Northern Lights GEM Series User manual

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M864W3
GEM Series Sound Enclosure
Assembly Instructions
06-78700 M864W3 GEM COVER PAGE

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Printed in U.S.A.
LIT NO.: L817 7/19

M864W3 GEM Sound Enclosure
1
SPECIFICATIONS
Enclosure (installed on generator base):
Length (OA) 48.9 in (1243 mm)
Width 25.0 in (635 mm)
Height 28.1 in (713 mm)
Assembled weight - shield only: 55.0 lbs (24.9 kg)
Assembled weight w/ genset: 952.2 lbs (432 kg)
ITEM # DESCRIPTION NLI P/N QTY NOTES
1. Rear panel assembly 06-78703 1
 2. M8atwasher 15-11000 4 loose,bagged
3. M8 lock washer 15-00705 4 loose, bagged
4. M8 hex head capscrew 12-00776 4 loose, bagged
5. Service side bottom valence assembly 06-78707 1
6. Non-service side bottom valence assembly 06-78709 1
7. Front bottom valence assembly 06-78719 1
8. Non-service side panel assembly 06-78715 1
9. Service side panel aft assembly 06-78713 1
10. Front panel assembly 06-78701 1
11. Seal bar assembly 06-78723 1
12. Top panel assembly 06-78705 1
13. Service side panel, fwd assembly 06-78711 1
14. Grommet 1-1/8” x 1-7/8” OD 00-70146 2 loose, bagged
15. Leak detection alarm light assembly 22-90382 1 loose, bagged
16. E-stop/leak alarm harness 22-72024 1 loose, bagged

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 right 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.
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.
2

A
06-78700 M864W3 GEM Bottom of page 2.
2.
A
B
STEP 1.
INSTALL REARPANEL ASSEMBLY (ITEM #1)
TO THE BACK FACE OF THE GENSET BASE.
ALIGN SLOTS IN TAB TO BASE FRAME HOLES.
SECURE WITH HARDWARE, ITEMS 2,3, AND 4.
DETAIL B
STEP 2.
WHEN THE REAR PANEL ASSEMBLY IS SECURED, INSERT
GENSET AIR INTAKE SNORKEL HOSE INTO THE RECIEVER
AS SHOWN. PUSH INTO HOLE FIRMLY BUT DO NOT FORCE
HOSE ALL THE WAY IN. THERE IS A TAB STOP THAT LIMITS THE
HOSE INSERTION. PUSHING THE HOSE TOO FAR INSIDE THE
RECIEVER WILL CAUSE INTAKE AIR BLOCKAGE AND POOR
ENGINE PERFOMANCE.
DETAIL A
M8 HEX HEAD CAPSCREW (ITEM #4 )
M8 LOCK WASHER (ITEM #3)
M8 FLAT WASHER (ITEM #2)
3

B
C
STEP 4.
INSTALL LEFT SIDE LOWER VALENCE (ITEM#6).
NOTE THERE ARE TWO CAPTIVE NUTS FEATURED
ON THE HORIZONTAL FLANGE OF THIS PART.
STEP 3.
INSTALL RIGHT SIDE LOWER VALENCE PANEL (ITEM#5).
NOTE THIS PART HAS TWO CLIP ON NUTS IN VERTICAL
FLANGE.
DETAIL C
NOTE PRE-INSTALLED PINS.
GUIDE THESE INTO CORRESPONDING HOLES
IN REAR PANEL/FRONT LOWER VALENCE
PANEL. PUSH FIRMLY TO SNAP INTO PLACE.
DISPLACED PINS MAY BE RE-SEATED USING
A LONG TOOL SUCH AS A SCREW DRIVER OR
PRY BAR FROM THE INSIDE.
MOVE SOUND FOAM OUT OF THE WAY FOR
ACCESS TO PINS.
D
STEP 5.
INSTALL FRONT LOWER VALENCE (ITEM#7).
ALIGN CORRESPONDING HOLES TO PINS ON
BOTH LOWER SIDE VALENCE PANELS.
PUSH FIRMLY UNTIL IT SNAPS.
DISPLACED PINS MAY BE RESEATED AS
DESCRIBED IN DETAIL "C".
DETAIL D
STEP 6.
SECURE FRONT VALENCE TO BASE FRAME WITH
TWO EA: M8 FLATWASHER, LOCKWASHER, AND
HEX HEAD CAPSCREW (ITEMS 2,3,4).
06-78700 M864W3 GEM Page 3.
B
3.
B
4

