Northern Lights GEM Series User manual

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M944T3F
GEM Series Sound Enclosure
Assembly Instructions
000 COVER PAGE

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Printed in U.S.A.
LIT NO.: L818 5/19

ITEM # DESCRIPTION ADE P/N QTY NOTES
1. 1/4” NPT x 3-1/2” pipe nipple 21-01208 1
2. 3/8” NPT x 3” pipe nipple 21-01207 1
3. 1/4” NPT brass pipe cap 21-72241 1
4. 3/8” NPT brass pipe cap 21-78004 1
5. Rear intake duct assembly 06-71272 1
6. M8 button head hex screw 12-00118 10
7. 5/16” ext tooth lockwasher 15-09204 16
8. 5/16” pan head machine screw 12-00119 6
9. Rear panel/valence assembly 06-71202 1 includes 06-71269
10. Hole plug 1” white 00-78006 6
11. 1/4”-20 pan head machine screw 12-45102 12
12. 1/4” ext tooth lockwasher 15-09103 12
13. Service side lower valence 06-71206 1
14. Non-service side lower valence 06-71207 1
15. Sound foam, side valence 55-71261 2
16. Front lower valence assembly 06-71213 1
17. Service side panel aft 06-71209 1
18. Non-service side panel aft 06-71212 1
19. Non-service side panel fwd 06-71211 1
20. Front panel assembly 06-71201 1
21. Seal bar 06-71271 1
22. Service side panel fwd assembly 06-71208 1
23. Top panel aft assembly 06-71204 1
24. Top panel fwd assembly 06-71203 1
25. Grommet, vented loop 00-70146 2 optional use
SPECIFICATIONS
Enclosure:
Length (OA) 60.1 in (1527 mm)
Width 29 in (737 mm)
Height 32.1 in (815 mm)
Assembled height on base frame: 32.1 in (815 mm)
Assembled weight w/o sub-base (est): 164 lbs (74 kg)
M944T3F GEM Sound Enclosure
1

Prior to assembly, inspect all components for damage. Report any damage to the shipping company. Check the packing list in the back of this manual
to be sure all parts are included.
Select a mounting location in accordance with the guidelines in the IM1000 Installation Manual. 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.
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 maintenance access.
Install the generator set in the vessel as near to a level attitude as possible. Ensure that the enclosure’s right hand side and rear are at the
recommended distances (6 inch recommended, 4 inch minimum.) from the vessel’s bulkheads.
A
Note: The Generator set may still possess original factory lifting points. These lifting points will need to be loosened and rotated down, below the highest
point of the engine. Be sure to tighten these bolts before installing generator set.
AVOID POSITIONING THE ENCLOSURE INTO CORNERS WITH OVERHEAD BLOCKED TO REDUCE CHANCE OF INTAKE/EXHAUST AIR
RECIRCULATION OUTSIDE THE SHIELD.
A
IN FRONT OF BASE FRAME.
(items #1 and 2.)
STEP 1.
INSTALL PIPE NIPPLES TO
CORRESPONDING SIZE PORTS
STEP 2.
INSTALL PIPE CAPS (items 3 and 4.)
TO PIPE NIPPLES.
VIEW: FRONT OF GENSET BASE FRAME
PAGE 2 GRAPHIC
2

3
A
DETAIL A
SCALE 1 : 4
STEP 3.
LOCATE AND INSTALL REAR LOWER INTAKE DUCT
ASSEMBLY (item 5.) TO TAPPED HOLES AT REAR OF BASE FRAME.
STEP 4.
INSTALL 4x BUTTON HEAD HEX SCREW AND 4x STARWASHER (items 6 AND 7.)
TO SECURE DUCT ASSEMBLY TO BASE FRAME USING 5mm HEX TOOL.
VIEW: REAR OF GENSET BASE FRAME.
SOUND FOAM OMITTED
FOR VIEW CLARITY.
B
PAGE 3 GRAPHIC
A
DETAIL A
SCALE 1 : 4
STEP 5.
INSTALL REAR PANEL/LOWER
VALENCE ASSEMBLY (item 9.)
TO REAR OF GENSET/BASE FRAME.
6x 5/16" EXTERNAL STARWASHER (item 7.)
6x 5/16" PAN HEAD MACHINE SCREW (item 8.)
VIEW: RIGHT CORNER AFT
F
DETAIL F
SCALE 1 : 4
VIEW: LEFT SIDE CORNER AFT
5/16" PAN HEAD MACHINE SCREW (item 8.)
5/16" EXTERNAL STARWASHER (item 7.)
PAGE 3 LOWER GRAPHIC
C
B
C

