Northern Lights Lugger M773LW3 User manual

www.northern-lights.com
M773LW3
Soundshield Assembly Instructions
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L613 9/15

M773LW3 SOUND SHIELD
ITEM DESCRIPTION NLI P/N QTY NOTES
1 TOE BRACKET 23-78007 4
2 #10-32 MACHINE SCREW x 1/2” LONG, STAINLESS STEEL 12-00000 8
3 #10 FLATWASHER, USS STAINLESS STEEL 15-70002 8
4 #10-32 NYLOCK HEX NUT, STAINLESS STEEL 14-00032 8
5 EXTRUSION, VERTICAL 05-78638 -001 4
6 BOLTING ASSEMBLY, SHORT, STAINLESS STEEL 00-75714 20
7 BOLTING ASSEMBLY, LONG, STAINLESS STEEL 05-72003 8
8 PANEL RETAINER BLOCK, SINGLE NOSE, NYLON 23-78016 4
9 EXTRUSION, HORIZONTAL, SIDES 05-78639 -001 2
10 EXTRUSION, HORIZONTAL, ENDS 05-78641 -001 2
11 CORNER CASTING 05-70001 -001 4
12 TOP PANEL ASSEMBLY 05-78637 -010 1
13 PENETRATION PANEL ASSEMBLY 05-78022 -010 1
14 REAR PANEL RETAINING BRACKET 23-78003 2
15 JUNCTION BOX SUPPORT BRKT COVER ASSEMBLY 05-78636 -010 1
16 REAR PANEL ASSEMBLY 05-78634 -010 1
17 LEFT SIDE PANEL ASSEMBLY 05-78632 -010 1 WITH VENT BOX
18 FRONT PANEL ASSEMBLY 05-78633 -010 1
19 RIGHT SIDE PANEL ASSEMBLY 05-78631 -010 1 NO VENT BOX
20 PLUG, BASE PAN MOUNTING FOOT POCKET 55-78663 4
21 GROMMET, 1-1/8” ID x 1-7/8” OD PENETRATION PLATE 00-70083 2 CUSTOMER OPTION
22 SOUND FOAM, PENETRATION PLATE OPTION 55-78066 2 CUSTOMER OPTION
23 KIT, WET EXHAUST OUTLET TUBE 27-28610 1
Specications:
Enclosure (Installed on Generator Base):
Length (OA)...........................................................35 in (889 mm)
Width.....................................................................22.0 in (558.8 mm)
Height....................................................................24.2 in (614 mm)
Assembled Weight:
60 lbs (27.2 kg) shield only
597 lbs (271 kg) with generator set
1

2
1
2
3
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.
Note: The Generator set features a single point lifting eye. However the generator may still possess
original factory lifting points, which will need to be loosened and rotated down, until they are below
the highest point on the engine. Be sure to retighten those bolts before moving on.
Select 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.
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 left hand side and rear are at the recommended distances (6 inch recommended,
4 inch minimum.) from the vessel’s bulkheads.
AVOID POSITIONING THE ENCLOSURE INTO CORNERS WITH OVERHEAD BLOCKED TO
REDUCE CHANCE OF INTAKE/EXHAUST AIR RECIRCULATION OUTSIDE THE SHIELD.
Install toe bracket (item 1) to each corner of the genset base anges with machine screws,
atwashers and nylock hex nuts (Items 2,3, and 4) into the holes indicated in Fig 1 and Fig 1a.
Fig. 1a
Fig. 1

3
Fig. 2
Fig. 2a
Fig. 3
Install the four vertical extrusions (item 5) with four bolting assemblies (item 6) per FIGS 2 and
2a. Don’t fully tighten these nuts until nal assembly. Extrusion should be loose enough for
adjustment during the building process. You should have what appears in Fig 3 at this time.
4

