Northern Lights Lugger M944W User manual

M944W
Soundshield Assembly Instructions
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L695 05/1

ITEM # DESCRIPTION ADE P/N QTY NOTES
1. Base board 05-71201 1
2. Extrusion, vertical 05-75423 4
3. Extrusion, horizontal, sides 05-75424 2
4. Extrusion, horizontal, ends 05-75426 2
5. Center post, top 05-75428 1
6. Center post, vertical 05-75427 2
7. Corner casting 05-70001 4
8. Bolting assembly 00-75714 22
9. Tie bracket 23-78701 2
10. Rear panel assembly 05-71222 1
11. Front panel assembly 05-71218 1
12. LH side panel forward assembly 05-71209 1 with vent box
13. LH side panel aft assembly 05-75408 1
14. RH side panel forward assembly 05-71207 1 no vent box
15. RH side panel aft assembly 05-75411 1
16. Top panel forward assembly 05-71217 1
17. Top panel aft assembly 05-75403 1
18. Penetration panel assembly 39-78008 1
19. Panel retainer bracket, 30R 23-70036 6
20. #10 screw s/s x 5/8”long 12-72002 12
21. Toe bracket, 30R 23-70038 4
22. Hex nut, nylock 1/4-20 14-00112 10
Specications
Enclosure:
Length (OA) 60.50 in (1536.7 mm)
Width 30.80 in (782.3 mm)
Height 32.10 in (815 mm)
Base:
Length 61.0 in (1549.4 mm)
Width 31.3 in (795 mm)
Height 0.75 in (19.05 mm)
Assembled Height:
32.85 in (834.4 mm)
Assembled Weight (est):
170 lbs (77 kg)
M944W Soundshield
1

4
3
Prior to assembly, inspect all of the components for damage, and report any
damage to the shipping company. Check the packing list to be sure all parts
have been included in the package.
Install the base board (Item 1) in the vessel in as near a level attitude as possi-
ble.
Observe the arrow symbol on the board’s topside surface; this indicates the top
and forward end orientation of the generator set/sound shield. Ensure that this
arrow is correctly positioned or the unit will not mount correctly within the sound
shield. Install toe bracket (item 21) to each corner of the base board to the pre-
drilled holes. Use screws (item 20) to secure to base board. See gure 1.
Use the larger thu-holes near the center of the board as a template to drill your
base mounting bolt holes into your oor or deck.
Place the generator set onto the baseboard, lining up the thru-holes with the
mounting holes in the genset base frame and secure the set to the base.
1
2Select a mounting location in accordance with the guidelines in the IM1000
Installation Manual (supplied with the generator set). The generator set must
typically be mounted on a rigid, at surface above a strong structure, such as the
vessel’s stringers, to minimize vibration transference to the hull. This is particu-
larly important when employing a sound shield, as the baseboard is a non-struc-
tural material and must be fully supported to minimize ex.
Note that the generator set is designed for single side service. When viewed
from the rear, the left hand side is the service side and should be exposed for
easy access for maintenance.
2

5
Install the four vertical corner extrusions (Item 2) with the bolting assemblies (Item
8). Install the bolt with the square head facing outwards. Loosely install the lock
washer and hex nut. Insert one end of the extrusion into the bolting assembly (Item
8), making sure that the square head goes inside the extrusion recess. See Figure
1B.
Figure 1A: Toe bracket shown with
vertical extrusion installed.
3
Figure 1B: Note how the square head
of the T-bolt goes inside the extrusion
recess.
Figure 1: Typical corner, top view.