C
5
A
E
B
D
F
C
G
REAR PANEL
06-78700 M864W3 GEM Page 4 upper.
4.
STEP 7.
CONNECT YOUR GENERATOR TO THE VESSEL.
C
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 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left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righthandside,throughthebottomholeintheright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rightmidside.
e. Connect the 12 volt battery leads to the generator set using the top hole on the left 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lowerholeontheright
side of the panel.
g. *OPTIONAL* These ports are used for siphon break 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:
STEP 7.
CONNECT YOUR GENERATOR TO
THE VESSEL

E
06-78700 M864W3 GEM Page 5.
D
STEP 8.
INSTALL NON-SERVICE SIDE PANEL (ITEM#8).
DETAIL E
SHOWING HOW THUMB SCREW
"B" ENGAGES LOWER CAPTIVE NUT.
F
G
THUMB SCREW A THUMB SCREW B
THUMB SCREW B
DETAIL F
THUMB SCREW "B"
DETAIL G
THUMB SCREW A
5.
PANEL ATTACHES TO REAR PANEL AND LOWER VALENCE
WITH THUMB SCREWS "A" AND "B".
WITH PANEL IN PLACE USE THUMB SCREW "A" TO RETAIN
SIDE PANEL, MOVING ON TO THUMB SCREWS "B".
APPLY DOWNWARD PRESSURE AS YOU TURN THUMB SCREW "B"
TO ENGAGE THE CAPTIVE NUTS INSIDE THE LOWER VALENCE.
DO THE OPPOSITE TO REMOVE.
D
6

7
H
ITEM#10
DETAIL H
THUMB SCREW A
I
DETAIL I
THUMB SCREW A
LOCATOR PINS
06-78700 M864W3 GEM Page 6.
E
6.
STEP 9.
INSTALL FRONT PANEL ASSEMBLY (ITEM#10)
POSITION FRONT PANEL ON TOP OF THE FRONT LOWER VALENCE.
NOTE THE PINS IN THE BOTTOM OF THE FRONT PANEL ALIGN
TO HOLES IN THE LOWER VALENCE. ENGAGE, AND SECURE
TO THE SIDE PANEL WITH THUMB SCREW 'A' (DETAIL H) AND
THUMB SCREW 'A' IN BOTTOM FLANGE INSIDE THE FRONT
PANEL (DETAIL I) .
E

F
PRE-INSTALLED EMERGENCY STOP SWITCH
ITEM #9.
LEAK ALARM LIGHT MOUNTING HOLE
LEAK ALARM LIGHT ASSEMBLY (ITEM#15)
J
EMERGENCY STOP TERMINALS
HARNESS MOUNTING POINT
HARNESS MOUNTING POINT
LEAK ALARM LIGHT TERMINALS
DETAIL J
SCREW COLLAR
ITEM#15.
SOUND FOAM OMITTED
FOR VIEW CLARITY.
NOTE POSITIVE TERMINAL
POLARITY, POSITION AT
TOP.
06-78700 M864W3 GEM Page 7
F
STEP 10
PRIOR TO INSTALLING THE SERVICE SIDE AFT PANEL (ITEM#9) THE LEAK ALARM LIGHT AND CONNECTING
HARNESS (ITEM#16) MUST BE INSTALLED. START WITH THE ALARM LIGHT, THEN FOLLOW WITH THE HARNESS
AS SHOWN IN THE FOLLOWING ILLUSTRATIONS.
7.
UNSCREW COLLAR RING FROM LIGHT
ASSEMBLY TO INSTALL THROUGH PANEL.
RE-INSTALL COLLAR TO SECURE.
8

