Northern Lights NL668T2 Parts Manual

PARTS

CATALOG

Publication #P668PT for models:

LP668D, LP668T, MP668D, MP668T, MP668QT,

MP668H, MP80C, MP99C, NL668T1, and NL668T2

— CALIFORNIA —

Proposition 65 Warning:

Diesel engine exhaust and some of its constitu-

ents are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

Alaska Diesel Electric, Inc.

4420 14th Avenue N.W. Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455

Copyright ©2005 Alaska Diesel Electric, Inc. All rights reserved. Alaska Diesel Electric™, the Alaska Diesel Electric logo, Northern Lights™, and the Northern Lights logo are all trademarks of Alaska Diesel Electric, Inc.

Printed in U.S.A. PART NO.: P668PT 09/05

PARTS CATALOG

for Models

LP668D, LP668T, MP668D, MP668T, MP668QT,

MP668H, MP80C, MP99C, NL668T1, NL668T2

Please read thoroughly before aempting to use this manual:

Table of Contents ............................................................................................................................................ I

Model Designation & Serial Numbers .............................................................................................................. II

Reading a Parts Page ..................................................................................................................................... III

Table of Contents

GROUP 1 - ENGINE

Cylinder Block Assembly ...............................0 - 3

Flywheel & Housing ....................................4 - 7

Crankshaft & Main Bearings ........................ 8 - 9

Crankshaft Pulley ................................... 10 - 11

Cylinder Liner Assembly & Connecting Rod ...12 - 13

Timing Cover Plate ........................................14

Camshaft ........................................................... 15

Timing Cover .............................................16 - 17

Oil Filter Assembly, Mounting, & Adapter ..... 18 - 22

Oil Pump ................................................................... 23

Oil Pan .............................................................. 24 - 25

Oil Drain & Dipstick ......................................... 26 - 27

Oil Fill Assembly .............................................. 28 - 29

Cylinder Head, Head Gasket, Valves ........... 30 - 31

Rocker Cover, Rocker Shaft, Rocker Arm ........32 - 34

Ventilating System .................................................... 35

GROUP 2 - INTAKE & EXHAUST

Intake Manifold and Air Cleaner (Propulsion) ..... 0 - 3

Air Intake & Turbocharger (Marine) .................4 - 5

Air Filter & Air Intake (Industrial) ............................ 6

Intake Manifold ......................................................7 - 8

Exhaust Elbow (Industrial) ......................................... 9

Exhaust Manifold .............................................. 10 - 11

Exhaust Elbows ................................................. 12 - 15

Turbocharger Assemblies .................................. 16 - 20

GROUP 3 - COOLING SYSTEM

Expansion Tank Assembly (Marine) ...................0 - 1

Heat Exchanger ..............................................2 - 3

Coolant Pump & Inlet ............................................4 - 5

Raw Water Pump & Mounting ...............................6 - 7

Thermostat & Housing ................................................ 8

Engine Oil Cooler ..................................................9

Idler Shaft Assembly ............................................ 10

Radiator & Mounting ................................................ 11

GROUP 4 - FUEL SYSTEM

Fuel Injection Pump & Fuel Lines .....................0 - 3

Double Wall Fuel Lines .........................................4 - 5

Injection Pump Applications ................................... 6

Fuel Injector ..........................................................7

Fuel Filter & Lines .............................................. 8 - 10

Fuel Transfer Pump ................................................... 11

Throttle .............................................................. 12 - 13

GROUP 5 - ELECTRICAL SYSTEM

12 & 24 Volt, Standard & Isolated Ground ..........0 - 9

Stop Solenoid ...................................................... 10

Alternator and Mounting ...............................11 - 15

12 & 24 Volt Relay Boards ...............................16 - 17

Drive Belts ................................................................18

S-1 Control Panel 12 & 24 Volt ................................19

S-3B Control Panel 12 & 24 Volt .............................. 20

S-3C Control Panel 12 & 24 Volt .............................. 21

Panels ................................................................ 22 - 24

Belt Guards .......................................................26 - 29

GROUP 6 - GASKET SETS

Engine Overhaul ...............................................0 - 1

GROUP 7 - GEAR AND ADAPTER PARTS

Consult dealer or factory.

