SteppIR DB42 MonstIR PRO User manual

DB42 MonstIR PRO Installation Manual
SteppIR Antennas 2112 116th Ave NE #1-5, Bellevue, WA 98004 Tel: [phone] www.steppir.com
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.
REV 10.0
02/20/2013
Mikhail Mogutuv
DB42 4 stack

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DB42 MonstIR PRO Specifications
Specifications DB42 Element Yagi
Boom length 42 ft 8 in / 13.0 m
Boom outside diameter 1.75 in—3 in / 4.45—7.6 cm
Longest element 49 ft / 14.9 m
Turning radius 29 ft / 8.8 m
Weight 238 lb / 108 kg
Wind load 19.9 sq ft / 1.85 sq m
Wind rating 100 mph
Adjustable elements 5
Power Rating 3000w Key Down / *1500w on 80m (option)
Feed points 2
Frequency coverage 6.8 MHz—54 MHz (*3.5MHz w/ 80m option)
Control cable 25 conductor shielded, 22AWG
Gain / Front to
rear
by band
Gain, dBi
Forward DIR
Front to rear,
db forward
Gain, dBi
Reverse DIR
Front to rear,
dB reverse
80M (option) 1.7 NA 1.7 NA
40M 8.0 25.5 8.0 23.2
30M 9.0 12.4 9.0 12.4
20M 10.1 22.0 10.0 23.2
17M 10.8 23.2 10.7 21.9
15M 11.0 25.7 10.6 20.0
12M 11.9 24.1 10.4 8.9
10M 12.2 20.0 10.5 11.7
6M 5.0 2.0 5.0 2.0
6M w/passive opt. 14.0 25.0 NA NA
DB42 with 6m passive option

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DB42 TABLE OF CONTENTS (page 1 of 4) Page(s)
PREAMBLE 7—17
OK, NOW WHAT? Advice on what to do after you order your antenna
—by Jim Streible K4DLI
7—8
DB42 Bill of Materials (BOM) 9—14
A word about stainless steel galling 15
Preparing to build the DB42 Yagi 16
Element configuration drawing 17
CHAPTER ONE—BOOM ASSEMBLY 18—21
SECTION 1.0
Boom assembly overview 18
Boom bolt / EZ-Eyebolt drawings 19
SECTION 1.1
Measuring and marking the boom 20
Boom marking table 21
CHAPTER TWO—MOUNTING THE EHU’s ON THE BOOM 22—25
SECTION 2.0
Center-to-center spacing measurements 22
Section 2.1
Element housing unit (EHU) wiring overview 23
Wiring the EHU 24—25
CHAPTER THREE—DIRECTOR 1 EHU 36—38
SECTION 3.0
Director 1 EHU and return tube assembly drawing 26
Attach the element mounting plate to boom 27—28
SECTION 3.1
Element support tube (EST) mounting overview 29
Prepare the mounting plate for attaching the EST’s 30
SECTION 3.2
Attach the EST’s to the mounting plate 31
SECTION 3.3
Secure the Director 1 EHU to the mounting plate 32—33
SECTION 3.4
Install the CPVC inner-guide tubes 34—35
SECTION 3.5
Return tube assembly—Director 1 36 –38

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DB42 TABLE OF CONTENTS (page 2 of 4) Page(s)
CHAPTER FOUR—REFLECTOR EHU 39—41
SECTION 4.0
Reflector EHU and return tube overview 39
Secure mounting plate and EHU to boom—Reflector 40
SECTION 4.1
Return tube assembly—Reflector EHU 41
CHAPTER FIVE—DRIVEN ELEMENT 42—43
SECTION 5.0
Driven element assembly drawing 42
Mount the Driven element on the boom 43
CHAPTER SIX—DIRECTOR 2 44—45
SECTION 6.0
Director 2 EHU assembly drawing 44
Mount the Director 2 EHU on the boom 45
CHAPTER SEVEN—DIRECTOR 3 EHU 46—48
SECTION 7.0
Director 3 EHU and element return assembly drawing 46
Mount the Director 3 EHU on the boom 47
SECTION 7.1
Return tube assembly—Director 3 48
CHAPTER EIGHT—MAST PLATE AND DOUBLE TRUSS 49—57
SECTION 8.0
Mounting the mast plate to the boom 49—50
SECTION 8.1
Secure the mast plate to the boom 51
SECTION 8.2
Attach the truss mast 52
SECTION 8.3
Attach the truss mast plate to the truss mast 53
SECTION 8.4
Attach the truss boom to the truss mast plate 54
SECTION 8.5
Phillystran truss assembly 55—57