DETAIL A
E
STEP 8.
INSTALL NON-SERVICE SIDE LOWER VALENCE (item 14.)
USING 1/4"-20 PAN HEAD MACHINE SCREW AND 1/4" STARWASHER
(items 11 and 12.) SEE INSET DETAIL, TYPICAL BOTH SIDES.
STEP 9.
INSTALL SERVICE SIDE LOWER VALENCE (item 13.)
USING 1/4"-20 PAN HEAD MACHINE SCREW AND
1/4" STARWASHER (items 11 and 12.)
INSET DETAIL A
3X 1/4"-20 PAN HEAD MACHINE
SCREW (item 11.) EACH SIDE.
3x 1/4" STARWASHER (item 12.)
EACH SIDE
PAGE 4 LOWER GRAPHIC
DETAIL A
E
STEP 8.
INSTALL NON-SERVICE SIDE LOWER VALENCE (item 14.)
USING 1/4"-20 PAN HEAD MACHINE SCREW AND 1/4" STARWASHER
(items 11 and 12.) SEE INSET DETAIL, TYPICAL BOTH SIDES.
STEP 9.
INSTALL SERVICE SIDE LOWER VALENCE (item 13.)
USING 1/4"-20 PAN HEAD MACHINE SCREW AND
1/4" STARWASHER (items 11 and 12.)
INSET DETAIL A
3X 1/4"-20 PAN HEAD MACHINE
SCREW (item 11.) EACH SIDE.
3x 1/4" STARWASHER (item 12.)
EACH SIDE
PAGE 4 LOWER GRAPHIC
A
DETAIL A
SCALE 1 : 4
D
VIEW: BOTTOM REAR OF SOUND SHIELD
STEP 6.
SECURE REAR LOWER VALENCE PANEL TO REAR OF
BASE FRAME WITH 3x BUTTON HEAD HEX SCREW (item 6.) AND
3x STARWASHER (item 7.) USING 5mm HEX TOOL.
STEP 7.
WHEN REAR PANEL/LOWER VALENCE ASSEMBLY IS SECURED
INSERT HOLE PLUGS (item 10.)
PAGE 4 GRAPHIC
D
E
4

STEP 10
INSTALL FRONT LOWER VALENCE ASSEMBLY (item 16.)
A
DETAIL A
VIEW: FRONT
3x BUTTON HEAD HEX SCREW (item 6.)
AND 3x STARWASHER (item 7.)
STEP 11
INSTALL 3x HOLE PLUGS (item 10.) WHEN
FRONT VALENCE (item 16) IS SECURED.
DETAIL B
FOLLOWING COMPLETION OF
FRONT VALENCE INSTALL SIDE
VALENCE SOUND FOAM (item 15.)
TYPICAL EACH SIDE.
DETAIL DETAIL B
SCALE 1 : 4
3x 1/4" STARWASHER
(ITEM 12.) EACH SIDE.
3x 1/4"-20 PAN HEAD
MACHINE SCREW
(item 11.) EACH SIDE.
INSET DETAIL B
F
PAGE 5 GRAPHIC
F
5

