SteppIR DB36 User manual

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Page
This assembly manual is intended to be
printed in full COLOR. If the manual is
printed in black and white, many im-
portant details could be lost.
DB36 Yagi
Assembly Manual
REV 10.5c
06/05/2014
2112 116th Ave NE #1-5, Bellevue, WA 98004 l Tel: [phone] l email: [e-mail]

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Specifications DB36 Element Yagi
Boom length 36 ft / 11.1 m
Boom outside diameter 1.75 in—2.50 in / 4.45 cm—6.35 cm
Longest element 49 ft / 14.94 m
Turning radius 26 ft / 8.0 m
Weight 160 lb / 72.8 kg
Wind load 17.5 sq ft / 1.63 sq m
Wind rating 100 mph
Adjustable elements 4
Power Rating 3000 watts continuous
Feed points 1
Frequency coverage 6.95—54 MHz (3.5-4, 5.3 MHz, & 6.95—
54 MHz w/ opt. 80m dipole)
Control cable 16 conductor shielded, 22 AWG
80m option—24 conductor
Frequency DB36 Gain, dBi DB36 Front to rear, dB
80M* (optional) 1.35 NA
40M 7.2 21
30M 8.2 18
20M 9.27 21.5
17M 9.88 26.5
15M 10.21 27.1
12M 10.43 21.1
10M 10.65 11.0
6M 4 1.78
6M w/passive opt. 12.75 27.4
DB36 Yagi Specifications

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Page 3
DB36 TABLE OF CONTENTS (page 1 of 4) Page(s)
PREAMBLE 2—18
A note from Mike Mertel, K7IR 6
What now? Advice from Jim Streible K4DLI 7—8
Parts check list 9—10
Bill of materials (BOM) - Individual kits 11—15
A word about stainless steel galling 16
Assembly notes 17
DB36 Element configuration 18
CHAPTER ONE
SECTION 1.0
Boom assembly 19—21
CHAPTER TWO 22—26
SECTION 2.0
Element housing unit placement 22
EHU center-to-center spacing measurements 23
SECTION 2.1
A look inside the EHU 24
EHU wiring 25—26
CHAPTER THREE 27—39
SECTION 3.0
Driven element & return tube assembly 27
Attach the element mounting plate to boom 28—29
SECTION 3.1
Prepare the element support tubes (EST’s) for mounting 30—31
SECTION 3.2
Attach the EST’s to the mounting plate 32
SECTION 3.3
Secure the Driven element EHU to the mounting plate 33—34
SECTION 3.4
Installing the CPVC inner guide tubes 35—36
SECTION 3.5
Return tube assembly—Driven Element 37—39

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DB36 TABLE OF CONTENTS (page 2 of 4) Page(s)
CHAPTER FOUR 40—42
SECTION 4.0
Reflector EHU overview drawing 40
Return tube assembly—Reflector 41
SECTION 4.1
Mounting the Reflector EHU onto the boom 42
CHAPTER FIVE 43—44
SECTION 5.0
Director 1 EHU overview drawing 43
Mount Director 1 EHU onto the boom 44
CHAPTER SIX 46—47
SECTION 6.0
Director 2 EHU overview drawing 45
Mount Director 2 EHU onto the boom 46
SECTION 6.1
Return tube assembly—Director 2 47
CHAPTER SEVEN 48—50
SECTION 7.0
Mast plate assembly overview 48
Attach the mast plate to the boom 49—50
CHAPTER EIGHT 51—54
SECTION 8.0
Attach the boom truss mast to the mast plate 51
SECTION 8.1
Phillystran truss 52—53
SECTION 8.2
Attach the Phillystran truss to the boom truss mast 54
CHAPTER NINE 55—61
SECTION 9.0
Mount the connector junction box onto the truss boom 55
SECTION 9.1
Wiring the connector junction box 56—58
SECTION 9.2
Optional 80m dipole wiring schematic
Connecting the control cable to the 25 pin dSUB splice 60—61