6
Take the pre-assembled enclosure top (Items 3, 4, 5, 7, 8, 16, 17, 18, 19 and 22)
and note the available leg on each of the cast corners (Item 7). Install a bolting
assembly (Item 8) to each of these legs. See Figure 2.
Figure 2: Internal view of corner casting,
part of the pre-assembled top enclosure
frame assembly.
Note arrangement of bolting assembly.
4
Figure 3: Note how the bolting assembly
ts inside the vertical extrusion. Only nger
tighten until all four corners have been fully
installed.
Make sure that you have the end with the triangular shaped penetration plate
(item 18) at the forward left hand corner of the genset. Then take the enclosure
top assembly and position it so that the legs are facing down and install each
of the legs into the top of each vertical extrusion. You may wish to temporarily
remove the top panel assemblies (items 16 & 17) and set them aside for now to
help improve visual and manual access to the bolting assemblies and for step 8.
See Figure 3.
7

9
After the basic frame is complete, install the rear panel assembly (item 10) to
the rear of the enclosure frame and secure using the pre-installed panel retainer
brackets (item 19) and 1/4-20 nylock nut (item 22). Ensure that the panel is prop-
erly tted into the back of the frame, with the panel surface to extrusion being
ush. Take the panel retainer bracket (item 19) and rotate it until it is directly on
top of the extrusion ange and then tighten down the 1/4-20 nylock nut so the
retainer e󰀨ectively clamps the panel against the extrusion ange.
Note: the black intake hose strapped to lower left hand side of generator; when
rear panel is fully installed just push the open end of this hose into the hole as
shown in the diagram.
Once all four corners of the enclosure top frame assembly have been
attached, install the left and right side vertical center posts (item 6) by aligning the
center post foot mounting holes to the pre-drilled holes at the side mid-section of the
base board. See Figure 4.
Use the #10 screws (item 20) to secure the center post to the base board. Then locate
the stud at the top of the center post of the previously installed tie bracket (item 9),
and secure it with 1/4-20 nylock nut (item 22). See Figure 5.
Do not tighten fully until remaining panels can be installed for clearance adjustment.
8
5
Figure 4: Vertical side posts. Figure 5: Top frame assembly.

10
6
Figure 6: Facing the rear panel.
Install connections for exhaust, fuel, AC power leads, DC control panel leads, battery,
and water through holes in the rear panel as shown in the drawing (Figure 6) and as
described below:
a. Connect the exhaust elbow of the diesel engine to the exhaust system of
the vessel. Pass the three inch exhaust hose through the opening provided
in the left mid-section of the rear panel.
b. Connect the sea water pump to the vessel’s water inlet. Pass a 3/4” hose
from the vessel’s sea water strainer, through the lower hole at the bottom
left of the rear panel to the sea water pump inlet tting.
c. Connect the vessel’s fuel supply, and fuel return to the generator set using
Coast Guard approved rubber fuel hoses. Pass these lines through the hole
provided at the bottom left of the rear panel and attach them to the
generator set’s 1/4” hose barb ttings.
d. Connect the DC control harness to the engine harness plug. Pass the
harness and plug through the top hole on the right side of the rear panel.
e. Connect the 12 volt battery leads to the generator set using the second
hole above the bottom right side of the rear panel.
f. Connect the AC output leads from the generator to the vessel’s power
distribution panel. Pass the two leads through the second hole from
the bottom left side of the rear panel.
g. For optional equipment, leave plug installed.

Note the pre-installed penetration plate (item 18) in the top of forward left corner
of the enclosure frame top.
Refer to the IM1000 Installation manual for the plumbing diagram in the mounting
and exhaust section. Read on to step 11.
Generator sets with wet exhaust that are installed near or below the vessel’s
water line MUST use a siphon break to prevent backow of water into the engine.
This backow can ruin an engine and, possibly, sink the vessel. The penetration
plate (item 18) facilitates the siphon break installation as follows:
a. Disconnect the hose from the seawater output and from the rubber
elbow from the expansion tank. Install two lengths of 3/4” hose. The
hose from the expansion tank must go through the
hole in the penetration plate closest to the side of the
shield.
b. The seawater output holes through the hole in the penetration plate
closest to the front of the shield. The hoses must be of ade-
quate length to allow mounting of a siphon break a mini-
mum of 12 inches above the vessel’s
loaded water line.
c. For more information, see the “Exhaust” section of the IM-1000 Installa-
tion Manual included with the generator set.
Start the generator set and run under load to check for leaks of fuel, water, or
exhaust gas.
11
12
13
7