GROUP 8 - BASE FRAME & MOUNTING

Engine Mounts (Propulsion) ....................................... 0

GROUP 9 - ACCESSORIES & OPTIONAL EQUIPMENT

Electric Clutch & PTO Assembly ............................... 1

Hydraulic Pump Drive Assembly ..........................2 - 4

Low Oil Level Switch/Gauge ..................................... 5

Low Coolant Level Switch/Gauge .............................. 6

Raw Water Flow Switch ..................................... 7 - 10

12 & 24 Volt Governor Actuator & Mounting .......... 11

Optional Alternators .......................................... 12 - 13

Proprietary Information

This publication is the property of Alaska Diesel Electric, Inc.

It may not be reproduced in whole or in part without the written permission of Alaska Diesel Electric, Inc.

P668PT 09/05

I

INTRODUCTION

MODEL DESIGNATION

Refer to the category designations below to nd the correct parts pages for your model.

LP - MP - NL

LP - Lugger propulsion unit MP - Northern Lights marine generator set NL - Northern Lights industrial generator set

LP 668 D

LP 668 T

MP 668 D

MP 668 T

MP 668 QT

Northern Lights naturally aspirated propulsion engine with a John Deere 6068 engine.

Northern Lights turbocharged propulsion engine with a John Deere 6068 engine.

Northern Lights naturally aspirated marine diesel generator set with a John Deere 6068 engine.

Northern Lights turbocharged marine diesel generator set with a John Deere 6068 engine.

668 D - T - H - C

Base Model #

(Deere 6068 Powertech

Series engine block)

MP 668 H

MP 80 C

MP 99 C

NL 668 D

NL 668 T

Aspiration

D Natural QT, T Turbocharged

Northern Lights turbocharged high output marine diesel generator set with a John Deere 6068 engine.

Northern Lights turbocharged marine diesel generator set with a John Deere 6068 engine, 80 kW.

Northern Lights turbocharged marine diesel generator set with a John Deere 6068 engine, 99 kW.

Northern Lights naturally aspirated industrial diesel engine, with a John Deere 6068 engine.

Northern Lights turbocharged industrial diesel generator set with a John Deere 6068 engine.

H High Output C Commercial

All model numbers in parentheses will indicate a John Deere base engine. All variations requiring serial

numbers for proper identication will be noted as ADE or John Deere.

SERIAL NUMBERS

NORTHERN LIGHTS

Your set has three serial numbers: 1 an engine number stamped on the block, 2 a generator plate, and 3 a generator set plate. Use the serial number on the generator set plate when ordering parts or in correspondence. The generator set plate is found on the service side of the generator and resembles one of the drawings below.

Generator Set Serial Number

Lugger Serial Number

Generator Set Serial Number

P668PT 09/05

II

INTRODUCTION

READING A PARTS PAGE

IMPORTANT:

Before selecting parts, be sure that you are choosing parts from the correct page.

Check the model designation at the page top.

Do not use this illustration for parts purchasing.

1

ELECTRICAL SYSTEM

ALTERNATOR ASSEMBLY: M - NL668

4

6

5

KEY PART NUMBER QTY. DESCRIPTION SERIALNUMBER

0 185046210 1 Alternator Assembly 1 185446219 1 Flywheel, complete 2 185446217 1 Plate, complete 3 185716200 1 Plate 4 185446218 1 Stator, complete 5 040126210 2 Bearing 6 020210010 1 Nut 7 027100010 1 Spring washer 8 026100010 1 Washer 9 185446220 1 Clamp 10 015140408 1 Screw 11 015140425 2 Screw 12 199236510 1 Collar -

7 8

10

23

9

13

11

P668PT 08/00

5-2

14

12

REFERENCES:

1. Grouping section title. 7. Quantity of parts used.

2. Model designation of equipment that uses parts 8. Description of each component part.

listed on this page. 9. Serial number of unit the part ts.