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DB36 TABLE OF CONTENTS (page 3 of 4) Page(s)
CHAPTER TEN 62—65
SECTION 10.0
Prepare the telescoping poles for the loop and non-loop elements 62—63
SECTION 10.1
Attach the sweep couplers to the sweep tubes, mount the fiberglass spreaders 64—65
SECTION 10.2
Attach the telescoping fiberglass poles to the sweeps 66
CHAPTER ELEVEN 67—69
SECTION 11.0
Prepare the CPVC inner guide tube and diverter cone 67
SECTION 11.1
Secure the element support tube (EST) to the EHU 68—69
CHAPTER TWELVE 70—73
SECTION 12.0
Installing the truss support mast 70
SECTION 12.1
Attach the truss couplers 71
SECTION 12.2
Routing the Dacron truss cord 72—73
CHAPTER THIRTEEN 74—75
SECTION 13.0
OPTIONAL 6m passive element kit 74—75
CHAPTER FOURTEEN 76—78
SECTION 14.0
Secure the cables onto the boom 76
SECTION 14.1
Mount the DB36 onto the tower mast 77—78
CHAPTER FIFTEEN 79—82
SECTION 15.0
Troubleshooting the DB36 Yagi 79—80
Warranty information 81
SteppIR contact information 82

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SteppIR - Why Compromise?
The SteppIR antenna was originally conceived to solve the problem of covering the six ham
bands (20m, 17m, 15m, 12m, 10m and 6m) on one tower without the performance sacrifices
caused by interaction between all of the required antennas.
Yagi’s are available that cover 40 meters through 10 meters by using interlaced elements or
traps or log periodic techniques, but do so at the expense of significant performance reduction
in gain and front to back ratios. With the addition of the WARC bands on 30m, 17m and 12m,
the use of interlaced elements and traps has clearly been an exercise in diminishing returns.
Obviously, an antenna that is precisely adjustable in length while in the air would solve the fre-
quency problem, and in addition would have vastly improved performance over existing fixed
length Yagi’s. The ability to tune the antenna to a specific frequency, without regard for band-
width, results in excellent gain and front to back at every frequency.
The patented folded dipole loop elements on the DB36 allow for outstanding performance on
40m and 30m with element lengths that are 40% shorter than a full sized Yagi—at the expense
of only 0.3dB of gain!
The SteppIR design was made possible by the convergence of determination and high tech
materials. The availability of new lightweight glass fiber composites, Teflon blended thermo-
plastics, high conductivity copper-beryllium and extremely reliable stepper motors has allowed
the SteppIR to be a commercially feasible product.
The current and future SteppIR products should produce the most potent single tower antenna
systems ever seen in Amateur Radio! We thank you for using our SteppIR antenna for your
ham radio endeavors.
Warm Regards,
Mike Mertel
Michael (Mike) Mertel - K7IR
President

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Page 7
You have ordered you SteppIR Antenna and are
waiting for delivery. What do you do in the meantime?
1. Go to the SteppIR web site at www.steppir.com and download the latest manual for your antenna,
and also the Operators Manual for the controller.
2. Read the manuals from cover-to-cover ---TWICE! Don’t just read them –Study them, so you are
familiar the terminology used about the antennas and have a good idea of how the antenna is as-
sembled and where the various parts go.
3. As you go through the manuals make notes of any instructions you may not clearly understand,
then call or email for clarifications. It is better to have it all sorted out before you start assembly.
We don’t mind answering your questions beforehand.
4. Now, wait for notification your antenna is being shipped.
Your antenna has arrived!
What is the first thing to do?
1. If the antennas is to arrive on Wednesday----DO NOT plan an antenna party for Saturday
2. Even if you plan to install the antenna weeks later, the first thing to do is to unpack the antenna
and do a complete inspection. Make sure nothing is missing or has been damaged in shipment.
3. Do a complete inventory of every part, nut and bolt. Yes it takes time, but it also allows you to noti-
fy SteppIR if anything is missing and allow time to get it to you before you start assembly of the
antenna. There is nothing more frustrating than realizing that something is missing, just hours be-
fore you want to install the antenna.
4. Go back to the SteppIR website and download the latest manual. SteppIR constantly is improving
and adding to the manual, so even though your paper instruction manual is going to have all the
data you need, it makes sense to check for the latest updates online. This is especially true If you
purchased the antenna and a period of time has passed between arrival and install dates.
5. Take the controller and power supply out of their wrappings and connect them. The controller does
not have to be connected to the antenna in order to familiarize yourself with it. In fact, it is best to
get familiar with the controller when it is not connected to the antenna. Turn on the controller and
read through the Operators Manual again while operating the controller in all it modes. Go through
the menus so you know what each does and how to navigate through the various menus and func-
tions.
OK - - - NOW WHAT?
(Sage advise from Jim Streible, K4DLI—SteppIR Technical Support Guru)
PREAMBLE