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DB42 TABLE OF CONTENTS (page 3 of 4) Page(s)
CHAPTER EIGHT (continued) - MAST PLATE AND DOUBLE TRUSS 58—60
SECTION 8.6
Double truss overview drawing 58
Phillystran double truss installation 59—60
CHAPTER NINE—OPTIONAL 6M PASSIVE ELEMENT KIT 61—62
SECTION 9.0
Mounting the 6m passive element kit 61
SECTION 9.1
Attacch the 6m passive elements to the boom 62
CHAPTER TEN—COAX SWITCH HOUSING 63—66
SECTION 10.0
Mounting the coax switch housing 63
SECTION 10.1
Coax switch wiring 64
SECTION 10.2
Sealing and securing the coax switch housing 65
SECTION 10.3
Attach the coax jumpers and feed line 66
CHAPTER ELEVEN—WIRING THE CONNECTOR JUNCTION BOX 67—75
SECTION 11.0
Mount the connector junction box onto the boom 67
SECTION 11.1
Wiring the connector junction box 68—70
Connect the cable from coax switch to the connector junction box 71
SECTION 11.2
Connect the control cable to the dSub splice 72—73
SECTION 11.3
Wiring Test 74—75

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DB42 TABLE OF CONTENTS (page 4 of 4) Page(s)
CHAPTER TWELVE—ELEMENT SUPPORT TUBE (EST) PREPARATION 77—82
SECTION 12.0
Prepare the telescoping poles for the 40/30 loop elements 77—78
SECTION 12.1
Attach the couplers to the sweep tubes 79—80
SECTION 12.2
Mount the fiberglass spreaders on the sweep couplers 81
SECTION 12.3
Attach foam plugs to the non-loop telescoping poles 82
CHAPTER THIRTEEN 83—85
SECTION 13.0
Prepare the CPVC inner-guide tube and diverter cone 83
SECTION 13.1
Attach the EST to the EHU 84—85
CHAPTER FOURTEEN—40.30 ELEMENT TRUSS KIT 86—89
SECTION 14.0
Installing the truss support mast 86
SECTION 14.1
Attach the truss couplers 87
SECTION 14.2
Routing the Dacron truss cord 88—89
CHAPTER FIFTEEN—SECURE CABLES & MOUNT DB42 ON TOWER MAST 90—92
SECTION 15.0
Secure the cables onto the boom 90
SECTION 15.1
Mount the DB42 onto the tower mast 91—92
Last steps—read before attaching antenna mast tower mast! 92
CHAPTER SIXTEEN—TROUBLESHOOTING TIPS 93—96
SECTION 16.0
Troubleshooting tips 93—94
Warranty Information 95
SteppIR Contact information 96

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OK - - - NOW WHAT?
(Sage advice from Jim Streible, K4DLI—SteppIR Technical Support Guru)
PREAMBLE
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.

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OK - - - NOW WHAT? (continued)
(Sage advice from Jim Streible, K4DLI—SteppIR Technical Support Guru)
PREAMBLE
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.
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 the
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.
8. When you are ready to use the antenna, be sure to “enable” the DB42 in the controller menu, or
your antenna will not work properly on 40m and 30m. If you purchased the 6m option, be sure to
enable that in the “options” menu of the controller. When done enabling, save and then turn the
controller off, and back on again.
9. Enjoy the antenna!
73
Jim Streible—K4DLI

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PREAMBLE
DB42 BILL OF MATERIALS
CONTROLLER & VOLTAGE SUPPRESSOR
QTY PART NUMBER DESCRIPTION
1 71-0020 DB42 Instruction manual
1 71-0010 SDA 100 Instruction manual
1 NA SDA100 Controller; INCLUDES *Advanced Lightning Protection (ALP)
1 20-8033-01 Power Supply 33v 100 watt, external
1 21-6005-71 24 WIRE CONTROL CABLE_____________ FT
SDA100 OPTIONS:
1 01321 *Transceiver interface
1 01322 *Tuning relay
1 01324 **Remote driver board
Voltage Suppressor (lighting arrestor) OPTION
1 20-8052-51 16 pin voltage suppressor
1 20-8052-41 8 pin voltage suppressor
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 DB42 Yagi—you will need to check these items off only if you purchased them.
*Note: The following items will arrive pre-installed in your SDA100 Controller:
Advanced lightning protection (ALP) - STANDARD
Transceiver interface—OPTIONAL
Tuning relay—OPTIONAL
**If you order the remote driver board option, the ALP board will NOT be mounted inside the SDA 100
controller. In this situation, the ALP board is then part of the remote driver board.