9
C
A
B
SHIPPED LOOSE
SOUND SHIELD WIRE HARNESS
STEP 12
INSTALL FLOAT SWITCH TO THE CORRESPONDING
BRACKET ON THE BASE FRAME. BE SURE TO CHECK THE
LEAK ALARM LIGHT BY LIFTING UP THE FLOAT AFTER
GENERATOR SET IS CONNECTED TO STARTER BATTERY.
FLOAT
DETAIL C
BASE FRAME
FLOAT SWITCH BRACKET
RED LEAD
RED LEAD
DETAIL A
RED LEAD (+)
BLACK LEAD (-)
DETAIL B
SHIPPED LOOSE
LEAK ALARM LIGHT
STANDARD ENGINE HARNESS CONNECTOR
WITH PRE-INSTALLED END PLUG
A
ENGINE HARNESS CONNECTOR
WITH THE END PLUG REMOVED
B
ENGINE WIRE HARNESS
CONNECTOR
END PLUG
SHIPPED LOOSE
SOUND SHIELD WIRE HARNESS
E-STOP SWITCH
LEAK ALARM LIGHT
FLOAT SWITCH
TO BE CONNECTED TO
ENGINE WIRE HARNESS
C
STEP 13
A. LOCATE AND IDENTIFY THE ENGINE WIRE HARNESS.
B. REMOVE THE ENGINE WIRE HARNESS END PLUG.
C. CONNECT SOUND SHIELD WIRE HARNESS TO THE ENGINE WIRE HARNESS.
PRE-INSTALLED
EMERGENCY STOP SWITCH
STEP 11
CONNECT SOUND SHIELD WIRE HARNESS TO
EMERGENCY STOP SWITCH AND LEAK ALARM
LIGHT AS SHOWN IN DETAIL A AND DETAIL B.
NOTES:
LEAK ALARM LIGHT WILL NOT
OPERATE IF POLARITY IS SWITCHED.
C
A
B
SHIPPED LOOSE
SOUND SHIELD WIRE HARNESS
STEP 12
INSTALL FLOAT SWITCH TO THE CORRESPONDING
BRACKET ON THE BASE FRAME. BE SURE TO CHECK THE
LEAK ALARM LIGHT BY LIFTING UP THE FLOAT AFTER
GENERATOR SET IS CONNECTED TO STARTER BATTERY.
FLOAT
DETAIL C
BASE FRAME
FLOAT SWITCH BRACKET
RED LEAD
RED LEAD
DETAIL A
RED LEAD (+)
BLACK LEAD (-)
DETAIL B
SHIPPED LOOSE
LEAK ALARM LIGHT
STANDARD ENGINE HARNESS CONNECTOR
WITH PRE-INSTALLED END PLUG
A
ENGINE HARNESS CONNECTOR
WITH THE END PLUG REMOVED
B
ENGINE WIRE HARNESS
CONNECTOR
END PLUG
SHIPPED LOOSE
SOUND SHIELD WIRE HARNESS
E-STOP SWITCH
LEAK ALARM LIGHT
FLOAT SWITCH
TO BE CONNECTED TO
ENGINE WIRE HARNESS
C
STEP 13
A. LOCATE AND IDENTIFY THE ENGINE WIRE HARNESS.
B. REMOVE THE ENGINE WIRE HARNESS END PLUG.
C. CONNECT SOUND SHIELD WIRE HARNESS TO THE ENGINE WIRE HARNESS.
PRE-INSTALLED
EMERGENCY STOP SWITCH
STEP 11
CONNECT SOUND SHIELD WIRE HARNESS TO
EMERGENCY STOP SWITCH AND LEAK ALARM
LIGHT AS SHOWN IN DETAIL A AND DETAIL B.
NOTES:
LEAK ALARM LIGHT WILL NOT
OPERATE IF POLARITY IS SWITCHED.
C
A
B
SHIPPED LOOSE
SOUND SHIELD WIRE HARNESS
STEP 12
INSTALL FLOAT SWITCH TO THE CORRESPONDING
BRACKET ON THE BASE FRAME. BE SURE TO CHECK THE
LEAK ALARM LIGHT BY LIFTING UP THE FLOAT AFTER
GENERATOR SET IS CONNECTED TO STARTER BATTERY.
FLOAT
DETAIL C
BASE FRAME
FLOAT SWITCH BRACKET
RED LEAD
RED LEAD
DETAIL A
RED LEAD (+)
BLACK LEAD (-)
DETAIL B
SHIPPED LOOSE
LEAK ALARM LIGHT
STANDARD ENGINE HARNESS CONNECTOR
WITH PRE-INSTALLED END PLUG
A
ENGINE HARNESS CONNECTOR
WITH THE END PLUG REMOVED
B
ENGINE WIRE HARNESS
CONNECTOR
END PLUG
SHIPPED LOOSE
SOUND SHIELD WIRE HARNESS
E-STOP SWITCH
LEAK ALARM LIGHT
FLOAT SWITCH
TO BE CONNECTED TO
ENGINE WIRE HARNESS
C
STEP 13
A. LOCATE AND IDENTIFY THE ENGINE WIRE HARNESS.
B. REMOVE THE ENGINE WIRE HARNESS END PLUG.
C. CONNECT SOUND SHIELD WIRE HARNESS TO THE ENGINE WIRE HARNESS.
PRE-INSTALLED
EMERGENCY STOP SWITCH
STEP 11
CONNECT SOUND SHIELD WIRE HARNESS TO
EMERGENCY STOP SWITCH AND LEAK ALARM
LIGHT AS SHOWN IN DETAIL A AND DETAIL B.
NOTES:
LEAK ALARM LIGHT WILL NOT
OPERATE IF POLARITY IS SWITCHED.