Before the top of the enclosure frame can be added, the front and left hand side panel retainer
blocks (item 8) must be installed.
The panel retainer blocks (item 8) are anchored to the vertical extrusion with a single long
bolting assembly (item 7). For now, loosely install these blocks to the position and orientation
indicated in Fig 4. The front left corner receives TWO of these blocks (item 8), while the front
right and the left rear receive only ONE each. You will go back later for nal positioning and
tightening of these blocks.
SEE FIG 4A.
Fig. 4a
Fig. 4
4
The top frame of the enclosure is pre-assembled with the top panel installed (items 6, 7, 8, 9, 10,
11, 12, 13, & 14.) For now, pop out the top panel (item 12) only from this assembly to facilitate
installation process.
Note the available leg on each corner casting (item 11.) Loosely install a short bolting assembly
(item 6) to each of these legs. SEE FIG 5.
Orient the top frame (items 6, 7, 8, 9, 10, 11, 12, 13, & 14.) with the triangular shaped penetration
plate (item 13) toward the front of the genset and unattached corner casting legs facing down.
Install each leg into the top of each vertical extrusion as shown in FIG 5a.
Check frame for squareness and commence tightening all bolting assemblies progressively and
gradually all the while ensuring that the top frame is pushed rmly down into vertical extrusions,
and no excessive gaps remain.
FRONT
5
DETAIL B
SCALE 1 : 2
INSTALL SINGLE NOSE BLOCK HERE.
ROUNDED NOSE POINTS TO FRONT.
DETAIL C
SCALE 1 : 2
INSTALL SINGLE NOSE BLOCK HERE.
BLOCK ROUNDED NOSE POINTS
TO THE ENGINE.
VIEW: TOP OF GENSET
A
RIGHT HAND (SERVICE SIDE)
B
FRONT
C
DETAIL A
SCALE 1 : 2
INSTALL 2 SINGLE NOSE BLOCKS HERE.
TOP BLOCK ROUNDED NOSE POINTS
TO THE REAR.
LOWER BLOCK ROUNDED NOSE
POINTS TO THE ENGINE.

Now install the junction box support cover (item 15) into place. Note the shape of the foam
backing and see the space beneath the generator junction box at the rear of the genset.
SEE FIG 6.
Insert the foam block portion of the J-box support cover (item 15) into the cavity of the support
bracket and push until rmly engaged.
SEE FIG 6a.
When correctly installed, the support cover (item 15) should have about an inch overlap on
the generator junction box rear face. The shape of the foam insert is self aligning and should
hold the cover in place. The part may appear to be pushing away from the rear face of the
junction box but, once the rear sound shield panel is installed, this unit will be pushed back
into position.
5
Fig. 5 Fig. 5a
(Viewed from Bottom)
Note how the
assembly ts inside
vertical extrusion.
Finger tighten only
until all four corners
have been fully
installed.
Fig. 6 Fig. 6a
6

Next, install the rear sound shield panel (item 16) to the rear of the enclosure frame.
The rear panel is designed to be stationary and is retained at the bottom by two short
5/16” bolts, and at washers as well as at the top of the panel using a set of
pre-installed retaining clips built into the top enclosure frame/top panel assembly.
SEE FIGs 7 & 7a.
The retaining clips will slide into the two rectangular slots in the top of the rear panel (item 16).
With the rear panel (item 16) in place, slide these retaining clips (item 14) along the top rail
until they meet the slots and can be inserted.
SEE FIG 7b.
Once both are fully engaged you will be able to push the rear panel in from the bottom until
ush with the back frame and base pan. Secure the rear panel with the provided 5/16” at
washer and 5/16” bolt as shown in FIGs 7 and 7c.
You may encounter some resistance as the rear panel comes into contact with the intake air
snorkel hose. Note that the rear panel has a small hole in the vicinity of the intake snorkel.
While holding the panel in place, guide this hose so that it is inserted within the panel hole,
ensure that the hose does not go too far into the rear panel so that the hose end is blocked.
(Generally this hose will install without adjustment at the retaining clamp.)
SEE FIGs 7d and 7e.
6
Fig. 7
Fig. 7a
7

