Wood-mizer D35 Series, Safety, Operation, Maintenance & Parts Manual

Page 1: ...0 rev J8 02 K5 01 LT30HD rev J8 02 K4 01 LT40HD rev J8 02 K7 01 LT40HD Super rev J9 02 K4 00 LT50HD rev A5 10 A6 00 Safety is our 1 concern Read and understand all safety information and instructions before oper ating setting up or maintaining this machine January 2010 Form 1573 ...

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Page 3: ...50 Rev A5 18 4 2 Fuel Tank D35 Tier4 Only 4 3 LT40 Rev K5 00 LT40HD Rev K7 00 LT40HD Super Rev K4 00 LT50HD Rev A6 00 4 3 Fuel Tank D35 D47 4 5 LT40 Rev K1 03 K4 08 LT40 Super Rev J6 00 J7 17 LT40HD Rev K3 01 K6 09 LT40HD Super Rev K2 00 K3 17 LT50 Rev A3 00 A5 17 4 4 Engine Mount Assembly D35 Tier4 4 6 4 5 Engine Mount Assembly D35 Tier2 D47 4 7 4 6 Engine Assembly D35 Tier4 Only 4 8 LT40 Rev K5 ...

Page 4: ... Assembly D35 Tier2 D47 4 23 4 16 Engine Pulley Guards D35 Tier4 Only 4 25 LT40 Rev K5 00 LT40HD Rev K7 00 LT40HD Super Rev K4 00 LT50HD Rev A6 00 4 17 Engine Pulley Guards D35 Tier2 D47 4 26 LT40 Rev K4 05 LT40HD Rev K6 05 LT40 Super Rev J7 14 LT40HD Super Rev K3 13 LT50HD Rev A5 13 4 18 Engine Pulley Guards D35 Tier2 D47 Only 4 27 LT40 Rev J8 02 K4 04 LT40HD Rev J8 02 K6 04 LT40 Super Rev J6 00 ...

Page 5: ...anual and manufacturer s manual before attempting to operate this equipment IMPORTANT Read the sawmill operator s manual and engine manu facturer s manual for instructions and safety precautions before oper ating 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 D35 Tier4 Engine 3H1185 ...

Page 6: ...1 2 3 10 20 1 D35 Tier2 Engine 3H1009 3 Radiator Muffler Oil Filter Fuel Filter Air Cleaner ...

Page 7: ...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 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 ...

Page 8: ... plug light will go out after the engine is started CAUTION Avoid leaving the key in the pre start 1 position for more than 30 seconds while the engine is not running Doing so will drain the sawmill battery which may reduce its service life 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 re...

Page 9: ...ed from the engine exhaust could ignite surrounding materials causing serious injury or death CAUTION Do not crank starter for more than 20 seconds at one time during starting attempts Damage to the engine may result CAUTION Let engine idle for 2 minutes before applying load to pre vent engine damage 1 See the engine manufacturer s manual for lubricating oil recommendations for specific temperatur...

Page 10: ... 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 especi...

Page 11: ...maintenance procedures for checking oil level and oil filter change intervals IMPORTANT The engine is equipped with a muffler rain cap to keep water out of the muffler and engine If the sawmill is stored outside or transported during rainy weather the muffler must be covered Change the engine oil and oil filter after the first 50 hours of operation then every 250 hours of operation 3 3 Cooling Sys...

Page 12: ... 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 3 Pry the belt idler up and remove the belt from the alternator and engine pulleys 4 While holding the idler up install the new belt around the alternator and engine pulleys 5 Release the idler on top of the belt and reinstall the alternator and drive belt cov...

Page 13: ...ged the linkage should rest against the high end adjustment screw and leave 0 to 1 32 of play in the linkage CAUTION Failure to properly adjust the throttle solenoid linkage may cause damage to the solenoid 1 Disengage the clutch and loosen the solenoid mounting bolts to adjust the throttle sole noid linkage 2 Adjust the solenoid as far to the right as possible and retighten the mounting bolts 3 E...

