Hy-Gain HG-54HD User manual

HG-54HD 54-Foot Self-
Supporting Tower

Overall View of HG-54HD Tower
-ii-

WARNING
Installation of this product near power lines
is dangerous. For your safety, FOLLOW
THE INSTRUCTIONS.
NOTE: If you are installing the Hy-Gain HDR-
300 Rotator on your tower, you will not be able
to nest the tower completely.
UNPACKING AND UNCRATING
GENERAL DESCRIPTION
This model is a 54-foot self-supporting tower
designed to support 16.0 square feet of antenna
area with winds up to 60 mph. This all steel
tower has a guide system that allows the
tubing to be open at each end insuring
complete galvanizing and total moisture
draina
g
e.
The tower is extended from its nested position
by manual crank. A thrust bearing can be
bolted to the top section allowing a 2"
diameter mast.
Be sure to check your tower for any freight
damage or missing parts. If you find damage,
notify the trucking line that delivered the
equipment immediately and advise Hy-Gain of
the damage. Send a copy of the freight damage
claim to:
Hy-Gain
Telex Communications, Inc.
8601 East Cornhusker Highway
P.O. Box 5579
Lincoln, Nebraska 68505-5579
EQUIPMENT
The HG-54HD tower is supplied complete, in-
cluding reinforcing steel and base mount. The
tower corresponds to the drawings contained
in this manual. Refer to the Parts List section
for a complete breakdown of parts.
The Parts List shows the standard commercial
packaging. Any changes or modifications, if
any, which may be incorporated as the result
of special contractual agreements are covered
under
EQUIPMENT REQUIRED BUT
NOT SUPPLIED

GENERAL SAFETY
Hundreds of people are killed each year
because they don't use common sense when
they install their towers or antennas. It
happens more often then you realize. Someone
falls off of a roof or gets electrocuted by
touching a power line with an antenna tower
or metal ladder.
There is no such thing as a good tower site if it
is near electrical power lines. Unfortunately,
most tower systems, and in many cases, the
ladders used during an installation, are metal.
If any metal tower part or ladder touches a
power line, it completes an electrical path
from the power line through the metal tower
and the installer (YOU!).
Don't overload. The design load limit is
16 square feet of antenna on a 2 foot mast
for winds u
p
to 60 m
p
h.
DO'S
Do install the tower away from power
lines. Check the distance to the power
lines before you start installing - we
recommend you stay a minimum of twice
the maximum length of the tower
assembly away from all power lines.
Do install the tower on a calm day and
assure yourself of having plenty of
da
y
li
g
ht to com
p
lete installation.
Do stay clear if the tower starts to fall or
come in contact with
p
ower lines.
Do call the power company to remove
fallen towers from power lines or to help
pick out a safe antenna site.
Do crank tower down to retracted position
when winds are anticipated to exceed 50
mph.
DON'TS
Don't install any tower near power lines.
Don't install a tower on a windy day.
Don't try to do the job by yourself.
Don't try to catch the tower if it starts to fall.
Don't try to remove any metal objects from
the power lines.
Don't be afraid to call the power company
for advice when picking a tower site or
removing a fallen tower from the power
lines
Don't remove winch handle; use safety
chain with lock to secure.
Don't climb tower, use separate ladder or
lower tower with gin pole for antenna
rotator servicin
g
.
If someone is accidentally electrocuted, don't
touch him or the tower if he is still in contact
with the tower or downed power lines. Use a
dry stick, like a broom handle or wooden
ladder, etc. and in one sweep, push the person
free from the tower or knock the wire away
and off the victim. Have someone call an
ambulance and the power company.
SITE SELECTION
The tower requires a concrete base ap-
proximately 42" x 42" x 72" (1067 mm x 1067
mm x 1829 mm) deep. Among the factors to be
evaluated in selecting a tower site are the types
of earth at the installation site and the
nearness of power lines or overhanging tree
limbs. Soil conditions around the tower
foundation should allow access to the tower
during all weather conditions.

Good planning is a key to a successful and safe
tower installation. If you're not sure about a
careful, safe installation, don't try to do it your-
self. Call for professional help (Yellow Pages
under Towers or
y
our local
p
ower com
p
an
y)
.
During shipment or
may have resulted to
foundation assembl
y
.
while in storage, damage
the tabs on the tower base
The tower should be as close as possible to its
related equipment. Determine the best possible
site while thinking about power lines, but also
think about overhanging tree limbs that may be
blown into the tower durin
g
hi
g
h winds.
Dig a hole 42" (1067 mm) square by 72" (1829
mm
)
dee
p
as shown in Fi
g
ure 3.
Before installation of this tower, check proper
alignment of the tabs. To do this, set the tower
horizontally on two supports. Attach the base
foundation assembly to the tower using the
three-quarter inch (3/4") hardware, as shown
below.
If the tabs on the base foundation assembly are
out of ali
g
nment
,
use a lar
g
e hammer to reali
g
n. Construct a wooden frame around the hole to
support the base foundation assembly as shown
in Fi
g
ure 4.