When making the intake air snorkel hose connection, It is important to
ensure that the hose is not kinked or bent in such a way to restrict the
engine’s intake air ow. This arrangement is designed to allow the hose
to follow it’s natural path when properly installed into the rear panel.
Some adjustment is possible by loosening either bolt of the snorkel
hose’s supporting bracket. Be sure to retighten any loosened bolts.
7
Fig. 7b
Fig. 7d
Fig. 7c
Fig. 7e

8
Following the installation of the rear panel, now take the tube (Item 23) and note its shape.
The short curved end connects to the exhaust elbow, the longer with slight curve goes through
the rear panel.
Apply some rubber lubricant to the inside of the short blue silicone hose part and push it on to
the tube.
Next apply rubber lube to the inside of the exhaust hole grommet and with a rm twisting mo-
tion squeeze the barbed end through the grommet hole.
Now install the four hose clamps. Note the orientation of these clamps in the picture. Don’t
tighten at this time. You may want to rotate the tube to determine it’s best position.
Apply some rubber lube to the inside of the available end of the blue hose and push on to the
genset’s exhaust elbow. Position the clamps and tighten.
When you are done, you should have results as shown in Figure 7F.
Now it is time to install the stainless steel wet exhaust tube included with this shield. The
stainless tube connects to the genset’s wet exhaust elbow and provides you with an external
exhaust stub connection outside of the shield.
Fig. 7f

Install connections for exhaust, AC power leads, DC Control panel leads, battery and
water through holes in the rear panel as shown in Figure 8 and as described below:
a. Connect the genset exhaust outlet to the exhaust system of the vessel.
Push the two inch hose on to the exhaust connection pipe
protruding through the left mid-section of the rear panel.
b. Connect the sea water pump to the vessel’s water inlet.
Push 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. Note the fuel connection couplings on the unit’s
forward right side under the base pan lip. The forward
1/4” npt coupling is the fuel suction, and the aft 1/4” npt
coupling is the fuel return.
d. Connect the DC control harness to the engine harness
plug. Pass the harness and plug through the hole at the
mid-section of the right side of the rear panel.
e. Connect the 12 volt battery leads to the generator set passing
the two leads through the second hole above the bottom left side
on 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 top
hole on the right side of the rear panel.
9
Fig. 8: Facing the Rear Panel
8
AF
D
EC
B

10
IF YOU HAVE CHOSEN TO INSTALL A SIPHON BREAK:
Note the pre-installed penetration plate (item 13) in the forward right corner of the top
of the enclosure. Reference 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 21) provided. Next install the piece of sound
foam (Item 22) to the underside of the penetration plate. Before removing the back
paper, position the foam piece underneath the plate and dry t by aligning the two
holes in the respective parts. Then remove the paper backing and press rmly to
adhere.
SEE FIGS 9, 9a and 9b.
Fig. 9
Fig. 9b
Fig. 9a
9

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 hole in the
penetration plate closest to the front of the shield. The hose from
the expansion tank must go through the hole in the penetration
plate closest to the side of the shield.
c. For more information, see the “Exhaust” section of the IM1000
Installation Manual included with the generator set.
11
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. The penetration plate (item 13) facilitates the siphon
break installation as follows:
Start the generator set and run under load to check for leaks of fuel, water or exhaust gas.
As you install the panels, observe that there should be a minimum clearance of approximately
1/32” around the panel parameter (except at the bottom of the side and front panels.) You may
adjust for this by loosening any number of corner bolting assemblies or toe brackets until t is
satisfactory. Tighten all connections when done.
To secure the left side panel and front panel retaining blocks, install the left panel in place,
taking note of the rectangular slots on each side of the panel. Slide the retaining blocks
(item 8) up the vertical extrusion legs until the blocks are captured by these slots. Proceed to
tighten the bolting assembly while holding the block in position. Then do similarly on the front
panel. Do ensure that the block does not rotate upon tightening as it may affect
engagement.
Northern LIghts sound shield removable panels now feature a nylon block retaining system
that omits all but one panel latch. Install the left side panel (item 17) and the front panel
(item 18) by aligning the panel bottom pins to the base pan ange grommets and push until
engaged. The panels are easiest to install by pushing the panel in near the location of the
retaining block. The top panel (item 12) is installed by rst placing the opposite side down on
the enclosure frame ange and then pushing down the near side. Install the right panel (item
19) by striking rmly with your hand to engage the paddle latch.
SEE FIG 10 and 10a.
10
11