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PREAMBLE
DB42 BILL OF MATERIALS
ELEMENT HOUSING UNIT (EHU)
QTY PART NUMBER DESCRIPTION
2 70-3422-01 REFLECTOR EHU, DIRECTOR 3 EHU
1 70-3412-01 DRIVEN ELEMENT EHU
1 70-3409-01 DIRECTOR 1 EHU
1 70-3408-01 DIRECTOR 2 EHU
16 60-1006-22 QUICK DISCONNECT BOOT w/SS HOSE CLAMPS
5 10-1502-12 NEOPRENE GASKET FOR EHU
1 10-1501-23 BOTTOM LID w/drain hole FOR DIRECTOR 1 EHU
MISCELLANEOUS
QTY PART NUMBER DESCRIPTION
1 20-6208-01 25 PIN DSUB SOLDER TYPE CONNECTOR
1 20-6209-01 25 PIN DSUB BACKSHELL
1 70-2038 CONNECTOR JUNCTION BOX W/ MTG PLATE
1 60-0117 ADHESIVE CABLE CLIP
1 70-3001-01 COAX SWITCH BOX W/ 3 SO-239 OUTPUTS
1 10-1619-01 COAX SWITCH BOX BRACKET
1 21-5001-01 65 FT 4 COND 22AWG CABLE (NEEDS TO BE CUT TO LENGTHS)
1 21-5013-01 40' 6 COND 22AWG CABLE (NEEDS TO BE CUT TO LENGTHS)
1 21-6301-80 8' COAX JUMPER CABLE (Used for D1)
1 21-6301-96 11' 6” COAX JUMPER CABLE (Used for DRV)
1 21-6301-98 15' COAX JUMPER CABLE (Used for D2)
1 10-1050-21 COUNTER WEIGHT, STEEL W/ POWDER COAT
4 70-1007-01 FOAM ELEMENT END PLUG ASSY
1 10-1028-21 ANTI-SEIZE STICK
1 72-0009-03 GLUE KIT, CPVC INNER GUIDE TUBE
1 09-0007 0.5” BLUE SILICON TAPE, POLE TIPS PREP
12 09-0013 GRIP TAPE, POLE TIPS PREP
3 09-0001 ELECTRICAL TAPE 66' X 3/4”
48 10-1059 CANUSA HEATSHRINK 1.5” x 3”
1 70-6010-01 25 PIN DSUB FIELD SPLICE ASSY
1 09-1025 STONE CHAMFERING TOOL, POLE TIP PREP
4' 09-1022 COAX Seal
1 10-1029-01 Connector protector packet
8 10-1510-01 Element Truss Clamp (halves)
3 72-0030-61 Sweep Hardware Kit
1 21-7002-01 95' OF 3/16” DACRON ROPE
1 21-8002 78 FEET OF 2100 PHILLYSTRAN

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PREAMBLE
DB42 BILL OF MATERIALS
MOUNTING PLATES
QTY PART NUMBER DESCRIPTION
4 70-2030-11 DB STYLE EHU MOUNTING PLATE (10-1609-05 Plate)
3 10-1608-01 EHU RETURN TUBE MTG PLATE
1 10-1605-11 DIR1 49' LOOP EHU MOUNTING PLATE
2 10-1606-01 ELEMENT SUPPORT REINFORCEMENT PLATE
4 10-1607-11 TRUSS ATTACHMENT PLATE
1 10-1021-43 TRUSS MAST PLATE 8” X 8” X .25”
TUBING ITEMS
QTY PART NUMBER DESCRIPTION
16 10-1013-02 18' TELESCOPING POLES (NO FOAM IN END)
6 70-2025-23 39-7/8” CPVC INNER GUIDE TUBE
6 70-2025-13 49” CPVC INNER GUIDE TUBE WITH COUPLER
2 70-2025-33 64” CPVC INNER GUIDE TUBE W/ FOAM RING, RUBBER COUPLER
4 10-1509-02 DIVERTER CONE FOR CPVC INNER GUIDE TUBE
2 70-1015-11 1.75” X 12” FIBERGLASS RETURN TUBE
6 10-1156-01 30/40M SWEEP (160PSI)
6 10-1503-21 31.75” Black Fiberglass rods – drilled
4 10-1630-11 2 IN X 3 IN ALUM SLEEVE
1 10-1630-21 2 IN X 12 IN ALUM SLEEVE
2 70-2028-01 66-3/8” EST EXT WITH ALUM RING
2 70-2029-01 60-3/4” EST EXT WITH ALUM RING
1 10-1018-11 1-3/4” X 48” BOOM TRUSS MAST
1 10-1618-21 1-3/4” X 36” BOOM TRUSS SUPPORT
HARDWARE KIT
QTY PART NUMBER DESCRIPTION
16 60-0014-01 6-32 X 7/8” SS PAN HEAD SCREW
16 60-0014 6-32 SS NYLOK NUT
28 60-0112 10-32 X 1/4” SET SCREW
4 60-0113 10-32 X 5/8” SS PAN HD SCREW ( SADDLES TO MAST PLT)
44 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 3/4” X 10-32 PAN HD SCREW WITH NYLOK PATCH
48 60-0018 #10 SS WASHER
46 60-0019 10-32 NYLOK 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” NYLOK NUT
30 60-0075 5/16” X 3-1/4” SS BOLT
16 60-0065 5/16” X 3-1/2” SS BOLT
18 60-0114 5/16” X 3-3/4” SS BOLT