TO-0130-A-002
In the U.S.A. the dimensions of lumber are
listed, and referred to, as the size after it is
rough-cut at the sawmill, prior to being dried,
planed and sold on the market. A sample
would be the two by four (2" x 4"), which
after being dried and planed will measure
11/2" x 3 1/2" (38 x 89 mm), or a two by six
(2" x 6") which will measure 11/2" x 5 1/2"
Orient your tower base in the direction your
tower will be raised. The two parallel ears of
the base foundation assembly will be in the
hinged side.
TO -130 -1 -B -007 The tabs on the tower base foundation
assembly may have been knocked out of
ali
g
nment durin
g
shi
p
ment or while in stora
g
e.

TO
-
130
-
1
-
B
-
003
In order to support the base foundation assemb- Attach the base foundation assembly to the ly
during concrete pouring, three wood supports wood supports using 3/4" bolts (not supplied).
are needed as shown in Figure 7.
Using a carpenter's level, check all points to Drill a 3/4" hole in each wood support in line with
make sure base foundation assembly is level. the lower holes in the base foundation assembly as
shown in Figure 7.
FORM FOR CONCRETE BASE '
APPROXIMATELY Sy' 033mm)
OF ASSEMBLY EAR BURIED IN CONCRETE
TO
-
130
-
1
-
8
-
00
•
BASE FOUNDATION STRUCTURE ASSEMBLY EAR
(TYPICAL THREE PLACES)
2"x4' (38.90--Octu01)WOOD SUPPORT TO WHICH
ASSEMBLY EARS ARE BOLTED
(TYPICAL THREE PLACES)
'A' NUT

Pour concrete carefully into hole. Make
certain base assembly maintains the proper
clearance from the outside edges of the hole.
Refer to Figure 9.
The concrete shall be designed to provide a
minimum 28 day strength of 2000 PSI and
shall contain not more than 71/2 gallons of
water per sack of cement.
After the concrete is poured, check base as-
sembly, making sure it is level and it hasn't
shifted durin
g
the
p
our.
T
O
-
0
1
30
-
8
-
If the base is not level, tap the ears of the base
with a hammer to level.
Let the base cure for at least one week before set-
tin
g
u
p
tower!
Set your tower on the hinged side of the base,
align the bottom holes of the tower with the
bottom holes in the base assembly. Install a
single 3/4" bolt in each of the two parallel
b
10
LETTER PRODUCT 130-1
DIMENSION
A 72"
(1829 mm)
B 83/411
(222 mm)
C6"
(152 mm)
D 351/411
(895 mm)
E34
11
(864 mm)
F 12" overla
p
(
min.
)
(305 mm)
G 14"
(356 mm)
H 10"
(254 mm)
T
O
-
0
1
30
-
0
-
1

The use of a thrust bearing, HG-TBT, Order
No. 121B, is recommended for use on this
tower if the combined weight of the antenna,
mast and rotor is greater than 150 pounds.
The use of this thrust bearing is also
recommended on all systems used in areas
where ice loading may be experienced.
For rotator mounted above the rotator mount-
ing plate, follow these instructions and refer to
Fi
g
ure 11
,
Detail B:
1. Insert the rotator mounting plate in the
tower so it rests on the mountin
g
p
late
Pull top tower section out only enough to
allow the rotator stops to clear the top of the
second tower section.
For a rotator that installs below the mounting
plate, follow the steps below and refer to
Fi
g
ure 11
,
Detail A:
1. Set the rotator in the tower with the shaft
bearing pointing up. If the mast brackets or
clamps are attached to the shaft, they must be
removed.
5thru
5. Install the thrust bearing (if used) and
secure it to the mast and tower according to
instructions supplied with the bearing. Check
for
p
ro
p
er centerin
g
of mast.
6. Mount your antenna(s) on the top of the
mast. If you are using coax arms, tie your
rotator cable and coax to the coax arms.
Allow enough length of each cable for full
tower extension.
2. Set the rotator mounting plate in the tower
so it will set directly on the three stops welded
to the inside of each tower le
g
.
7. Connect your cable to the radio equipment,
and rotator cable to controller to check for
proper length.
3. Bolt the rotator to the mounting plate using
the mounting bolts supplied with the
rotator.
Lift tower into place with gin pole and block
and tackle as shown in Figure 12
4. Assemble the rotator-to-mast clamp, mast
platform and mast as shown in Figure 11,
Detail A.