G
M
ITEM #11
DETAIL M
THUMB SCREW A
06-78700 M864W3 GEM Page 9
G
STEP 11
INSTALL SEAL BAR ASSEMBLY (ITEM#11).
LOCATE BAR TO CORRESPONDING HOLES AND
SECURE WITH THUMB SCREW 'A', FOUR PLACES.
HAND TIGHTEN FIRM, DO NOT USE TOOLS.
9.
STEP 14
10

11
H
N
O
10.
ITEM#12
DETAIL N
LOCATOR PIN
DETAIL O
LOCATOR PIN
06-78700 M864W3 GEM Page 10.
H
STEP 12
INSTALL THE TOP PANEL ASSEMBLY (ITEM#12). NOTE THAT THE PANEL HAS LOCATING PINS
UNDER THE MATING FLANGE ( 6 TOTAL). ALIGN THESE WITH THE CORRESPONDING HOLES
ON THE TOP OF THE FRONT AND REAR PANELS ASSEMBLIES. REFER TO DETAILS 'N' AND 'O'.
THE RING LATCHES ARE FACTORY PRESET BUT OCCASIONALLY REQUIRE SOME ADJUSTMENT.
SEE THE LATCH ADJUSTMENT SECTION (PAGE 12) OF THESE INSTRUCTIONS.
STEP 15

I
06-78700 M864W3 GEM Page 10.
I
11
STEP 13
INSTALL THE SERVICE SIDE PANEL ASSEMBLY (ITEM#13).
NYLON LOCATOR PINS
NYLON LOCATOR PINS
ITEM #13
GUIDE THE BLACK NYLON LOCATOR PINS ON PANEL (ITEM#13) INTO THE
CORRESPONDING SLOTS ON THE LOWER VALENCE. TWIST RING LATCH
TO CLOSE AND LOCK. THE RING LATCH IS PRESET FROM THE FACTORY
BUT MAY OCCASIONALLY REQUIRE SOME ADJUSTMENT. REFER TO
THE LATCH ADJUSTMENT SECTION (PAGE 12) OF THE INSTRUCTIONS.
STEP 16
12

13
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.
J

K
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.
OUT TO VENTED LOOP
IN FROM VENTED LOOP
FOR APPLICATIONS USING A SIPHON BREAK:
Remove the white plastic hole plugs by pushing them out from the inside and
replace with the two rubber grommets (item 15) provided.
a. Disconnect the hose from the seawater pump output and from the rubber
elbow on the expansion tank. Install two lengths of 3/4” hose. The hoses
must be of adequate length to allow mounting of a siphon break, a minimum
 of12inchesabovethevessel’sloadedwaterline.
b. Pass the seawater pump output hose through the top hole in the panel. The
hose from the expansion tank must go through the bottom hole in the panel.
c. For more information, see the “Exhaust” section of IM1000 Installation
Manual.
CAUTION: GENERATOR SETS WITH WET EXHAUST THAT ARE
INSTALLEDNEARORBELOWTHEVESSEL’SWATERLINEMUSTUSE
A SIPHON BREAK TO PREVENT BACKFLOW OR WATER INTO THE
ENGINE. THIS BACKFLOW CAN RUIN AN ENGINE AND POSSIBLY
SINK THE VESSEL.
14

REAR PANEL ASSEMBLY
06-78703 QTY 1.
SERVICE SIDE LOWER VALENCE 06-78707
QTY: 1.
ITEM#5
NON-SERVICE SIDE LOWER VALENCE 06-78709
QTY: 1.
ITEM#6
FRONT LOWER VALENCE
ASSEMBLY 06-78719 QTY 1.
NON-SERVICE SIDE PANEL ASSEMBLY 06-78715
QTY 1.
ITEM#8
SERVICE SIDE AFT
PANEL ASSEMBLY
06-78713 QTY 1.
FRONT PANEL ASSEMBLY
06-78701 QTY 1.
ITEM#10
SEAL BAR ASSEMBLY 06-78723
QTY: 1.
ITEM#11
TOP PANEL ASSEMBLY 06-78705
QTY 1.
ITEM#12
SERVICE SIDE FWD PANEL
ASSEMBLY 06-78711 QTY 1.
ITEM#13
06-78700 M864W3 GEM Page14.
PACKING LIST
CABLE ROUTING CLIP 00-40052 QTY 2.
E-STOP/LEAK ALARM HARNESS
22-72024 QTY 1.
LEAK DETECTION ALARM
LIGHT 22-90382 QTY 1.
VENTED LOOP GROMMETS
00-70083 QTY 2
ITEM#1
ITEM#7
ITEM#9
ITEM#17
ITEM#15
ITEM#16
ITEM#14
ITEM#2
ITEM#3
ITEM#4
ITEMS IN THIS BOX ARE ENLARGED FOR DETAIL
M8 FLATWASHER
15-11000 QTY4
M8 LOCK WASHER
15-00705 QTY4
M8 HEX CAPSCREW
12-00776 QTY 4
Packed By : Date :
00-70146
LIT NO.: L817 4/20