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PREAMBLE
DB42 BILL OF MATERIALS
HARDWARE KITS (continued)
QTY PART NUMBER DESCRIPTION
12 60-0066 5/16” X 4” SS HEX BOLT
8 60-0115 5/16” X 4-1/2” SS HEX BOLT
6 60-0141 5/16” X 5” SS BOLT
92 60-0046 5/16” NYLOK NUT
16 60-0033 5/16” SS WASHER
2 60-0151 3/8” x 2-1/2” Eye-bolt S/S
1 60-0145 3/8” X 4-1/2” EYEBOLT
3 60-0034 3/8” SS WASHER
2 60-0152 3/8” X 1-3/4” SS BOLT
5 60-0050 3/8” SS NYLOK NUT
1 60-0142 7/16” X 5” BOLT, ALL THREADED
1 60-0143 7/16” NYLOCK NUT
1 60-0160 7/16" LOCK WASHER
2 60-0161 7/16" STANDARD NUT
6 60-0144 7/16” GALVANIZED WASHER
4 60-0157 1/8” Wire Clamp
2 60-0158 1/8” Thimble
32 60-0045 3/16” WIRE CLIPS
8 60-0048 3/16” WIRE THIMBLE
4 10-1613-01 1” ALUM SPACER
12 10-1613-11 1/4” ALUM SPACER
8 60-0044-00 PHILLYSTRAN CAP, BLACK
2 60-6000-15 SS HOSE CLAMP #016
2 60-0083 1/4" x 4" SS TURNBUCKLE
4 60-0070 3/8" x 6 “ GALV TURNBUCKLE
ALUMINUM SADDLES
QTY PART NUMBER DESCRIPTION
36 10-1601-03 1-3/4” ALUMINUM SADDLE HALF
28 10-1601-22 2” ALUMINUM SADDLE HALF
4 10-1601-32 2-1/4” ALUMINUM SADDLE HALF
6 10-1601-41 2-1/2” ALUMINUM SADDLE HALF
10 10-1601-61 3” ALUMINUM SADDLE HALF
BOOM & MAST PLATE MATERIALS
QTY PART NUMBER DESCRIPTION
2 10-1202-01 1-3/4” X 72” BOOM SECTION
2 10-1202-11 2” X 72” BOOM SECTION
2 10-1202-21 2-1/4” X 48” BOOM SECTION
2 10-1203-21 2” X 10” SLEEVE FOR 2 1/4” BOOM SECTION
2 10-1202-71 2-1/2” X 44” BOOM SECTION
1 10-1202-81 3” X 72” (.25” WALL) BOOM SECTION
1 10-1610-23 11-1/2” X 11-1/2” X .25” BOOM TO MAST PLATE
1 10-1054-02 36” TRUSS SUPPORT FOR D1, 49' LOOP ELEMENT