3. Title and description of assembly. 10. Assembly or kit designated by Key 0 or ••/•.

4. Drawing numbers that correspond to key 11. Grouping index number.

column numbers for parts identication. 12. Page number within the grouping index.

5. Key column for locating parts shown on drawing. 13. Manual title.

6. Part number. 14. Page publication date.

NOTE: a Arrows always point toward the front of the engine.

P668PT 09/05

III

GROUP 1 – ENGINE

Cylinder Block

P668PT 09/05

TP55073

1 - 0

GROUP 1 – ENGINE

Cylinder Block

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 1 Cylinder Block (marked R119565)* 2 R114241 6 Main Bearing Cap 3 R132186 1 Main Thrust Bearing Cap 4 T23474 14 Cap Screw 5 T20168 14 Washer 6 R119874 1 Camshaft Bushing 7 R132518 1 Plate 8 19M8999 2 Screw, M8 x 25 9 R121043 1 Valve, Oil By-pass 10 R111137 1 Spring 11 R26493 1 Bushing, Oil pressure regulating 12 R116466 1 Bushing 13 R26650 2 Dowel Pin 14 15H623 1 Pipe Plug, 3/8" 15 R115390 1 Bushing 16 R75892 1 O-ring 17 R48685 4 Dowel Pin 18 T18891 2 Cap 19 R55233 1 Pipe Plug, 1/4" 20 R104592 7 Pipe Plug -

 21 R131182 6 Orice -

22 R39741 2 Drain Plug 23 U13639 2 O-ring 24 T43514 1 Gasket 25 15H624 1 Pipe Plug, 1/2", 26 AT13740 1 Drain Valve -

(without turbo) -

*Not available separately - see short block listing.

P668PT 09/05

1 - 1

GROUP 1 – ENGINE

Cylinder Block

P668PT 09/05

TP55074

1 - 2

GROUP 1 – ENGINE

Cylinder Block

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 RE516155 1 Short Block RE516153 1 Short Block (MP668T & MP80C, formerly RE65962) RE516152 1 Short Block (LP668T - MP668H - NL668T2 & MP99C, formerly

RE65981)

(LP668D, formerly RE65960)

P668PT 09/05

1 - 3

GROUP 1 – ENGINE

Flywheel Housing

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 R500329 1 Flywheel Housing 2 R131769 1 Plug 3 R61467 1 O-ring 4 RE44574 1 Seal 5 15H624 1 Pipe Plug, 1/2" 6 19M8306 4 Capscrew, M12 x 50 mm 7 R135918 8 Bolt 8 R39112 1 Fitting -

P668PT 09/05

RGP7315

1 - 4

GROUP 1 – ENGINE

Notes

P668PT 09/05

1 - 5

GROUP 1 – ENGINE

Flywheel Housing SAE #2

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 R500129 1 Flywheel Housing, SAE #2 2 RE44574 1 Seal 3 R135918 10 Bolt 5 R27149 1 O-ring 6 AR61533 1 Plug 7 AR61589 1 Plug 8 19M8306 4 Screw 9 R131769 1 Plug 10 T22867 1 Plug -

P668PT 09/05

RGP6019

1 - 6

GROUP 1 – ENGINE

Flywheel SAE #11-1/2

TP58401

KEY PART NUMBER QTY DESCRIPTION John Deere S/N

1 RE500398 1 Flywheel Assembly SAE #11-1/2 (marked 500219 - includes key #2) 2 R28811 1 Ring Gear

(129 teeth) -

3 19M7493 ** Cap Screw, M12 x 40 up to - 708963 4 T77258 ** Washer up to - 708963 5 R135918 6 Bolt from 708964 -