G
A
E
G
B
F
D
C
VIEW: REAR
G
PAGE 6 GRAPHIC
For keel cooled
application.
STEP 12
CONNECT GENERATOR SET TO THE VESSEL. SEE PICTURE BELOW AND LEGEND.
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
right side of the rear panel.
b. Connect the sea water pump to the vessel’s water inlet. Pass a 3/4” ID hose from the vessel’s sea water strainer, through the bottom hole on the right side
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 hose. Fuel connections are 5/16-37T JIC inlet
and 1/4-37T JIC outlet located at the fuel manifold on the base frame of the generator set’s left hand side, through the bottom hole in the left side of the rear
panel.
d. Connect the DC control panel harness to the genset engine harness plug through the middle hole on the rear panel’s left lower side.
e. Connect the 12 volt battery leads to the generator set using the top slot on the right side of the rear panel.
f. Connect the AC output leads from the generator junction box to the vessel’s power distribution panel. Pass the two leads through the top slot on the left side
of the panel.
g. *OPTIONAL* This port is used for water outlet in Keel Cooled applications.
Install connections for exhaust, AC power
leads, DC control panel leads, battery and
water inlet through holes in the rear panel
as shown in the drawing and as described
below:
A
6

7
C
STEP 13
INSTALL SERVICE SIDE PANEL AFT (item 17.)
DETAIL C
CAPTIVE SCREWS.
FINGER START AND WITH FINISH LIGHT HAND TIGHT
USING PHILLIPS HEAD SCREW DRIVER.
DO NOT OVER TIGHTEN.
STEP 14
INSTALL NON-SERVICE SIDE PANEL
AFT (item 18.) SEE DETAIL C.
H
PAGE 7 GRAPHIC
H

I
D
STEP 15
INSTALL NON SERVICE SIDE PANEL FWD (item 19.)
SEE DETAIL D.
DETAIL D
CAPTIVE SCREWS.
FINGER START AND FINISH LIGHT HAND TIGHT
USING PHILLIPS HEAD SCREW DRIVER.
DO NOT OVER TIGHTEN .
I
PAGE 8 GRAPHIC
8

9
REMOVE AND DISCARD
THIS HOSE.
RAW WATER PUMP OUTLET.
CONNECT LOOP
TO THIS FITTING.
HEAT EXCHANGER INLET.
CONNECT LOOP TO
THIS FITTING.
REMOVE HOLE PLUGS AND
INSTALL GROMMETS (item 25.)
HOSES FROM RAW WATER PUMP
OUTLET AND HEAT EXCHANGER INLET
GO THROUGH HERE TO THE SIPHON BREAK.
HOSES MUST BE OF SUFFICIENT LENGTH TO ALLOW YOU TO MOUNT
THE SIPHON BREAK A MINIMUM OF 12 INCHES ABOVE THE VESSEL'S
LOADED WATERLINE.
J
PAGE 9 GRAPHIC
STEP 16
VENTED LOOP ROUTING. GENERATOR SETS WITH WET EXHAUST THAT ARE INSTALLED NEAR OR BELOW THE
VESSEL'S WATER LINE MUST USE A SIPHON BREAK TO PREVENT BACKFLOW OF WATER INTO THE ENGINE.
THIS BACK FLOW CAN RUIN AN ENGINE AND, POSSIBLY SINK THE VESSEL.
CONNECT ONE SIDE OF THE LOOP FROM THE OUTLET OF THE RAW WATER PUMP, AND THE
OTHER TO THE RAW WATER INLET OF THE HEAT EXCHANGER, AS INDICATED ON THE DIAGRAM BELOW.
REFER TO THE IM1000 INSTALLATION MANUAL, IN THE PLUMBING AND EXHAUST SECTION.
.
J