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Page 13
PREAMBLE
DB42 BILL OF MATERIALS
OPTIONAL 6M PASSIVE ELEMENT KIT
QTY PART NUMBER DESCRIPTION
QTY PART DESCRIPTION
3 10-1019-31 6M MOUNTING PLATE
4 60-0075 5/16” X 3 1/4” SS BOLT
2 60-0115 5/16” X 4 1/2” SS BOLT
6 60-0046 5/16” SS NYLOK NUT
6 60-0001 1 INCH SS U- BOLT .25”
12 60-0030 1/4” NYLOK NUT
6 60-6000-60 .5 INCH SS HOSE CLAMP
4 10-1601-22 2” ALUM SADDLE
2 10-1601-61 3” ALUM SADDLE
1 70-1001-81 6M element tube set
3 10-1027-36 58” X .5”ALUMINUM TUBE, SLIT ON BOTH ENDS CPVC INSULATOR
6 10-1026-58 36” X .375” ALUMINUM TUBE, NO HOLES
OPTIONAL *39 FT END TRUSS KIT
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
*The parts shown represent a single truss kit. There will be two of these kits, one for each 39 ft end
element.

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Page 14
PREAMBLE
DB42 BILL OF MATERIALS
OPTIONAL 80M DIPOLE
QTY PART NUMBER DESCRIPTION
1 70-3003-01 80M BALUN/SWITCH BOX (not in kit bag)
Following Bagged in a Kit:
1 21-5009-01 50' ULTRA-FLEX 12 GA WIRE WITH TERMINAL LUGS
1 21-7002-01 60' 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
8 60-0046 5/16” NYLOK NUT
2 10-1601-02 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 4” X 5/16” GALVANIZED EYEBOLT
4 60-0033 5/16” SS WASHER
2 10-1613-01 1” ALUMINUM SPACER
2 10-1607-01 TRUSS ATTACHMENT PLATE
1 216301-70 4' COAX JUMPER CABLE
1 21-5001-01 5' 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
3 60-0112 10-32 X 1/4” SET SCREW
With 80m dipole option customer
2 10-1054-02 36” Element Truss Supports
2 72-0018-31 39' Element Truss Kit

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Page 15
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 16
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.
Following this page are inventory break down lists for each portion of the installation. When doing in-
ventory on the parts, we recommend you divide the items needed for each of the separate steps. It
will make handling and organization of the parts a much easier task!
We recommend you follow the sequence that the inventory breakdown lists are in, regardless of layout
of the DB42 instruction manual.
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 disassamble as needed for transportation to the
tower area.
Be sure to refer to the DB42 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.
There is one exception to using the anti-seize - do NOT use the anti-seize compound when connecting
the plastic sweeps coupler to the pole ends. This will be covered in more detail later in the manual.
Preparing to Build the DB42 Yagi
PREAMBLE

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DB 42 ELEMENT CONFIGURATION DRAWING
DIRECTOR 2 (20M-6M) NOT ACTIVE (40M/30M)
DIRECTOR 1 (20M-6M) DRIVEN (40M/30M)
DRIVEN (20M-6M) NOT ACTIVE 40M/30M
REFLECTOR (20M-6M) DIRECTOR (40M/30M)
REFLECTOR (ALL BANDS)
Optional 6m passive element
BOOM
MAST
PLATE
DRIVEN (20M-6M) NOT ACTIVE
DIRECTOR 1 (20M-6M) DRIVEN (40M/30M)
DIRECTOR 2 (20M-6M) NOT ACTIVE 40M/30M
FORWARD DIRECTION (Normal)
REVERSE DIRECTION (180 deg)
DIRECTOR 3 (20M-6M) DIRECTOR (40M/30M)
DIRECTOR 3 (20M-6M) DIRECTOR (40M/30M)
Optional 6m passive element
Optional 6m passive element
PREAMBLE
RELAY
RELAY
RELAY