**As required

P668PT 09/05

1 - 7

GROUP 1 – ENGINE

Crankshaft and Main Bearings

P668PT 09/05

TP60710

1 - 8

GROUP 1 – ENGINE

Crankshaft and Main Bearings

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 RE52850 1 Crankshaft (marked R116076, also order #9) 2 R48685 1 Dowel Pin 3 26M4224 1 Shaft Key 4 R120631 1 Gear 5 RE65165 6 Bearing Kit, Standard RE65911 6 Bearing Kit 6 RE65168 1 Thrust Bearing Kit, Standard RE65912 1 Thrust Bearing Kit 7 34H283 ** Spring Pin 8 R114194 1 Shaft, Lower 9 RE59811 1 Sleeve 10 RE56313 1 Gear, Upper Idler 11 R123174 1 Lock Washer 12 R120641 1 Shaft, Upper 13 34H288 1 Spring Pin 14 R101225 1 Thrust Washer 15 R114193 1 Bushing 16 R131206 1 Thrust Washer 17 19M8997 1 Screw, M10 x 65 18 19M8966 1 Screw, M10 x 50 19 R131283 1 Thrust Washer 20 RE56369 1 Gear, Lower Idler -

(30 teeth) -

(undersize .254 mm) -

(with installation tool) -

(marked R120635) -

**As required

P668PT 09/05

1 - 9

GROUP 1 – ENGINE

Crankshaft Pulley and Damper

TP50816

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 R133296 1 Pulley, 188 mm O.D. (replaces R123188) - R133295 1 Pulley, 168 mm O.D. 2 RE59355 1 Torsional Dampener

(LP668D only) -

(marked R59355) -

3 R121897 4 Capscrew, Hex Head Flanged M10 x 1.25 x 50 mm Grade 10.9 -

P668PT 09/05

1 - 10

GROUP 1 – ENGINE

Crankshaft Pulley

A-8582, A-8583/ B-3732

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 34-69502 1 Pulley, Crankshaft, 3-A/B x 8" 34-69501 1 Pulley, Crankshaft, 4-A x 8" 2 12-00318 4 Capscrew, Hex Head, 3/8-16 x 2-1/2" 3 15-00321 4 Flat Washer, 3/8" SAE -

P668PT 09/05

1 - 11

GROUP 1 – ENGINE

Cylinder Liner Assembly and Connecting Rod

P668PT 09/05

1 - 12

GROUP 1 – ENGINE

Cylinder Liner Assembly and Connecting Rod

KEY PART NUMBER QTY DESCRIPTION DEERE S/N

• RE505110 6 Piston-Liner Kit (LP668D, includes keys 1, & 4-6, formerly RE65966) -

•• RE505111 6 Piston-Liner Kit (MP668T, includes keys 1, & 4-6, formerly RE65967) -

•• RE505112 6 Piston-Liner Kit (LP668T-MP668H & NL668T2, includes keys 1, & 4-6, formerly RE65969) 1 RE66271 6 Piston Ring Kit (LP668D - MP668T) RE66820 6 Piston Ring Kit 2 M41029 12 Snap Ring R54114 12 Snap Ring 3 R123178 6 Piston Pin R123177 6 Piston Pin 4 Piston 5 Cylinder Liner 6 AR65507 6 O-ring Kit 7 RE60272 6 Connecting Rod

RE500002, includes keys 8-9) up to 036627 Torreon

RE500002 6 Connecting Rod (LP668D - MP668T, marked R500000, from 794055 Dubuque

includes keys 8-9) from 036628 Torreon

RE50770 6 Connecting Rod

RE500608, includes keys 8-9)

RE500608 6 Connecting Rod

8-9)