Page 14: ...es 6 With the engine at idle adjust the low end RPM to 1500 To increase speed tighten the idle adjustment screw The high end adjustment screw should not be adjusted FIG 3 2 TIER2 ENGINE ONLY 3H1010 Throttle Solenoid Linkage Turnbuckle Idle Adjustment Screw High End Adjustment Screw Engage clutch and push here to check for play 0 to 1 32 ...

Page 15: ...IPTION Indicates Parts Available In Assemblies Only PART QTY TRAY ASSEMBLY LT40 50 DIESEL TANK 074830 1 1 Tank 5 Gallon Low Pro Diesel 103928 1 2 Grommet Shut Off 046881 061250 1 3 Cap Fuel Tank Diesel 080185BE 061257 1 4 Fitting Return tube Diesel 468489 061256 1 5 Grommet Shut Off 046881 061250 1 6 Fitting Pick Up Tube Diesel 468871A 061255 1 7 Tank Weldment Fuel LT40 50 103943 1 3 6 2 5 4 1 8 7...

Page 16: ...4 20 Hex Lock F05010 21 5 12 Bolt 1 4 20 x 3 4 Carriage F05005 113 2 13 Clamp 1 2 EMT Coated P07584 6 14 Washer 1 4 SAE Flat F05011 11 2 15 Bolt 1 4 20 x 3 4 Hex Head Grade 5 F05005 123 3 16 Bolt 5 16 18 x 1 2 Hex Head Grade 5 F05006 15 4 17 Washer 5 16 Split Lock F05011 13 4 18 Washer 5 16 SAE Flat F05011 17 4 Hose Fuel 5 16 EPA 15G CARB R02423 3 7 Ft Hose Fuel 1 4 EPA 15G CARB R02423 2 8 Ft ...

Page 17: ...ART QTY TRAY ASSEMBLY LT40 50 TIER4 DIESEL TANK 079637 1 1 Tank 5 Gallon Low Pro Diesel 103928 1 2 Grommet Shut Off 046881 061250 1 3 Cap Fuel Tank Diesel 080185BE 061257 1 4 Fitting Return tube Diesel 468489 061256 1 5 Grommet Shut Off 046881 061250 1 6 Fitting Pick Up Tube Diesel 468871A 061255 1 7 Tank Weldment Fuel LT40 50 103943 1 8 Cover Fuel Tank 103867 1 3 6 2 5 4 1 8 7 9 3H1187 1 10 17 18...

Page 18: ... F05006 15 4 17 Washer 5 16 Split Lock F05011 13 4 18 Washer 5 16 SAE Flat F05011 17 4 19 Hose Clamp 7 32in 5 8in P649 4 Separator Assembly D35 T4 ECU F W 079409 1 20 Mount Weldment D35 T4 ECU F W Separator 079471 1 21 Bolt 1 4 20x1 Carriage F05005 34 5 22 Bolt 5 16 18x4 Hex Head Grade 5 F05006 109 2 23 Nut 5 16 18 Nylok Hex F05010 58 2 24 Nut 1 4 20 Nylock F05010 69 5 25 Washer 1 4 SAE Flat F0501...

Page 19: ...ale Quick Disconnect 015583 1 5 Fitting Female Quick Disconnect Barb 015582 1 6 Fitting 1 4 NPT Plastic Female Disconnect P12175 1 7 Fitting 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 4 11 BULB 5 16 FUEL LINE PRIMER 006687 1 ADDITIVE DIESEL FUEL 16OZ BOTTLE 004878 1 1 Stanadyne Performance Formula helps elim...

Page 20: ... 2 PIVOT WELDMENT D35 T4 ENGINE PIVOT 079365 1 3 MOUNT WELDMENT D35 T4 LEFT ENGINE MOUNT 079372 1 4 MOUNT WELDMENT D35 T4 RIGHT ENGINE MOUNT 079377 1 5 BOLT 1 2 13X1 1 4 HEX HEAD GRADE 5 F05008 37 1 6 BOLT 1 2 13X1 3 4 HEX HEAD GRADE 5 FT F05008 88 4 7 NUT 1 2 13 NYLON HEX LOCK F05010 8 5 8 WASHER 1 2 SAE FLAT F05011 2 8 9 WASHER 10MM SPLIT LOCK F05011 88 16 10 BOLT M10 1 5X25MM HEX HEAD GRADE 8 8...