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OK - - - NOW WHAT? (continued)
(Sage advise from Jim Streible, K4DLI—SteppIR Technical Support Guru)
6. When you have finished working with the controller be sure the display indicates “Elements Home”
and the controller has been turned OFF. When the controller is connected to the antenna and the
controller is turned back on the next time, it will immediately tune to whatever position the con-
troller was left in last time you were using it, so you want to be sure that position is HOME.
7. Once the antenna is completely assembled and ready to mount on the antenna tower, use an an-
tenna analyzer, if you have one, to test resonance of the antenna.. If you don’t have an analyzer,
try to borrow one. It will save you a lot of time and worry. Check the antenna on each band for
some sign of resonance within the frequency range. Leave the antenna on the default frequency
and tune the analyzer to see where the dip occurs. It will be somewhere below the lower band
edge on each band with the antenna 3 or 4 feet above the ground on sawhorses. Also, don’t ex-
pect to see a 1:1 SWR here, just look for a good indication of resonance.
Once it has been determined this part of the antenna is working correctly do the following: Select
the lowest band and establish the dip condition by tuning the analyzer. Do not touch the analyzer
again. Retract the elements and then reselect the same band. The antenna should come back to
very near the same setting. Do this 2 or 3 times on each band. Also, try going from the band being
tested to any other band and back again and observe that the antenna comes back to the same
resonant point. Now you know the antenna is tuning correctly from band to band and is consistent.
Enjoy the antenna!
73
Jim Streible—K4DLI
PREAMBLE

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Page 9
DB36 PARTS CHECKLIST
It is important that you do an inventory of the items that were shipped to you. Nothing is worse than
discovering a day before a planned installation that there are missing parts! We do our very best to en-
sure that you receive everything needed for construction of your antenna, but better to be safe than
sorry—inventory your parts well in advance of your installation. The items in blue represent options
available for the DB36E Yagi—you will need to check these items off only if you purchased them.
PREAMBLE
QTY PART NUMBER DESCRIPTION
1 70-3405-01 30/40m Driven EHU
1 10-1501-23 Lid with drain hole (Driven element)
1 70-3420-01 20m Passive EHU
2 70-3422-01 30/40m Passive EHU w/ terminal lug
4 10-1502-12 EHU Gasket
1 71-0007 DB36 Instruction manual
1 71-0010 SDA 100 Instruction manual
1 NA SDA100 Controller
1 20-8033-01 Power supply 24V external
1 21-5003-01 16 Wire control cable___________ FT
SDA100 OPTIONS:
1 01321 *Transceiver interface
1 01322 *Tuning relay
1 01323 Advanced lightning protection (ALP)
1 01324 Remote driver board
1 20-8030-02 Power Supply 33V external
Voltage Suppressor (lighting arrestor) OPTION
1 20-8052-51 16 pin voltage suppressor
1 20-8052-41 8 pin voltage suppressor
1 70-6010-01 25 pin dSub splice assembly
ANTENNA COMPONENTS
QTY PART NUMBER DESCRIPTION
2 10-1610-23 11.5” x 11.5” x 0.25” Mast Plate
3 70-2030-11 EHU mounting plate with aligning gasket
3 10-1608-01 Return Plate
1 10-1605-11 Driven Element Plate