8 R123960 6 Bushing (LP668D, MP668T) R114082 6 Bushing 9 R114083 12 Screw

up to 036627 Torreon

(LP668T - MP668H - NL668T2) - (LP668D - MP668T) - (LP668T - MP668H - NL668T2) -

(LP668D - MP668T) - (LP668T - MP668H - NL668T2) -

} Not available separately

(Cylinder Liner) -

(LP668D - MP668T, marked R123959, replaced by up to 794054 Dubuque

(LP668T - MP668H - NL668T2, replaced by -

(LP668T - MP668H, marked R500335, includes keys -

(LP668T, MP668H, & NL668T2) -

up to 794054 Dubuque

R501124 12 Screw from 794055 Torreon from 036628 Torreon 10 RE65908 6 Bearing (Standard) RE65909 6 Bearing

(.010" undersize) -

Note: Cylinder Liner Shims, 002" #CD15466 and .004" #R65833,

Refer to Workshop Manual CTM104 for application instructions.

P668PT 09/05

1 - 13

GROUP 1 – ENGINE

Timing Cover Plate

TP50813ab

KEY PART NUMBER QTY DESCRIPTION John Deere S/N

1 R121671 Plate* up to - 703905 R134526 1 Plate from - 703906 2 R136475 6 Screw up to - 703905 R136475 4 Screw up to - 703905 3 R135757 1 Cover 4 T20758 1 O-ring 5 19M7790 2 Capscrew, M12 x 1.75 x 35 mm -

*No longer available: Replaced by Plate 134526, Cover R501297, Gasket

R136515, Stud 134518 (2 ea.), and Nut 14-80811 (2 ea.)

P668PT 09/05

1 - 14

GROUP 1 – ENGINE

Camshaft

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 RE56578 1 Camshaft and Gear (marked R135440) -

P668PT 09/05

TP60711

1 - 15

GROUP 1 – ENGINE

Timing Cover

P668PT 09/05

TP59257

1 - 16

GROUP 1 – ENGINE

Timing Cover

KEY PART NUMBER QTY DESCRIPTION John Deere S/N

1 R121625 1 Cover* up to - 703904 R501297 1 Cover from 703905 2 R136515 1 Gasket 3 RE501938 1 Plug 4 51M7044 1 O-ring 5 19M8317 10 Capscrew, M8 x 1.25 x 40 mm RE67239 1 Capscrew, M8 x 1.25 x 45 mm 6 19M8291 1 Capscrew, M8 x 1.25 x 35 mm 19M7801 1 Capscrew, M8 x 1.25 x 60 mm 7 R121424 1 O-ring 8 R121411 1 Cover 9 19M7775 3 Capscrew, M6 x 1.0 x 16 mm 10 R67239 2 Capscrew, M8 x 1.25 x 45 mm 11 RE59810 1 Seal 12 R83169 1 Pressure Relief Valve 13 T27658 1 Spring 14 A4827R 1 Washer 15 T27657 1 Plug 16 14-80811 2 Flange Nut, M10 x 1.5 17 19M7979 2 Capscrew, M8 x 1.25 x 55 mm 18 R123584 4 Stud 19 R134518 2 Stud from 703905 20 14-80811 2 Flange Nut, M10 x 1.5 from 703905 -

(includes key #4) -

(with sealant) -

*

R136515, Stud R134518 (2 ea), and Hex Nut 14-80811 (2 ea).

No longer available. Replaced by Cover R501297, Gasket

P668PT 09/05

1 - 17

GROUP 1 - ENGINE

Oil Filter Assembly and Mounting LP668

Early Production

P668PT 09/05

1 - 18

A-8771/ B-6183

GROUP 1 - ENGINE

Oil Filter Assembly and Mounting LP668

Early Production

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 RE60153 1 Oil Filter Head Assembly (Includes key #20) 2 23-09601 1 Bracket 3 12-10815 1 Capscrew, Flat Head, M10 x 1.5 x 40 mm 4 01435-01040 1 Capscrew, Hex Head Flanged, M10 x 1.5 x 40 mm 5 21-13110 1 Spacer 6 12-00809 2 Capscrew, Hex Head, M10 x 1.25 x 25 mm 7 15-00804 2 Wave Washer, M10 8 18-09601 1 Hose Assembly, 1/2" I.D. x 18" 9 18-09601 1 Hose Assembly, 1/2" I.D. x 18" 10 R123525 1 Gasket 11 RE71062 1 Adapter 12 RE52242 ** Plug 13 19M7913 1 Screw, M8 x 90 14 RE67238 1 Screw, M8 x 20 15 19M7802 4 Screw, M8 x 65 16 21-09505 4 Elbow Fitting 17 21-09504 4 Adapter