Page 21: ... 3 BOLT 1 2 13 X 1 1 4 HEX HEAD GRADE 5 F05008 37 1 4 NUT 1 2 13 HEX NYLON LOCK F05010 8 3 5 BOLT 1 2 13 X 1 3 4 HEX HEAD GRADE 5 F05008 88 2 6 NUT M12 X 1 75 HEX NYLON LOCK F05010 209 1 7 BOLT M12 X 1 75 X 90MM HEX HEAD FULL THREAD F05004 250 1 BUSHING ASSEMBLY MOTOR MOUNT 016380 3 8 Bushing 2 OD x 2 016378 1 9 Bearing 1 x 1 1 4 x 2 016379 1 10 CLAMP WELDMENT MOTOR MOUNT 014540 3 11 BOLT 3 8 16 X...

Page 22: ...r Cleaner Assembly 35 9HP Yanmar 006541 1 Air Filter Yanmar 3TNV88 129087 12510 057948 1 Cap Air Filter Assembly Yanmar 061100 1 Filter Oil 129150 35170 057935 1 Filter Fuel 129A00 55800 061308 1 Throttle Solenoid Relay Parts See Section 4 8 Filter Assembly Fuel Water Separator 129A00 59700 061309 1 Bracket Fuel Water Separator Mount 006561 1 Filter Water Separator Yanmar 129A00 55730 061310 1 Muf...

Page 23: ...01800 057932 1 Injector Assembly Yanmar 129A00 53100 078716 1 Switch Yanmar Oil Pressure 119761 39450 061245 1 Seal Yanmar Rear Main 129795 01780 061311 1 Starter Motor Yanmar 129242 77010 057937 1 Thermostat Yanmar 129155 49801 057938 1 Gasket Thermostat 129150 49811 061312 1 Gasket Thermostat Cover 129795 49551 044652 1 Pump Yanmar Water 129A01 42000 061313 1 Gasket Yanmar Water Pump 129486 4202...

Page 24: ... 006541 1 Air Filter E1 Primary Element Enginaire 028597 2 1 Cap Air Filter Assembly Yanmar 061100 1 3 Filter Oil 129150 35153 12 057935 1 4 Filter Fuel 119802 55801 057933 1 5 Throttle Fuel Pump Parts See Section 4 9 6 Filter Assembly Fuel Water Separator 040345 1 Bracket Fuel Water Separator Mount 006561 1 Filter Water Separator Yanmar 061099 1 7 Muffler Assembly 35 9HP Yanmar Diesel 006543 1 8 ...

Page 25: ...00 044657 1 Timer Yanmar Air Heater 128300 77920 057941 1 Fan Engine 7 Blade 360mm 121267 44741 AP0114 1 Gasket Yanmar Head 129001 01340 057942 1 Plug Yanmar Oil Drain 119640 01640 057943 1 Seal Yanmar Oil Drain 22190 220002 057944 1 Plug Yanmar Glow 129008 77800 057945 1 Dip Stick Yanmar Oil 129004 34802 057946 1 Belt Yanmar Fan 25132 003600 044668 1 Pipe Yanmar Fuel Return 129004 49610 057947 1 ...

Page 26: ...1 1 2 Hex Head Grade 5 F05005 124 4 5 Nut 1 4 20 Nylock F05010 69 4 6 Washer 1 4 SAE Flat F05011 11 8 7 Washer 1 4 Split Lock F05011 14 6 8 Bolt M6 1 x 20 Class 8 Hex Head F05020 6 2 9 Yanmar T4 Final ECU Supplied w Engine N A 1 1 When replacing the ECU it is necessary to update the software of the ECU using the designated service tool Please contact Yanmar for details 1 10 Assembly D46 T4 Fuse Re...