STEP 17
INSTALL FRONT PANEL ASSEMBLY (item 20.)
REFER TO DETAIL VIEWS 'E' AND 'F' FOR CONNECT POINT LOCATIONS.
BOTTOM LEFT
SIDE CORNER
F
E
TOP RIGHT
SIDE CORNER
DETAIL F
THUMBSCREW LATCH. BEFORE PLACING
FRONT PANEL IN POSITION ROTATE KNOBS
TO THE LEFT UNTIL STOP. INSTALL PANEL.
TO ENGAGE ROTATE KNOB TO RIGHT UNTIL
STOP. TWIST WITH FIRM PRESSURE TO SECURE.
DETAIL E
HINGE LATCH. WHEN POSITIONING FRONT
PANEL TO SHIELD ENSURE THE UPPER HINGE
RECEPTACLE RECIEVES THE LOWER PIN THAT
IS ATTACHED TO THE RIGHT SIDE PANEL.
K
PAGE 10 GRAPHIC
K
10

L
11
G
STEP 18
INSTALL SEAL BAR ASSEMBLY (item 21.)
DETAIL G
CAPTIVE THUMBSCREWS.
CONNECT FRONT PANEL
(item 20.) TO SERVICE SIDE
AFT PANEL (item 17.)
L
PAGE 11 GRAPHIC

H
STEP 19
INSTALL TOP AFT PANEL ASSEMBLY
(item 23.)
LOCATE PINS TO HOLES WHERE
INDICATED.
SEE DETAIL H.
PIN RECEPTACLE
PIN RECEPTACLE
PIN RECEPTACLE
PIN RECEPTACLE
DETAIL H
UNIT IS SHIPPED WITH LATCH IN DISENGAGED POSITION.
WHEN PANEL IS PLACED WITH PINS ALIGNED, PULL RING
HANDLE UP AND ROTATE 180 DEGREES AND PULL DOWN.
LATCHES ARE PRE-SET AT FACTORY BUT SOME ADJUSTMENT
MAY BE REQUIRED FOR FULL PANEL RETENTION.
(REFER TO LATCH SUPPLEMENT INCLUDED WITH ASSEMBLY
INSTRUCTIONS.)
M
PAGE 12 GRAPHIC
M
12

N
13
I
PIN RECPTACLE
PIN RECPTACLE
STEP 20
INSTALL TOP FWD PANEL ASSEMBLY
(item 24.)
LOCATE PINS TO HOLES WHERE
INDICATED.
DETAIL I
DRIP CHANNEL/SEAT.
TOP FWD PANEL MUST SEAT
INSIDE THIS CHANNEL.
N
PAGE 13 GRAPHIC

STEP 21
INSTALL THE SERVICE SIDE PANEL
(item 22.)
RING LATCH MAY REQUIRE
SOME ADJUSTMENT, SEE LATCH
SUPPLEMENT INCLUDED WITH
ASSEMBLY INSTRUCTIONS.
O
PAGE 14 GRAPHIC
O
14

REAR PANEL VIEW
FROM SEA WATER PUMP OUTLET TO SIPHON BREAK
FROM SIPHON BREAK TO HEAT EXCHANGER INLET
06-78700 M864W3 GEM Page 13
13.
IF YOU HAVE CHOSEN TO INSTALL A SIPHON BREAK:
Note the two plugged penetrations in the top left corner
of the rear panel. These are the ports through which the
siphon break lines will be routed.
At this time you should refer to the plumbing diagram in the
mounting and exhaust sections of the IM1000 Installation manual.
Remove the white plastic hole plugs by pushing them out
from the inside and replace with the two rubber grommets
(ITEM#14) provided.
CAUTION. GENERATOR SETS WITH WET EXHAUST THAT ARE
INSTALLED NEAR OR BELOW THE VESSEL'S HULL WATER LINE
MUST USE A SIPHON BREAK TO PREVENT BACK FLOW OF
WATER INTO THE ENGINE. THIS BACKFLOW CAN RUIN AN
ENGINE AN POSSIBLY SINK THE VESSEL.
Disconnect the hose from the sea water pump output and a.
the inlet to the heat exchanger. Replace this single hose
with two 3/4" ID lines, one from the sea water output and
the other to the heat exchanger inlet. These hoses must
be of adequate length to mount a siphon break a min
of 12 inches above the vessel's loaded water line.
b. Pass these lines through the two holes in the rear panel,
as indicated per the diagram.
c. For more information, see the "Exhaust" section of the
IM 1000 Installation Manual.
15