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PREAMBLE
 QTY PART NUMBER DESCRIPTION
6 10-1156-01 Poly sweep (160 psi)
6 10-1503-21 Black fiberglass rod 31.75”
3 72-0030-61 Sweep Hardware Kit
2 10-1015-11 12” Return EST
14 60-1006-22 Fernco 1.5” x 1.25” quick disconnect boot
42 10-1059-01 Polyolefin heat shrink 1.5” x 3”
1 NA 65' 4 Conductor cable w/ 32” coax seal
1 21-8002 30' 2100I Phillystran
1 21-7002-01 95' of 3/16” Dacron rope
1 03322 16 Conductor control cable Length _________________
2 10-1202-01 1-3/4” x 72” Boom section *PN is not marked on boom
2 10-1202-21 2-1/4” x 48 Boom section *PN is not marked on boom
2 10-1202-11 2” x 72” Boom section * PN is not marked on boom
1 10-1202-32 2-1/2” x 72” Boom section *PN is not marked on boom
1 10-1618-41 1-3/4” x 48” Boom truss support mast
2 70-2029-01 60 3/4” EST with ring
2 70-2028-01 66 3/8” EST with ring
1 10-1630-21 2” x 12” Slotted aluminum sleeve
4 10-1630-11 2” x 3” Slotted aluminum sleeve
2 10-1617-01 64” CPVC w/foam sealing ring and rubber coupler
6 70-2025-23 39 7/8” CPVC inner guide tube
6 70-2025-13 49” CPVC inner guide tube w/coupler
1 10-1054-02 36” Truss support arm
2 10-1203-21 2” x 10” Boom reinforcement splice
ANTENNA COMPONENTS (continued) - DB 36 PARTS CHECK LIST
 QTY PART NUMBER DESCRIPTION
1 72-0100 DB36 Hardware Box
1 72-0102 DB36 Saddle Box
1 72-0104 DB36 Misc Parts Box
2 72-0018-31 OPTION: 39' Element truss kit
2 10-1054-02 OPTION: 36” Truss support for end element truss kit
2 72-1002 OPTION: DB 36 6m Hardware Kit
2 10-1001-91 OPTION: Tubing kit for optional 6m passive element kit
1 OPTION: 80M Dipole kit
ANTENNA KITS

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PREAMBLE
 QTY PART NUMBER DESCRIPTION
16 60-0014-01 6-32 x 7/8” SS Pan Head Screw
16 60-0014 6-32 SS Nylock Nut
25 60-0112 10-32 x 1/4” Set Screw
4 60-0113 10-32 x 5/8” Pan Head Screw
34 60-0017 10-32 x 3/4” SS Screw
2 60-0017-10 10-32 x 3/4” SS Flat Head Screw
4 60-0101 10-32 x 3/4” Pan Head Screw w/ Nylon Patch
40 60-0018 #10 SS Washer
36 60-0019 10-32 SS Nylock Nut
1 60-0110 1/4” - 20 x 1-1/4” SS Bolt
4 60-0029 1/4” - 20 x 3” SS Bolt
4 60-0063 1/4” - 20 x 3-1/4” SS Bolt
4 60-0100 1/4” - 20 x 3-1/2” SS Bolt
60 60-0041 1/4” SS Washer
13 60-0030 1/4” SS Nylock Nut
1 60-0103 5/16” x 3” SS Bolt
36 60-0065 5/16” x 3-1/2” SS Bolt
18 60-0114 5/16” x 3-3/4” SS Bolt
8 60-0066 5/16” x 4” SS Bolt
8 60-0115 5/16” x 4-1/2” SS Bolt
70 60-0046 5/16” SS Nylock Nut
4 60-0033 5/16” SS Washer
1 60-0145 3/8” x 4-1/2” SS Eyebolt
7 60-0034 3/8” SS Washer
1 60-0050 3/8” SS Nylock Nut
DB36 Hardware Box Bill of Materials
(PN 72-0100)

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PREAMBLE
 QTY PART NUMBER DESCRIPTION
1 60-0142 7/16” x 5” SS Bolt, Full Thread
1 60-0143 7/16” SS Nylock Nut
2 60-0160 7/16” SS Lock Washer
2 60-0161 7/16” SS Standard Nut
4 60-0144 7/16” Galvanized Washer
4 60-0157 1/8” Wire Clamp
2 60-0158 1/8” Thimble
16 60-0045 3/16” Wire Clips
4 60-0048 3/16” Wire Thimble
4 10-1613-01 1” Alum Spacer
12 10-1613-11 1/4” Aluminum Spacer
2 60-6000-15 SS Hose Clamp #016
2 60-0083 1/4” x 4” SS Turnbuckle
2 60-0159 5/16” x 8” SS Turnbuckle
2 10-1606-01 Element Support Reinforcement Plate
2 10-1607-11 Truss Attachment Plate
DB36 HARDWARE BOX BILL OF MATERIALS (continued)
(PN 72-0100)
DB36 SADDLE BOX BILL OF MATERIALS
(PN 72-0102)
 QTY PART NUMBER DESCRIPTION
28 10-1601-03 1-3/4” Aluminum saddle half
28 10-1601-22 2” Aluminum saddle half
10 10-1601-32 2-1/4” Aluminum saddle half
4 10-1601-41 2-1/2” Aluminum saddle half