Page 27: ...t F05011 3 1 8 Nut 5 16 18 Hex Nylon Lock F05010 58 2 9 Spring 42 x 1 34 x 061 P11644 1 10 Bolt 1 4 28 x 2 Hex Head Grade 5 F05005 188 1 11 Bolt 5 16 18 x 3 Hex Head Grade 5 F05006 62 1 12 Bracket Fuel Water Separator Mount 006561 1 13 Bolt M8 1 25 x 1mm Hex Head F05004 40 2 14 Nut M8 Hex Nylon Lock F05010 132 2 15 Bolt 1 4 20 x 1 Hex Head Grade 5 F05005 101 2 16 Washer 1 4 Sae Flat F05011 11 5 17...

Page 28: ... Plug Relay w Fuse Holder 024554 1 30 Fuse Link 50 Amp 024597 1 31 Washer M5 Wave F81052 4 2 32 Screw M5 0 8 x 8mm Phillips Head Black Oxide F81000 14 2 33 Fuseholder In Line 3 20A ATC w Cover 024555 1 34 Fuse 4A ATO Blade Pink 024150 4 1 Resistor Assembly 3K Cat Glow Plug Wire 052662 1 35 Relay Diesel Glow Plug 023359 1 36 Washer 1 4 SAE Flat F05011 11 1 37 Cover Relay Assembly 045824 1 38 Nut 1 ...

Page 29: ... PART QTY 1 SHEAVE 5V X 4 46 POLY V GAS DIESEL 016533 1 2 BUSHING SH X 1 7 16 016535 1 3 BELT 3 5VFL765 KEVLAR 110268 1 4 SHAFT D35 T4 YANMAR LARGE STUB 079481 1 5 BOLT M8 1 25 X 30MM FLAT SOCKET HEAD F05004 245 8 6 BRACKET DRIVE BELT SUPPORT 016364 1 7 WASHER 3 8 SAE FLAT F05011 3 4 8 BOLT 3 8 16 X 1 HEX HEAD F05007 7 2 9 NUT 3 8 16 HEX NYLON LOCK F05010 10 2 1 2 3 3H1185 3 4 5 6 7 8 9 ...

Page 30: ...7 16 016535 1 3 BELT 3 5VL770 046571 1 4 PLATE YANMAR ENGINE STOP 006620 1 5 SHAFT YANMAR LARGE DRIVE STUB LONG 071326 1 6 BOLT M8 1 25 X 30MM FLAT SOCKET HEAD F05004 245 8 7 BOLT M10 1 5 X 25MM HEAD HEAD GRADE 8 8 F81003 11 2 8 WASHER 10MM SPLIT LOCK F05011 88 2 9 BRACKET DRIVE BELT SUPPORT 016364 1 10 WASHER 3 8 SAE FLAT F05011 3 4 11 BOLT 3 8 16 X 1 HEX HEAD F05007 7 2 12 NUT 3 8 16 HEX NYLON L...

Page 31: ...35 4 12 Radiator Assembly D35 Tier4 Only LT40 Rev K5 00 LT40HD Rev K7 00 LT40HD Super Rev K4 00 LT50HD Rev A6 00 REF DESCRIPTION Indicates Parts Available In Assemblies Only PART QTY 3H1185 5 6 1 2 5 4 3 7 8 9 10 12 13 14 15 18 16 16 17 19 20 21 22 23 34 24 25 26 27 28 29 30 31 32 30 33 8 9 10 ...

Page 32: ...ubber Mount 018734 2 14 Bolt 1 2 13 x 2 1 2 Hex Head Grade 5 F05008 74 2 15 Washer Engine Mount 018751 2 16 Bolt 3 8 16x1 1 4 FT Hex Head Grade 5 F05007 123 4 17 Nut 3 8 16 Hex Nylon Lock F05010 10 4 18 Washer 3 8 Flat SAE F05011 3 4 19 MOUNT WELDMENT D35 T4 FRONT ENGINE 079350 1 20 PLATE YANMAR FRONT ENGINE MOUNT 058714 1 21 BOLT M10 1 5 X 25MM HEX HEAD GRADE 8 8 F81003 11 8 22 WASHER 10MM SPLIT ...