A
A
A
SECTION A-A
PAWL SLOT
TOP NUT
BOTTOM NUT
STAR WASHER
LATCH SHAFT
LATCH PAWL
ALL LATCHES ARE PRE-ADJUSTED FROM FACTORY. IN THE EVENT A LATCH REQUIRES ADJUSTMENT, FOLLOW THESE STEPS:
NOTE THE INTERFERENCE, OR REASON WHY THE LATCH PAWL WILL NOT ENGAGE THE PAWL SLOT. IF PAWL HITS SLOT BRACKET 1.
OR SHELF IT MUST BE MOVED TO ALLOW PAWL TO ROTATE INSIDE SLOT.
2. LATCH PAWL SHOULD OPERATE WITHIN SLOT FREELY WHEN LATCH HANDLE ROTATES ON REMOVAL.
3. WITH LATCH IN CLOSED POSITION, (LATCH PAWL POINTING TOWARDS SLOT, LOOSEN THE BOTTOM NUT. TURN TOP NUT
TO CHANGE POSITION OF PAWL AND THEN RE-TIGHTEN THE BOTTOM NUT. ENSURE THE NUT IS FULLY TIGHT BEFORE
OPERATING THE LATCH.
4. AN IDEAL LATCH CONDITION IS WHEN THE PAWL SWINGS INTO POSITION ON CLOSING, PULLS UP AND ENGAGES THE TOP OF
THE SLOT WITH INCREASING RESISTANCE. WHEN THE LATCH RING IS FULLY DEPRESSED THERE SHOULD BE FIRM COMPRESSION OF
PANEL PERIMETER SEAL.
5. IF YOU CAN LIFT UP A CORNER OF THE TOP PANEL AND SEE A SPACE, THE LATCH IS NOT TIGHT ENOUGH.
RING LATCH GRIP ADJUSTMENT INSTRUCTIONS
SOME MODELS USE
THIS SURFACE TO LATCH
SOUND FOAM OMITTED FOR VIEW CLARITY
06-78700 M864W3 GEM Page 12.
12.
16

ITEM # DESCRIPTION NLI P/N QTY PACKED
5. Rear intake duct assembly 06-71272 1 c
9. Rear panel/valence assembly 06-71202 1* c
13. Service side lower valence 06-71206 1 c
14. Non-service side lower valence 06-71207 1 c
16. Front lower valence assembly 06-71213 1 c
17. Service side panel aft 06-71209 1 c
18. Non-service side panel aft 06-71212 1 c
19. Non-service side panel fwd 06-71211 1 c
20. Front panel assembly 06-71201 1 c
21. Seal bar 06-71271 1 c
22. Service side panel fwd assembly 06-71208 1 c
23. Top panel aft assembly 06-71204 1 c
24. Top panel fwd assembly 06-71203 1 c
 * includes 06-71269
HARDWARE BAG
ITEM # DESCRIPTION NLI P/N QTY PACKED
1. 1/4” NPT x 3-1/2” pipe nipple 21-01208 1 c
2. 3/8” NPT x 3” pipe nipple 21-01207 1 c
3. 1/4” NPT brass pipe cap 21-72241 1 c
4. 3/8” NPT brass pipe cap 21-78004 1 c
6. M8 button head hex screw 12-00118 10 c
7. 5/16” ext tooth lockwasher 15-09204 16 c
8. 5/16” pan head machine screw 12-00119 6 c
10. Hole plug 1” white 00-78006 6 c
11. 1/4”-20 pan head machine screw 12-45102 12 c
12. 1/4” ext tooth lockwasher 15-09103 12 c
15. Sound foam, side valence 55-71261 2 c
25. Grommet, vented loop 00-70146 2 c
Packed By : Date :
M944T3F GEM Sound Enclosure Packing List