Yanmar D10, Safety, Operation, Maintenance & Parts Manual

Page 1: ...ty Operation Maintenance Parts Manual LT15 rev C3 01 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 1098 ...

Page 2: ... 2 Air Filter Pre Cleaner 2 2 2 3 Oil Oil Filter 2 3 2 4 Fuel Filter 2 4 2 5 Drive Belt Adjustment 2 5 2 6 Alternator Belt 2 7 2 7 RPM Adjustments 2 9 SECTION 3 REPLACEMENT PARTS 3 1 3 1 How To Use The Parts List 3 1 3 2 Sample Assembly 3 1 3 3 Engine Assembly 3 2 3 4 Brake Belt Tensioner Assembly 3 4 3 5 Key Switch Mount Bracket 3 7 SECTION 4 ELECTRICAL INFORMATION 4 1 4 1 Electrical Wiring Diagr...

Page 3: ...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 ...

Page 4: ...irst and every 3 months or 200 hours thereafter DANGER Always drain the oil while the engine is still warm It may be difficult to drain the oil completely when the engine is cold 3 Check the fuel level in the fuel indicator pipe Do not allow the fuel tank to become empty If this should happen perform the following steps a Fill the tank with diesel fuel b Unbolt the fuel tank mounting bolts c Raise...

Page 5: ...ION Use only recommended diesel fuel Failure to do so may result in serious engine damage CAUTION The cetane value of the diesel fuel should be above 45 This will ensure easy engine start and will prevent misfiring and white exhaust gases CAUTION Diesel fuel substitutes are not recommended they may cause damage to the fuel system CAUTION The fuel should be free of water and dust Damage to the fuel...

Page 6: ...ways check the engine oil level before starting the engine Add oil if necessary If the lubricating oil level is too low it may result in engine damage If it is too high a sudden increase of RPM can occur as a result of the lube oil combustion Use 5W 40 engine oil Pour the oil up to the mouth of the filler port Make sure the engine is level when pouring the oil Lube oil capacity 1 65 l Red Plug Cap...

Page 7: ...nut 1 Element CAUTION Do not clean the air cleaner element with detergents as it is of an oil soaked type CAUTION Replace the element when the power output decreases or a bad color of the exhaust gases is noticed CAUTION Never run the engine without the air cleaner element Doing so may result in quick engine wear ...

Page 8: ...e 1 1 5 D10doc041409 OPERATION 1 2 Starting The Engine Recoil Starting 1 Fuel cock Perform the following steps to start the engine 1 Set the fuel cock in the open O position 2 Put the engine speed lever in the START position Grip ...

Page 9: ...ill return automatically to its original positionwhen the start rope is pulled again c Pull out the start rope briskly holding the handle with both hands CAUTION Do not allow the start rope handle to rapidly return to its original position Release it gently to avoid damage to the starter CAUTION Always pull the start rope firmly to start the engine WARNING Never use any cold starting aids such as ...

Page 10: ...OPERATION Starting The Engine 1 1 7 D10doc041409 OPERATION ...

Page 11: ...n the tensioner lever is in the ENGAGED up position Always be sure the blade is disengaged and all persons are away from the sawmill before starting the engine 1 Set and lock with the pin the tensioner lever in the ENGINE START middle position See Figure 1 1 2 Turn the key to the START position See Figure 1 2 FIG 1 1 FIG 1 2 ...

Page 12: ...ERATION 3 When the engine is started release the tensioner lever to the IDLING down position See Figure 1 3 4 To engage the blade press and hold the green button on the control box and push the tensioner lever to the ENGAGED up position FIG 1 3 FIG 1 3 ...

Page 13: ...y hot during engine operation Be careful not to touch the silencer WARNING Never perform refueling while the engine is running Battery Check the level of the fluid in the battery once a month When the level has dropped to the lower mark replenish with distilled water up to the upper mark CAUTION If the battery fluid is short the engine may not start because too little electricity is reaching the s...