14
Install all of the cover panels respectively (item 11) in front, (items 12, with vent
box, and 13) on the genset’s left side, and (items 14, without vent box, and 15)
on the right side.
As you install the panels, observe that there should be a minimum clearance of
approximately 1/32” around the panel perimeter (except at the bottom of the side
panels). You may adjust for this by loosening any number of corner bolting as-
semblies until t is satisfactory. Tighten all connections when done.
Occasionally one or more of the panel latches may need a minor adjustment; al-
though they are factory preset. If the panel appears ‘loose’ when latched, all that
is needed is a 1/4” open end or box end wrench and a half a turn counter-clock-
wise to start. If too tight, and won’t latch, then turn clockwise until the panel latch-
es rmly and easily. The threads are coated with a locking compound, so there is
no locking nut.
8

L695 05/16
ITEM # DESCRIPTION ADE P/N QTY NOTES PACKED
1 Base board 05-71201 1 assembled c
2 Extrusion, vertical 05-75423 4 loose c
6 Center post, vertical 05-75427 2 loose c
10 Rear panel assembly 05-71222 1 assembled c
19 Panel retainer bracket, 30R 23-70036 4 installed c
22 Hex nut, nylock 1/4-20 14-00112 4 installed c
Enclosure top, assembled. 1 c
Consists of the following parts:
3 Extrusion, horizontal, sides 05-75424 2 assembled –
4 Extrusion, horizontal, ends 05-75426 2 assembled –
5 Center post, top 05-75428 1 assembled –
7 Corner casting 05-70001 4 installed –
8 Bolting assembly 00-75714 10 installed –
18 Penetration panel assembly 39-78008 1 installed –
19 Panel retainer bracket, 30R 23-70036 2 installed –
22 Hex nut, nylock 1/4-20 14-00112 4 installed –
16 Top panel forward assembly 05-71217 1 assembled –
17 Top panel aft assembly 05-75403 1 assembled –
11 Front panel assembly 05-71218 1 assembled c
12 LH side panel forward assembly 05-71209 1 assembled c
13 LH side panel aft assembly 05-75408 1 assembled c
14 RH side panel forward assembly 05-71207 1 assembled c
15 RH side panel aft assembly 05-75411 1 assembled c
8 Bolting assembly 00-75714 12 loose (bagged) c
20 #10 screws s/s x 5/8” long 12-72002 12 loose (bagged) c
21 Toe bracket, 30R 23-70038 4 loose (bagged) c
Packed By : Date :
M944W Soundshield Packing List

revised 5-23-16
• M673L3 05-78025
• M773L3 05-78625
• M843NW3 05-73120
• M844W/LW3 05-70020
• M864W3 05-78725
• M944W3 05-01205
This a󰀨ects the following Sound Enclosure Assembly Instructions:
A NORTHERN LIGHTS SOUND ENCLOSURE ASSEMBLY ADDENDUM PAPER
WATER INLET
FUEL LINES
EXHAUST OUTLET
GENERATOR INLET PLENUM
OUTPUT CABLES
DC CONTROL CABL
E
ENGINE AIR INTAKE
SNORKE
L
NOTE: SOME LOCATIONS CONSIST OF TWO LAYERS
OF SOUND FOAM. TWO PLUGS MAY BE PRESENT
AND MUST BE REMOVED BEFORE PANEL INSTALLATION.
SHOWN BELOW IS THE INTERIOR VIEW OF A TYPICAL
SOUND SHIELD REAR PANEL. APPEARANCE MAY VARY
DEPENDING UPON GENSET MODEL.
REMOVE FOAM PLUGS AT LOCATIONS AS SHOWN BELOW.
Completed By: Date:
Northern Lights, Inc. • 4420 14th Ave. NW., • Seattle WA 98107
Tel: [phone] • 1-800-762-0165 • Fax: [phone]
Information and dimensions subject to change without notice.
Northern Lights and Lugger are registered trademarks of Northern Lights, Inc.
© 2015 All rights reserved. Litho USA. 5/16