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CHAPTER ONE
SECTION 1.0 BOOM ASSEMBLY
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. If your boom ever gets damaged
or destroyed we can send the specific replacement boom piece(s) required. Always apply an anti-seize
lubricant to stainless steel bolts that are using stainless steel nuts. This will prevent the two from gall-
ing together. Galling of stainless steel is common and has nothing to do with the quality of the materi-
al. Each bolt has a specific length for the tubing it is holding together this is critical so that only the
shank is engaged in the tubing. Use 5 washers per bolt to secure the bolt as shown in figure 1.02.
1. Apply a thin film of connector protector or a spray-on lubricant (i.e. Anti-seize, Noalox) to the male
engagement area of the boom sections. Failure to do so may cause the tubes to seize inside each
other.
2. Match the boom pieces as shown in figure 1.01 below and slide each boom piece together until the
pre-drilled holes align.
3. Secure the correct bolts and washers onto the boom as shown in figure 1.02.
4. Repeat this for each section until the boom is completely assembled.
5. Secure the 7/16” eyebolt as shown in figure 1.01 and figure 1.03. Note that in the event of a tight
fit, it is acceptable to use a mallet to drive the eyebolt in as shown in figure 1.04.
1-3/4”
Boom Section
10-1202-01
2”
Boom Section
10-1202-11
2-1/4”
Boom Sec-
tion
10-1202-21
2-1/2” Boom
Section
10-1202-71
3” Boom
Section
10-1202-81
2-1/2” Boom
Section
10-1202-71
2-1/4” Boom
Section
10-1202-21
2” Boom
Section
10-1202-11
1-3/4” Boom
Section
10-1202-01
7/16” Eyebolt
QTY 1: 60-0029
1/4” x 3” Hex bolt
and
QTY 5: 60-0041
1/4” Flat washer
QTY 1: 60-0063
1/4”x3-1/4” Hex bolt
and
QTY 5: 60-0041
1/4” Flat washer
QTY 1: 60-0100
1/4”x3-1/2” Hex bolt
and
QTY 5: 60-0041
1/4” Flat washer
QTY 1: 60-0066
5/16”x4” Hex bolt
and
QTY 2: 60-0033
5/16” flat washer
QTY 1: 60-0063
1/4”x3-1/4” Hex bolt
and
QTY 5: 60-0041
1/4” Flat washer
QTY 1: 60-0029
1/4” x 3” Hex bolt
and
QTY 5: 60-0041
1/4” Flat washer
QTY 1: 60-0100
1/4”x3-1/2” Hex bolt
and
QTY 5: 60-0041
1/4” Flat washer
Be sure the
10-1203-21
Boom sleeve
is in place
Be sure the
10-1203-21
Boom sleeve
is in place
Note: Check the following page for information on washer placement
FIG. 1.01
BOOM ASSEMBLY OVERVIEW

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CHAPTER ONE
SECTION 1.0 BOOM ASSEMBLY (continued)
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. Note: In the event the EZ-
eyebolt resists when you insert it into the boom, you can use a hammer or mallet as long as you strike
it with something that will not damage the eyebolt, as shown in figure 1.04.
BOOM BOLT / EZ EYEBOLT DRAWINGS
FIG. 1.02—Inserting the boom bolts into the boom
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
FIG. 1.03—EZ Eyebolt configuration
No washers are required
for the eyebolt
QTY 1: 60-0151
3/8”x4-1/2”
Stainless Eyebolt
QTY 1: 60-0050
3/8” Nylock nut
Top of boom
FIG. 1.04

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Page 20
CHAPTER ONE
SECTION 1.1 BOOM ASSEMBLY (continued)
With the DB42 Yagi there are quite a few components that are mounted on the boom. All of these
items are mounted using aluminum saddles. The following instructions will allow you to pre-measure
the placement of the saddles, making it much easier to assemble the required items. In addition to
marking the saddle placement, you may also want to label the marking so you can easily identify it
later. Measuring and marking helps to simplify the process, but NEVER use the saddle marks as the
permanent measurement—you must always defer to the center-to-center measurements for each ele-
ment or the antenna will not function properly.
We recommend that you use an aluminum saddle half for drawing your marks on the boom. Deter-
mine your mark using the table on the following page. The measurement shown is to the closest edge
of the saddle from the starting point, then draw a line on each side of the saddle piece as shown in
figure 1.12 and figure 1.13. This prevents any possible mistakes on where the saddle edge should be
on the measurement. The truss anchor point between the boom bolts shown below in figure 1.10 is
the same configuration on each side of the boom.
The EZ-Eye is NOT at the center point of the boom. Because of this, you will have a short side and a
long side (on the 3” boom section) in relation to the EZ-Eye. Position boom as shown below when
measuring for your marks. Mount each aluminum plate and truss saddle as shown in the table, be
aware that the dimensions shown in the table below refers to the saddles closest to the reflector end
MEASURING AND MARKING THE BOOM
Continue measuring to the right
for all boom items located on the
table below. Place your respective
part at your mark and fasten to
boom
Start your measurements by
securing your measuring
tape to the edge of boom
that is 251-5/8” inches from
the EZ eye-bolt located near
center of the boom.
Using a permanent mark-
er, precisely mark the
location for placement of
each item to be placed
on the boom.
0.75” 20.75” 30.75” 84.75”70.125”
START HERE
Boom truss bracket
Remainder of boom
FIG. 1.10
Short side of boom Long side of boom
FIG. 1.11
EZ Eyebolt is NOT at the center of the boom