After tower is up, put all base bolts in place
and secure tower in vertical
p
osition.
Attach winch assembly to tower winch plate
as shown in Figure 13 and in the instructions
enclosed with the winch.
Connect the cable to the winch as shown in
Fi
g
ure 14.
When lowering the tower, simply crank the
winch in the opposite direction. Constantly
check the upper section cables to make sure
they remain taut as the tower is lowered.
A second person should watch the lowering se-
quence carefully to make sure all sections of
the tower lower to
g
ether.
A good way to tell is by watching the raising
cable. If any of the cables become slack at any
location, STOP. The tower section is binding
up and must be cleared before lowering
continues.
PROCEDURES FOR FREEING
BINDING TOWER SECTIONS
Some causes for the sections to bind can
1. Bent tower braces during shipment or
installation.
2. A heavy object has been accidentally knock-
ed into the tower, bracing after
installation is com
p
lete.
3. Excessive wind force can cause a tower sec-
tion to bind up and not retract straight in
line with the next lar
g
er tower section.
RAISING AND LOWERING TOWER 4. Unbalanced antenna or other e
q
ui
p
ment.
Before cranking the winch to raise the tower,
examine the raising cables to be certain that
they are securely terminated and properly
p
ositioned in the cable sheave
g
rooves.
The tower should raise with only moderate ef-
fort with the hand crank winch. If excessive
force is required, check again for possible
shipment damage. DO NOT force the tower
up. It may become jammed in an extended
position and won't retract under its own
weight.
5. Foreign objects such as tree limbs, dirt or
ice can reduce clearance between sections.
To correct these problems, crank the tower
back up until the cable is tight. A soft, rubber
faced hammer can be used on the tower legs
while lowering the tower to jar the obstruction
free. If you use a rubber mallet, tap only on
the tower leg where the bracing meets the leg
and tap as far up on the bottom section as you
can reach. NEVER TAP ON ANY TOWER
BRACING! ! ! See Fi
g
ure 15.
-

27026
-
A
-
If cable becomes slack again, raise the tower to
ti
g
hten the cable and re
p
eat the
p
rocedure.
Another procedure to free binding sections is
to rotate the antenna to a different heading one
or more times. Doing so can help solve the
bindin
g
caused b
y
3 and 4 above.
If foreign objects must be removed to free the
tower, DO NOT CLIMB THE TOWER! Be
sure all cables are tight before removing the
ob
j
ect.
All Hy-Gain towers are factory tested (fully ex-
tended and retracted) and inspected before
bein
g
shi
pp
ed
,
to insure
p
ro
p
er o
p
eration.
To protect your installation and your radio
equipment, the tower system must be properly
grounded. Drive a 4'-8' ground rod as close as
possible to the tower structure. Then connect a
#8 (or larger) copper or aluminum wire be-
tween the base of the tower and the ground
rod.
If none of the previous methods work to free
the tower, seek professional help. A snorkel or
boom truck can be utilized to inspect, and cor-
rect the cause of the binding. Never leave the
cable slack hoping the tower will free itself. If
it does come free, it could collapse completely,
damaging both the tower and the antenna.

To maintain proper and safe operation, inspect
and lubricate your tower at least once a year;
more often if subject to heavy or frequent use.
Always be sure your tower is in the retracted
position before attempting any maintenance
p
rocedures.
Inspect all bolts for tightness including cable
termination, winch and base bolts.
Inspect raising cables and replace if exces-
sively kinked or frayed.
Inspect pulleys and pins for excessive wear
a
n
d
r
ep
l
ace
as
r
equ
ir
ed.
In order to insure maximum performance, a
periodic inspection for any necessary
preventive maintenance should be made.
Check at least once annually and more
frequently when the winch is exposed to an
environment which is particularly dirty or wet.
For continued smooth performance and
increased life, occasionally grease gears, reel
shaft, and handle threads. An occasional drop
of oil on the drive shaft bearings is also
recommended.
NOTE: DO NOT OIL OR GREASE BRAKE
MECHANISM (Pressure Plate)
Place a few drops of light machine oil on all
pulley bearings.
Refer to winch manual for proper lubrication
of winch.
The winch finish can be protected and will
provide longer service if it is periodically
washed with water and then wiped with light
oil or wax.