23
4
56
7
8