Page 33: ...In Assemblies Only PART QTY RADIATOR KIT YANMAR KR2 044804 1 1 Radiator Diesel Engines 129689 44510 057949 1 2 Cap Yanmar Radiator 129987 44570 044660 1 3 Bottle Assembly Yanmar 123987 43600 040387 1 4 Hose Yanmar Lower Radiator 129689 49020 057950 1 3H1009 6D 1 6 7 8 9 10 11 12 13 14 15 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 30 33 3 5 4 2 8 9 10 34 ...

Page 34: ...FRONT ENGINE MOUNT 058714 1 19 BOLT M10 1 5 X 25MM HEX HEAD GRADE 8 8 F81003 11 8 20 WASHER 10MM SPLIT LOCK F05011 88 8 21 BOLT 5 16 18 X 3 4 HEX HEAD F05006 5 2 22 NUT 5 16 18 HEX NYLON LOCK F05010 58 2 MOUNT ASSEMBLY 35 9HP UPPER RADIATOR 074228 1 23 Plate Yanmar Top Radiator support 006531 1 24 Plate Top Radiator Mount Spacer 006557 1 25 Plate Yanmar Top Radiator Mount 006558 1 26 Bolt M8 x 125...

Page 35: ... Alternator 140 Amp 023695 1 2 Pulley 2 3 4 Dia Alternator 046402 1 3 Mount Weldment D35 T4 Altenator 079394 1 4 Tensioner Alternator Belt 034464 1 5 Bolt 3 8 16 x 1 1 2 Hex Head Grade 5 F05007 78 1 6 Washer 3 8 Split Lock F05011 4 1 7 Bolt M10 1 50x20mm HH FT 8 8 F05004 207 1 8 Washer 10mm Split Lock F05011 88 1 9 Nut 3 8 16 Hex Nyloc F05010 10 1 10 Bolt 3 8 16x3 HH Gr5 F05007 73 1 Cover Assembly...

Page 36: ...Replacement Parts Alternator Assembly D35 Tier4 4 4 22 D3507doc031020 Replacement Parts D35 15 Cover Weldment D35 T4 Lower Alt 079576 1 16 Bolt 1 4 20x1 2 Hex Head F05005 15 8 17 Belt 6PK1145 006524 1 ...

Page 37: ... x 1 1 2 Hex Head Grade 5 F05007 78 1 6 Washer 3 8 Split Lock F05011 4 1 7 Washer 8mm Split Lock F05011 45 1 8 Mount Weldment Yanmar ALternator 058708 1 9 Bolt M8 x 1 25 x 90mm Hex Head Full THread F05004 247 1 10 Nut M8 Hex Nylon Lock F05010 132 1 11 Bolt 3 8 16 x 3 1 2 Hex Head Grade 5 F05004 123 3 12 Nut 3 8 16 Hex Nylon Lock F05010 10 3 13 Bolt M8 x 125 x 16mm Hex Head F05004 47 1 14 Bolt 3 8 ...

Page 38: ...asher 5 16 Split Lock F05011 13 5 20 Washer 5 16 SAE Flat F05011 17 5 21 Bolt 5 16 18 x 1 2 Hex Head Grade 5 F05006 15 4 22 Cover Weldment Yanmar ALternator 058704 1 23 Bolt 3 8 16 x 3 4 Hex Head Grade 2 F05007 27 2 24 Cover Weldment Lower Yanmar Alternator 058712 1 25 Washer 3 8 Split Lock F05011 4 2 ...

Page 39: ...K5 00 LT40HD Rev K7 00 LT40HD Super Rev K4 00 LT50HD Rev A6 00 REF DESCRIPTION Indicates Parts Available In Assemblies Only PART QTY COVER ASSEMBLY D35 T4 TOP PULLEY 079718 1 1 Cover Weldment D35 T4 Top Pulley 079473 1 2 Plate D35 T4 Cover 079707 1 3 Plate D35 T4 Side Guard 079714 1 4 Bolt 1 4 20x3 4 HH w Conical Washer F05005 134 6 1 3 4 3H1186 2 ...