(Includes keys #18 & 19) -

18 51M7045 4 O-ring 19 T77932 4 O-ring 20 Adapter

(R123591 no longer available, replaced by RE60153) -

21 24-01002 1 Oil Filter -

**

As required

(with pre-applied sealant) -

(Includes keys #18 & 19) -

P668PT 09/05

1 - 19

GROUP 1 - ENGINE

Oil Filter Assembly and Mounting LP668

Late Production

P668PT 09/05

1 - 20

A-8771/ B-6183

GROUP 1 - ENGINE

Oil Filter Assembly and Mounting LP668

Late Production

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 31-79601 1 Oil Filter Head Assembly (Includes key #20) 2 23-09601 1 Bracket 3 12-10815 1 Capscrew, Flat Head, M10 x 1.5 x 40 mm 4 01435-01040 1 Capscrew, Hex Head Flanged, M10 x 1.5 x 40 mm 5 21-13110 1 Spacer 6 12-00809 2 Capscrew, Hex Head, M10 x 1.25 x 25 mm 7 15-00804 2 Wave Washer, M10 8 18-09401 1 Hose Assembly, 1/2" I.D. x 16" 9 18-09401 1 Hose Assembly, 1/2" I.D. x 16" 10 R123525 1 Gasket 11 RE71062 1 Adapter 12 RE52242 ** Plug 13 19M7913 1 Screw, M8 x 90 14 RE67238 1 Screw, M8 x 20 15 19M7802 4 Screw, M8 x 65 16 21-09504 4 Adapter

(Includes keys #18 & 19) -

17 21-09503 2 Plug, Socket Head M22 x 1.5 18 51M7045 4 O-ring 19 T77932 4 O-ring 20 Adapter

(no longer available separately - order #31-79601) -

21 24-01002 1 Oil Filter -

**

As required

(with pre-applied sealant) -

(Includes key#18) -

P668PT 09/05

1 - 21

GROUP 1 - ENGINE

Oil Filter and Adapter

TP61873

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 RE71598 1 Filter Head 2 RE52242 ** Plug

(includes key #3) -

3 51M7042 ** O-ring 4 R501484 1 Gasket 5 19M7802 5 Capscrew, M8 x 1.25 x 65 mm 6 RE67238 1 Capscrew, M8 x 1.25 x 20 mm 7 24-01002 1 Oil Filter -

**

As required

P668PT 09/05

1 - 22

GROUP 1 - ENGINE

Oil Pump

TP49336& TP49656

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 RE504914 1 Oil Pump (marked R502687, formerly RE502269, RE70153, all -

marked R123179)

2 R120638 1 Gear

(30 teeth) -

3 14M7066 1 Nut, M12 4 19M8987 2 Screw, M8 x 65 5 R121376 1 Tube 6 R97185 1 O-ring 7 RE71143 1 Oil Pump Intake 8 R61871 1 O-ring 9 19M8986 2 Screw, M8 x 100 -

P668PT 09/05

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GROUP 1 - ENGINE

Oil Pan

Aluminum

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 R134898 1 Oil Pan 2 R123354 1 Gasket 3 12-80753 6 Screw, M8 x 30 4 19M7799 2 Screw, M8 x 45 5 19M7867 28 Screw, M8 x 25 6 RE46685 ** Plug, M18 x 1.5 7 16-09503 2 O-ring 8 21-13101 ** Plug, 1/2 NPT 9 RE46687 2 Plug 10 16-09501 1 O-ring -

**

As required

P668PT 09/05

TP62205

1 - 24