Page 14: ...e slowly until you feel resistance i e until the engine is in the compression position where the intake and exhaust valves are closed and leave the engine in this position This prevents rusting while the engine is not in use WARNING If the engine keeps on running even after the speed lever is placed in the STOP position stop the engine either by closing the fuel cock S position or by loosening the...

Page 15: ...uctions WARNING Remove the blade before performing any engine service Failure to do so may result in serious injury This symbol identifies the interval hours of operation which each maintenance procedure should be performed AR signifies maintenance procedures which should be performed as required 2 1 Air Cooling System Wash the engine or brush off sawdust and debris every 50 hours of operation Cle...

Page 16: ... sawdust and debris from the foam piece Clean the air filter air cleaner element and pre cleaner element wrapper every eight hours of operation See the engine manual for further instructions Change the air cleaner element every 6 months or 400 hours or earlier if dirty CAUTION Never run the engine without the element or with a defective element CAUTION A clogged element hinders the flow of air to ...

Page 17: ...nth whichever comes first and every 3 months or 200 hours thereafter CAUTION Always drain the oil while the engine is still warm It may be difficult to drain the oil completely when the engine is cold Change the oil filter every 6 months or 400 hours of operation Lube oil capacity 1 65 l CAUTION Before adding oil make sure the engine is not tilted ...

Page 18: ... Clean Every 3 months or 200 Hrs Every 6 months or 400 Hrs The fuel filter has to be cleaned regularly to insure maximum engine output 1 Drain fuel from the fuel tank 2 Loosen the fuel cock nuts and remove the filter from the F O tank filler port Wash the filter thoroughly with diesel oil ...

Page 19: ...rs and every 50 hours thereafter The drive belt tension should be adjusted with the tensioner handle engaged in the up position by moving the engine assembly on the engine mount plate To make the adjustment perform the following steps 1 Loosen the engine mounting bolts and the jam nuts 2 Using the adjustment bolts shown in the figure below adjust the belt tension to approximately 11 mm deflection ...

Page 20: ...ve Belt Adjustment 2 2 6 doc041409 Maintenance See Figure 2 1 Periodically check all belts for wear Replace any damaged or worn belts as needed FIG 2 1 Jam Nut Adjustment Bolt Adjustment Bolt Engine Mounting Bolts AR ...

Page 21: ... 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 0mm wit...

Page 22: ...e belt Adjust the bolt until the proper belt tension is achieved CAUTION Do not overtighten the alternator belt Damage to the alternator will occur 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 FIG 2 3 Lower Alternator Mounting Bolt Belt Tension Adjustment Bolt with Nut ...

Page 23: ...ttle linkage is not affecting the engine RPM while the clutch brake handle is disengaged Make sure the cable is not bent or kinked Refer to the engine manual to adjust the low end RPM 2 Engage the clutch handle to throttle the engine and measure the high end RPM Readjust the throttle linkage if necessary to increase or reduce the high end engine speed The engine should start to throttle as soon as...

Page 24: ... parts M06666 and F07777 77 The diamond indicates M06666 is not available except in subassembly K05555 To Order Parts From Europe call our European Headquarters and Manufacturing Facility in Kolo Poland at 48 63 2626000 From the continental U S call 1 800 448 7881 to order parts Have your customer number vehicle identification number and part numbers ready when you call From other international lo...

Page 25: ...1 Rope 114699 76630 Starter 092617 1 Spring 114699 76540 Helical 092618 1 Injector Assembly 714650 53100 Fuel 500607 1 Nozzle Assembly 114650 53000 Fuel Injector 500608 1 Filter 114250 35110 Oil 500609 1 Gasket Kit 714988 92610 500610 1 Filter 114250 55121Fuel 090163 1 Starter 114362 77011 093453 1 Brush 114371 79040 093454 1 Brush 114371 79050 093455 1 Injection Pump Complete 500611 1 Valve Solen...