Page 40: ...2 D47 LT40 Rev K4 05 LT40HD Rev K6 05 LT40 Super Rev J7 14 LT40HD Super Rev K3 13 LT50HD Rev A5 13 REF DESCRIPTION Indicates Parts Available In Assemblies Only PART QTY 1 GUARD WELDMENT YANMAR ENGINE TOP PULLEY 075542 1 2 BOLT 1 4 20 X 3 4 HEX HEAD WITH CONICAL WASHER F05005 134 3 3 GUARD SIDE ENGINE PULLEY 016152 1 1 2 3 3H1141 2 ...

Page 41: ...Rev J8 02 K4 04 LT40HD Rev J8 02 K6 04 LT40 Super Rev J6 00 J7 13 LT40HD Super Rev J9 02 K3 12 LT50HD Rev A4 00 A5 12 REF DESCRIPTION Indicates Parts Available In Assemblies Only PART QTY 1 GUARD WELDMENT CATERPILLAR ENGINE PULLEY 046560 1 2 BOLT 1 4 20 X 3 4 HEX HEAD WITH CONICAL WASHER F05005 134 3 3 GUARD SIDE ENGINE PULLEY 016152 1 1 2 3 3H0931B 2 ...

Page 42: ...mblies Only PART QTY SUPPORT ASSEMBLY D35 T4 FINAL BEARING 079402 1 1 Bearing 1 7 16 4 Bolt Flange 071491 1 2 Support Weldment D35 T4 Final Bearing 079401 1 3 Bolt 1 2 13x1 3 4 Hex Head Grade 5 FT F05008 88 4 4 Washer 1 2 SAE Flat F05011 2 4 5 Washer 10mm Split Lock F05011 88 5 6 Washer 1 2 Split Lock F05011 9 4 7 Bolt M10 1 5x140 Hex Head FT F05022 21 5 1 5 3 4 7 3H1185 7 2 6 ...

Page 43: ...1 Bearing 1 7 16 4 Bolt Flange 071491 1 2 Spacer 1 Hex x 7 31 071493 2 3 Spacer 1 Hex x 4 38 071499 1 4 Spacer 1 Hex x 2 03 075103 1 5 Spacer 1 Hex x 6 63 075104 1 6 Weldment Yanmar Bearing Support 075538 1 7 Bolt M12 x 1 75 x 90mm Hex Head Full Thread Cl10 9 Zinc F05004 249 1 8 Bolt M12 x 1 75 x 40mm Hex Head Full Thread Cl10 9 Zinc F05004 250 4 9 Bolt 1 2 13 x 1 3 4 Hex Head Grade 5 Full Thread ...

Page 44: ...4 Guard Weldment Cat Top Pulley 075534 1 5 Spacer 1 Hex x 4 31 075754 1 6 Spacer 1 Hex x7 31 w Stud 075755 1 7 Weldment Cat Bearing Support 075757 1 8 Bolt 3 8 16x1 1 4 Hex Head Grade 5 F05007 123 3 9 Bolt 3 8 16x2 1 2 Hex Head Grade 5 F05007 125 1 10 Bolt 3 8 16x4 Hex Head Grade 5 F05007 126 2 11 Bolt 3 8 16x1 Hex Head Grade 5 F05007 87 1 12 Bolt 1 2 13x1 3 4 Hex Head Grade 5 FT F05008 88 4 13 Wa...

Page 45: ...fety 3 1 O operation 2 1 control lights 2 1 shutoff 2 3 starting 2 2 P parts list alternator 4 21 4 23 alternator assembly 4 24 drive assembly 4 15 4 16 engine assembly 4 8 4 10 engine mount assembly 4 6 4 7 fuel tank 4 1 4 3 4 5 motor assembly 4 8 4 10 pulley guards 4 25 4 26 radiator assembly 4 17 4 19 relay throttle assembly 4 12 4 13 INDEX ...