Ground Control Toughsat Flyaway User manual

Ground & Fly-And-Drive Bracketing
Toughsat Flyaway
TOUGHSAT FLYAWAY BRACKETING MANUAL
Ground Control
April 2010

Toughsat Flyaway Bracketing Manual Ground Control
FLYAWAY SETUP
Ground Mounting Bracketing
The 4-rail aluminum bracket assembly is a lightweight, stable platform for mounting a Toughsat case-based system
on the ground, or on top of a vehicle roof rack. Below are instructions for setting a system up for ground mounting.
STEP 1
Unpack the bracketing bag which includes:
1. Four aluminum rails
2. A three-piece dolly (two wheels & axle)
3. Hardware pouch (bolts & nuts)
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Toughsat Flyaway Bracketing Manual Ground Control
Step 2 – Assemble the dolly. Remove cotter pins from the axle, slide on the wheels, and reinsert the cotter pins.
Step 3 – Line up dolly axle pins with the holes on the heavy end of the case bottom, and rest the case on the dolly.
Once the dolly wheels are in place, the largest crate is easily moved.
The weight of the crate keeps the dolly in place.
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Toughsat Flyaway Bracketing Manual Ground Control
Step 4 – Place one of the rails on the ground and slide the two T-nuts into place on the two black marks.
Step 5 – Place the other rails together as shown. Line up the top rails so that ends are above the T-nuts.
Step 6 - From the hardware pouch, find four 9/16 bolts (with washers) that will secure the rails to each other.
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Toughsat Flyaway Bracketing Manual Ground Control
Step 7 - A ratchet wrench and a 9/16 socket is used to secure the four bolts on the rails.
Step 8 – There are four T-nuts on the top rails. Slide them to the ends of the top rails. Note the positions above.
Step 9 – You may now move the bracket to a location where the flyaway will stay. To place the dish on the ground
bracket, simply roll it into place.
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Toughsat Flyaway Bracketing Manual Ground Control
Step 10 – The dolly wheels will pop out when the mobile system is placed on the brackets. You will need to adjust
the case to align the four holes over the T-Nuts at the ends of the rails.
Lining up the holes takes some practice. Try finding one hole and placing a bolt in before lining up other holes.
Secure all the bolts with a ratchet wrench. Use the leveling posts to level the system on uneven ground.
The Flyaway Ground Bracketing is now installed. Please refer to the Flyaway Users Manual for instructions on
attaching the .98 Meter reflector, cables, electronics and other operation.
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Toughsat Flyaway Bracketing Manual Ground Control
FLYAWAY SETUP
Fly-And-Drive Bracketing
The ground mount bracketing used for the Toughsat flyaway can double as a fly-and-drive system. Below are the
steps required to place the system on most vehicle roof racks.
Step 1 – Measure the top of the roof rack (from front to back in this case) to find the distance the rails may sit on the
rack. Adjustments are easily made by moving one of the bottom rails.
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Toughsat Flyaway Bracketing Manual Ground Control
Step 2 – Make sure all bolts are secure. Slide the system into place over the bracketing. Note the heavy side of
the case must be positioned over the aluminum rail at a far end, as shown in the right image above.
Step 3 – Line up the four holes on the top rails over the T-nuts. Secure the case to the rails with the four bolts.
Step 4 – Move the complete system on top of the vehicle. This normally takes about four people, but it can be done
with two stronger individuals. Note that the heavy end of the mobile system is mounted on the front of the vehicle.
You have the choice of putting the .98 meter dish reflector on or not. With the dish on, the system is ready to be
used any time. If the dish is off, the case lid top can be secured, but it’s not ready to use.
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Toughsat Flyaway Bracketing Manual Ground Control
Step 5 – There are four U-Bolts in the hardware pouch. Remove the nuts, washers & spacers from one of the U-
Bolts and insert the U-bolt under a roof-rack rail into any of the bottom bracketing rail holes. (See red arrow above)
Step 6 – On top, slip the washers first over the U-bolt, then the spacer, and then the nut. Use a ratchet wrench to
tighten the U-bolt into place. Repeat this step for the three other U-bolts to secure the bracket to the roof rack.
Step 7 – The leveling posts at the end of the rails should be raised up and tightened so they do not lower. You
have the option of removing the leveling posts entirely by loosening a tightening nut (right image arrow) below the
handle. Once the handle is removed, you may screw the long bolt down and out of the T-Nut.
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Toughsat Flyaway Bracketing Manual Ground Control
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The Fly-And-Drive system is ready to be connected to the electronics. Please refer to the Flyaway Users Manual for
detailed instructions.
The wire run can be threaded through a slightly open window. It’s ready to go!