Page 26: ...c Plated 096447 1 1 19 Screw Set M8x8 33H Fe Zn Hex Sckt Head F81014 1 1 20 Screw 7 16 20 x 1 1 2 SHC F05007 55 1 21 Bracket 30A Alternator Upper 095271 1 1 22 Alternator D42 089661 1 23 Bracket Denso 30A Alternator 095268 1 1 24 Cover Alternator Belt 095323 1 1 25 Cover Alternator 095320 1 1 26 Washer M8 Flat Zinc F81054 1 14 27 Bolt M8x20mm Hex Head Zinc Grade 5 8 F81002 4 7 28 Bolt M8x16mm Hex ...

Page 27: ...D BRAKE COMPLETE 097436 1 Plate Tensioner Brake Handle Complete 097437 1 1 Plate Tensioner Brake Handle 097438 1 1 2 Fitting M6 Type A Grease 086280 1 3 Bushing GFM 1618 12 Igus 091455 2 4 Grip Tensioner Brake Handle 095318 1 1 1 2 3 4 5 8 6 7 9 10 11 12 8 13 14 15 15 12 17 18 19 19 16 20 15 21 15 15 15 22 23 24 25 26 27 41 29 30 31 32 32 33 34 34 35 36 37 39 38 40 42 43 44 43 42 43 43 28 29 42 45...

Page 28: ...81032 2 3 23 Pin 45308DNW Detent 089939 1 24 Seal Wire Rubber Inside Dia 6mm 085338 1 25 Axle Grip Rotation 097698 1 1 26 Knob 1 135 120 13 Crank Handle 097696 1 27 Bolt M8x150 8 8 Hex Head Zinc F81002 36 1 TENSION ROLLER W BRAKE COMPLETE 097446 1 28 Mount Wldmt Tensioner Shaft Ptd 091112 1 1 29 Bushing MFM 3240 30 IGUS 088461 2 30 Shaft Belt Tensioner 096451 1 1 Roller Tension Complete 097832 1 3...

Page 29: ...asher 5 3 Flat Zinc F81052 1 6 49 Nut M5 8 DIN 985 Zinc F81030 2 6 50 Pivot FI 13 M8 T17628 ULMER Angle 095285 2 51 Screw M8x40 8 8 Hex Socket Head Cap Zinc F81002 29 1 52 Nut M8 8 B FeZn5 Hex Nylon Zinc Lock F81032 2 1 53 Spring FI 1 9 x fi 14 2 x 104 091865 1 54 Pusher Short Zinc 097445 1 1 55 Nut M8 8 B Hex Zinc F81032 1 2 56 Bushing Tensioner Zinc 097447 1 1 57 Fitting M6 Type A Grease 086280 ...

Page 30: ...unt Bracket REF DESCRIPTION Indicates Parts Available In Assemblies Only PART QTY BRACKET D10 KEY SWITCH MOUNT COMPLETE 092510 1 1 Bracket D10 Key Switch Mount Painted 092511 1 1 2 Switch Key P04350 1 3 Light KLA GS 10 2 Control 091051 1 4 Decal D10 Key Switch Mount Bracket 092517 1 15d013 1 2 3 4 ...

Page 31: ...CAL INFORMATION 4 1 Electrical Wiring Diagram LT15D10 SW08 FIG 4 1 LT15D10 SW08 BAT ACC IGN ST Battery Negative Contact B1 L1 W2 W3 W2 W3 GND IGN IGN ST ST R1 P1 D1 LED 086486 W3 Pk1 Starter GND SOL1 S1 Alternator S1 W2 W3 1 2 3 4 5 6 1 2 3 4 5 6 D2 D1 SOL2 SOL1 M1 OUT1 OUT2 12V SW 08 Vcc GND W1 W2 ENKODER S2 Vcc GND CAL ...

Page 32: ...scription B1 091775 Battery 36Ah S1 094328 Button M22 Momentary Mushroom Green Pk1 086486 Relay D9120 IP 65 64 W1 094232 Safety switch Guard W2 W3 100910 Safety Switches Up Down L1 091051 Light KLA GS 10 2 Control SOL1 092803 Valve ET 3 12V Fuel Solenoid S3 095332 Joysick 2 position Up Down S2 100931 Limit Switch GLCB01A1B L2 095331 Control Light TABELA 4 1 ...