12
Finally, note the generator set base frame pan has four mounting feet “pockets.” Take foam
block (item 20) but do not remove the backing paper at this time, and insert it into each
mounting foot pocket as shown in FIG 11. Note that the upper portion of the block lays
against the angled surface of the base pan. The foam part will compress slightly when inside
the foot pocket as it provides a noise seal from the engine mounts. After you have noted how
the foam block is situated, withdraw it and remove only the top half of the backing paper to
expose the adhesive layer. Then pinching the block at the top outer corner, reinstall it and
press rmly against the contact area to ensure good adhesion.
SEE FIG 11a.
To access the top panel, remove the latched right side (service) panel. Reach in with your
ngers and push up on the panel from the inside. The front and left side panels remove
similarly, by pushing out from the inside.
Fig. 10
Fig. 11
Fig. 10a
Fig. 11a
12

ITEM# DESCRIPTION NLI PART # QTY NOTES: PACKED
Enclosure frame top, pre-assembled: p
(consists of the following parts and assemblies)
9 Extrusion, horizontal, sides 05-78639 -001 2 assembled
10 Extrusion, ends 05-78641 -001 2 assembled
11 Corner casting 05-70001 -001 4 assembled
7 Bolting assembly, long 00-72003 4 installed
6 Bolting assembly, short 00-75714 12 installed
Penetration panel retainer bracket (inc. w/ #13 assy) 23-78006 2 installed
13 Penetration panel assembly 05-78022 -010 1 installed
14 Rear panel retainer bracket 23-78003 2 installed
8 Panel retainer block, single nosed 23-78016 4 installed
12 Top panel assembly 05-78637 -010 1 assembled
Sound shield panels:
15 Junction Box Support Bracket Cover Assy 05-78636 -010 1 p
17 Left side panel assemby 05-78632 -010 1 assembled p
19 Right side panel assembly 05-78631 -010 1 assembled p
18 Front panel assembly 05-78633 -010 1 assembled p
16 Rear panel assembly 05-78634 -010 1 assembled p
Hardware box:
(consists of the following parts)
1 Toe bracket 23-78007 4 loose (bagged) p
7 Bolting assembly, long (hardware loose) 05-72003 4 loose (bagged) p
6 Bolting assembly, short (hardware loose) 00-75714 8 loose (bagged) p
8 Panel retainer block, single nosed 23-78016 4 loose (bagged) p
2 #10-32 machine screw x 1/2” long s/s 12-00000 8 loose (bagged) p
4 #10-32 nylock hex nut stainless steel 14-00032 8 loose (bagged) p
5 Extrusion, vertical 05-78638 -001 4 loose p
3 #10 atwasher USS stainless steel 15-70002 8 loose (bagged) p
21 Grommet 1-1/8 ID x 1-7/8 OD 00-70083 2 loose (bagged) p
5/16-18 hex head capscrew, stainless steel 12-09203 2 loose (bagged) p
5/16 atwasher, USS stainless steel 15-11000 2 loose (bagged) p
23 Kit Wet Exhaust Outlet Tube (Consists of) 27-38610 1 p
Hose 2” ID x 3-1/2” 3 Ply Silicone 18-21018 1 p
Extended band clamps 19-01032 4 p
Exhaust outlet tube S/S 27-38602 1 p
20 Sound foam, base pan mounting foot pocket 55-78068 4 loose (bagged) p
22 Sound foam, penetration plate option 55-78066 1 loose (bagged) p
Packed By: Date:
M773LW3 SOUND SHIELD PACKING LIST
L613 11/15

• M673L3 05-78010
• M773L3 05-78610
• M843NW3 05-73110
• M844W/LW3 05-70010
• M864W3 05-78720
• M944W3 05-01200
The following notice effects 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. 7/15
added 9/2/15