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PREAMBLE
 QTY PART NUMBER DESCRIPTION
2 72-0009-03 Glue Kit
2 70-1007-01 Foam Plug Assembly
1 09-0007 Blue Silicone Tape
1 09-1025 Conical Grinding Stone 11/16”
2 09-0001 Electrical Tape
1 10-1028-21 Anti-seize Stick
1 10-1029-01 Connector Protector
4 10-1509-02 Diverter Cone for CPVC inner guide
8 10-1510-01 Element Truss Clamps (halves)
4 60-0044-00 Phillystran Cap, black
DB36 MISC. PARTS BOX BILL OF MATERIALS
(PN 72-0104)
DB36 OPTIONAL 6M PASSIVE ELEMENT KIT
(PN 72-1002)
 QTY PART NUMBER DESCRIPTION
2 10-1019-31 Mounting Plate
4 60-0001 1” U-bolt
8 60-0030 1/4” Nylock Nut
4 60-6000-60 1/2” SS Hose Clamp
2 10-1601-03 1.75” Aluminum Saddle
2 10-1601-41 2.5” Aluminum Saddle
2 60-0075 5/16” X 3-1/4” SS Bolt
2 60-0066 5/16” X 4” SS Bolt
4 60-0046 5/16” Nylock Nut

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Page 14
PREAMBLE
QTY PART NUMBER DESCRIPTION
1 10-1054-02 36” TRUSS SUPPORT ARM
2 10-1601-03 1-3/4” ALUMINUM SADDLE HALF
8 10-1510-01 ELEMENT TRUSS CLAMP HALF
2 60-0083 4” STAINLESS TURNBUCKLE
1 60-0110 1/4” x 1-1/4” HEX HEAD BOLT
1 60-0030 1/4” NYLOCK NUT
2 60-0065 5/16” x 3-1/2” HEX HEAD BOLT
2 60-0046 5/16” NYLOCK NUT
2 60-0033 5/16” FLAT WASHER
1 21-7001-01 75 FT 1/8” DACRON ROPE
16 60-0014 6-32 NYLOCK NUT
16 60-0014-01 6-32 x 7/8” PAN HEAD SCREW
2 60-0158 1/8” THIMBLE
4 60-0157 1/8” WIRE CLAMP
1 10-1028-01 ANTI SEIZE PACKET
1 09-0001 ELECTRICAL TAPE
1 60-0112 SET SCREW
DB36 OPTIONAL END ELEMENT TRUSS KIT
OPTIONAL END ELEMENT TRUSS KIT (PN 72-0018-31)

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Page 15
PREAMBLE
OPTIONAL 80M DIPOLE KIT (PN 72-0028-01 AND 72-0028-11)
QTY PART NUMBER DESCRIPTION
1 70-3003-01 80M BALUN/SWITCH BOX (not in kit bag)
Following Bagged in a Kit:
2 70-2040-01 80m Dipole 25 ft element assembly
2 21-7002-01 25 ft 3/16” DACRON ROPE
2 60-0066 5/16” x 4” SS HEX BOLT
2 60-0114 5/16” X 3 3/4” SS BOLT
2 60-0075 5/16” X 3 1/4” SS BOLT
4 60-0046 5/16” NYLOK NUT
2 10-1601-03 1 3/4” ALUM SADDLE
2 60-0028 1/4” X 2 1/4” SS BOLT
2 60-0030 1/4” X 20 NYLOK NUT
2 60-0116 1/4” X 20 REGULAR NUT
2 60-0034 3/8” SS WASHER
2 60-0094 3/16” SS QUICK LINK
2 60-0037-21 4” X 5/16” GALVANIZED EYEBOLT
4 60-0033 5/16” SS WASHER
2 10-1613-01 1” ALUMINUM SPACER
3 10-1607-11 TRUSS ATTACHMENT PLATE
1 21-6301-60 6' COAX JUMPER CABLE
1 21-5001-01 3' 4 CONDUCTOR 22 GA CABLE
1 09-0001 ELECTRICAL TAPE 66' X 3/4”
1 10-1029-01 CONNECTOR PROTECTOR
1 60-0117 CABLE CLIP WITH ADHESIVE BACK
1 60-0112 10-32 X 1/4” SET SCREW
With 80m dipole option customer
needs end element truss kits
2 10-1054-02 36” Element Truss Supports
2 72-0018-31 39' Element Truss Kit
DB36 OPTIONAL 80M DIPOLE KIT

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Page 16
From time to time, we get complaints from customers regarding galling of stainless steel fasteners.
Here is an excerpt from the Industrial Fastener Institute's Standards Book:
Thread galling seems to be the most prevalent with fasteners made of stainless steel, aluminum,
titanium and other alloys which self-generate an oxide surface film for corrosion protection. During
fastener tightening, as pressure builds between the contacting and sliding thread surfaces, protec-
tive oxides are broken, possibly wiped off and interface metal high points shear or lock together.
This cumulative clogging-shearing-locking action causes increasing adhesion. In the extreme, galling
leads to seizing - the actual freezing together of the threads. If tightening is continued, the fastener
can be twisted off or its threads ripped out.
During minor galling, the fastener can still be removed, but in severe cases of galling, a strong bond
between the bolt and nut can prevent removal of fasteners. Unfortunately, little is known on how to
control it, but here are two ways to minimize this effect:
Decreasing installation RPM speed will cause less friction and decrease heat generation. Lubrication
used prior to assembly can dramatically reduce or eliminate galling. Recommended lubricants should
contain higher amounts of molybdenum disulfide, such as graphite which is very commonly used as
a solid lubricant or special anti-galling lubricants sold by chemical companies.
We provide an anti-seize compound stick called “Thread Magic” (shown in picture below) with all of
our antennas and strongly encourage you to use it to reduce the aggravation of galling. The
Thread Magic stick is fantastic—you can get plenty of anti-seize on the fastener without getting it on
your hands!
Contrary to popular belief, galling of stainless steel is not a symptom of a "cheap" fastener - it is
prevalent in all types of stainless steel, aluminum and titanium fasteners. You can be assured that
the stainless steel fasteners we provide with our products are manufactured of very high quality.
A WORD ABOUT STAINLESS STEEL GALLING
PREAMBLE

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Page 17
Before beginning assembly of this antenna, please read the manual in it’s entirety to familiarize your-
self with the task at hand. Doing so will eliminate potential confusion.
Be sure to do an inventory of your parts as soon as possible after receipt of the antenna, and well be-
fore your intended installation date - this way we can get you the parts required before it’s too late.
When doing inventory on the parts, we recommend you divide the items needed for each of the sepa-
rate steps. It will make handling and organization of the parts a much easier task!
A large, cleared flat area is recommended for assembly of an antenna of this size and complexity. Typ-
ically, an area 40 ft x 50 ft would be ideal. We recommend using sawhorses or sturdy tables when in-
stalling the boom. By having the boom elevated, it is easier to ensure that the elements are level.
Rubber or Nitrile gloves are recommended when applying the anti-seize to the stainless steel fasteners
or the aluminum boom sections.
If you do not have room near the tower to assemble the antenna, we suggest you find a place that you
can put the antenna together in it’s entirety and then disassemble as needed for transportation to the
tower area.
Be sure to refer to the DB36 configuration drawing on the following page so that you can fully under-
stand how the antenna operates. In addition, the configuration drawing identifies EHU placement,
which is important as you progress in your installation of the antenna.
Use of a level for adjusting the Element Housing Units (EHU’s) is highly recommended. This is a sur-
prisingly accurate and consistent method. Simply place the level on the mast plate, and adjust each
element accordingly.
Be sure to use the anti-seize compound supplied to prevent the galling of the stainless steel fasteners.
If you do not use the anti-seize, count on issues with the hardware galling. Heat is one of the primary
culprits with galling, so if you use a ratchet, steady speed as you tighten will help minimize galling. We
have found that when the anti-seize is applied to the bolt portion of the hardware, it will eliminate any
galling issues.
ASSEMBLY NOTES
PREAMBLE

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Page 18
DB 36 ELEMENT CONFIGURATION GUIDE
PREAMBLE
DIRECTOR (ALL BANDS)
DRIVEN (ALL BANDS)
REFLECTOR (20M-6M)
NOT USED (40M/30M)
DIRECTOR 1 (20M-6M) NOT USED (40M/30M)
REFLECTOR (ALL BANDS)
DIRECTOR 2 (20M-6M DIRECTOR (40M/30M)
DRIVEN (ALL BANDS)
NOT USED (20M-6M)
REFLECTOR (40M/30M)
FORWARD DIRECTION (Normal)
REVERSE DIRECTION (180 deg)
BOOM
MAST
PLATE
Optional 6m Passive Element
Optional 6m Passive Element

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Page 19
FIGURE 1.01
QTY 2: 60-0029
1/4” x 3” Hex bolt
and
QTY 10: 60-0041
1/4” Flat washer
and
QTY 2: 60-0030
1/4” Nylock nut
QTY 2: 60-0063
1/4” x 3-1/4” Hex bolt
and
QTY 10: 60-0041
1/4” Flat washer
and
QTY 2: 60-0030
1/4” Nylock nut
QTY 4: 60-0100
1/4” x 3-1/2” Hex
bolt
and
QTY 20: 60-0041
1/4” Flat washer
and
QTY 4: 60-0030
1/4” Nylock nut
QTY 2: 60-0063
1/4” x 3-1/4” Hex bolt
and
QTY 10: 60-0041
1/4” Flat washer
and
QTY 2: 60-0030
1/4” Nylock nut
QTY 2: 60-0029
1/4” x 3” Hex bolt
and
QTY 10: 60-0041
1/4” Flat washer
and
QTY 2: 60-0030
1/4” Nylock nut
1-3/4” x 72”
Boom section
10-1202-01
2” x 72”
Boom section
10-1202-11
2-1/4” x 48”
Boom section
10-1202-21
2-1/2” x 72”
Boom section
10-1202-32
2-1/4” x 48”
Boom section
10-1202-21
2” x 72”
Boom section
10-1202-11
1-3/4” x 72”
Boom section
10-1202-01
Be sure the
10-1203-21
Boom sleeve
is in place
Be sure the
10-1203-21
Boom sleeve
is in place
3/8” EZ Eyebolt
Our boom pieces are all drilled on a very precise drill press. This ensures that all the bolts are snug
when assembled. It is always better to be too tight than too loose. Always apply an anti-seize lubri-
cant to stainless steel bolts that are using stainless steel nuts. This will prevent the two from galling
together. Galling of stainless steel is common and has nothing to do with the quality of the material.
Refer to the galling information in the Preamble section of this manual.
Each bolt has a specific length for the particular tubing it is holding together. It is important that the
shank of the bolt is engaged in the tubing, since that is the strongest portion of the bolt. Use 5 washers
per bolt to secure the bolt as shown in figure 1.02 on the following page.
Apply a thin film of a lubricant such as Anti-seize or Noalox to the male engagement area of the alumi-
num boom sections. Failure to do so may cause the tubes to seize inside each other. Match the boom
pieces as shown below and slide each boom piece together until the pre-drilled holes align.
Secure the correct bolts and washers onto the boom as shown in figure 1.01. Repeat this for each
section until the boom is completely assembled
Secure the 3/8” eyebolt as shown in figure 1.03. This eyebolt is part of our EZ-Eye system, which
helps to level the boom and also assists in keeping the boom from shifting during high winds.
CHAPTER ONE
SECTION 1.0 BOOM ASSEMBLY
BOOM LAYOUT

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Page 20
Figure 1.02
See prior page for the
specific bolt lengths
required for each boom
section
QTY 3: 60-0041
1/4” Flat washers
QTY 1: 60-0030
1/4” Nylock nut
QTY 2: 60-0041
1/4” Flat washers
Bolt head facing up
Top of boom
When securing the eye-bolt and boom bolts to the boom, install the eye and the head of the bolts on
the same side of the boom, so that they will be facing upwards when the boom is secured to the tow-
er. The 1/4” boom bolts require 5 washers, as shown below in figure 1.02.
CHAPTER ONE
SECTION 1.0 BOOM ASSEMBLY (continued)
BOOM BOLT / EZ-EYEBOLT DETAIL
When securing the EZ-Eyebolt to the boom, five 3/8” flat washers (PN 60-0034) are used as a spacer
as shown in figure 1.03.
QTY 5: 60-0034
3/8” Flat washer
QTY 1: 60-0151
3/8”x4-1/2”
Stainless Eyebolt
QTY 1: 60-0050
3/8” Nylock nut
Top of boom
Figure 1.03