Relay_Aluma_Tower_TM_DRAFT_051310_GPM_B3.pdf

FLEXTRAIN

TELESCOPING TOWERS

Aluma Tower Company T100H Telescoping Towers

TM52 – 60EB4 Heavy Duty Dual Axle Trailers

FT TOWER 10/20

WORKING DRAFT MAY 2010

THIS VERSION SUPERSEDES ALL

PREVIOUS VERSIONS

DRAFT 051310 GPM

DRAFT 051310 GPM

THIS DOCUMENT IS A WORKING

DRAFT.

For questions about procedures in this document or recommendations to format or content……

CONTACT:

GARTH P. MAHNS

garth.mahns@sri.com i

HIGH VOLTAGE

ABOVE

DANGER

WARNING

DO NOT RAISE TOWER UNDER

OR WITHIN 120’ OF POWER LINES.

CONTACT WITH POWER LINES WILL

CAUSE SERIOUS INJURY OR DEATH

ii

DO NOT RAISE TOWER UNDER OR WITHIN 120’ OF POWER LIN ES.

CONTACT WITH POWER LINES WILL CAUSE SERIOUS INJURY OR DEATH

Keep personnel clear of area under tower while rais ing to vertical position.

If lifting winch cable fails personnel under tower or between tower and frame could be seriously injured.

DO NOT CLIMB TOWER ABOVE THE BOTTOM SECTION WHEN TO WER

IS ERECT. IT WILL NOT SUPPORT YOUR WEIGHT. A FAL L CAN RESULT

IN A SERIOUS INJURY OR DEATH.

A SAFETY HARNESS MUST BE WORN WHEN WORKING ON ANTEN NA

MAST WHEN TOWER IS NESTED TO PREVENT AN ACCIDENTAL FALL.

ALL PERSONNEL WORKING UNDER THE TOWER WHEN RAISING OR

LOWERING MUST WEAR A HARD HAT. FALLING EQUIPMENT O R

DEBRIS CAN CAUSE SERIOUS INJURY OR DEATH.

DO NOT RAISE THE TOWER HIGHER THAN 20’ ABOVE THE NES TED

POSITION IF WIND GUSTS ARE IN EXCESS OF 15 MPH.

HIGH WINDS CAN RESULT IN CATASTROPHIC TOWER FAILURE

AND INJURY TO PERSONNEL

DO NOT RAISE OR LOWER THE TOWER IF LIGHTINING

AND/OR THUNDERSTORMS ARE REPORTED WITHIN 18 TO 20

MILES OF THE SITE.

LIGHTENING STRIKES CAN RESULT IN SERIOUS

INJURY OR DEATH!

SUMMARY OF WARNINGS

The summary of WARNINGS is intended to “summarize” all Warnings contained in a publication. Because t his is a Working Draft all Warnings may not be listed.

ALWAYS PUT SAFETY FIRST

and

BE ALERT FOR DANGEROUS SITUATIONS

and

NEVER RUSH WHERE SAFETY IS CONCERNED

iii

SECTION I

INTRODUCTION

TABLE OF CONTENTS

EQUIPMENT DESCRIPTION

INTRODUCTION

This Manual is for use by trained personnel to ensure the safe and efficient deployment of Aluma Tower Company T100H series Telescoping Towers.

The Aluma Towers are part of the Communications Relay subsystem of the Deployable Force on Force Instrumented Range System DFIRST™.

HOW TO USE THIS MANUAL

This manual is written in a generic format and follows the sequence in which tasks should be performed with Appendices to detail special equipment and unusual operating circumstances or conditions.

WARNINGS, CAUTIONS, & NOTES

Warnings, Cautions and Notes are utilized throughout this document to alert personnel of unsafe conditions, prevent damage to equipment, and provide recommendations to promote safety, proper conduct, and efficiency

I – 1

Page Numbering Format: Pages are numbered at the bottom center indicating Section and Page. Example: ( II – 2 ) = Section II, Page 2.

Figure - Illustration Numbering Format: Figures and/or illustrations are Identified with the word “Figure” followed by a number. Numerical identifiers continue sequentially throughout the document and do not start over at “1” at the beginning of each Section. Figure numbers in Appendices begin at 1 within each Appendix.

Organization: This document is organized by Section, Page, Task, Step, and sub-step. Appendices are used to provide additional or special information.

TABLE OF CONTENTS

SUMMARY OF WARNINGS

SECTION I

INTRODUCTION

TABLE OF CONTENTS

EQUIPMENT DESCRIPTION

1. General Equipment Description

2. Dimensions, weight, Capacities

SECTION II

PMCS & EQUIPMENT INVENTORY

ELECTRONICS POWER SUPPLY

SECTION III

SET UP and OPERATION Periodic Checks

SECTION IV

RECOVERY and PREPARATION FOR MOVEMENT

APPENDICES:

APPENDIX A: TOOLS & EQUIPMENT

Tools & Equipment Inventory Hi Lift Jack Manual ( Extract ) Operate Hi Lift Jack & Ground Rod Puller

APPENDIX B: EF1000is YAMAHA GENERATOR

APPENDIX C: ALTERNATE GUYING TECHNIQUES

APPENDIX D: TOWER TRANSPORT CONFIGURATION

FLAT BED LOADING

APPENDIX E: REFERENCES

INDEX I – 2

Equipment Description

Mobile Relay Trailer The Mobile Relay Trailer is a self contained transportable antenna tower system with the primary purpose of providing a platform and power supply for data and radio signal retrans or relay equipment.

The tower consists of four 25-ft nested sections and a 2.0 “ dia Mast head for mounting a variety of antenna arrays.

The Aluma Tower trailers are equipped with a standard 2” ball hitch assembly or a cast metal 2 5/16s Ball hitch assembly. They are also equipped with a 3” Pintle hitch assembly for towing with tactical vehicles.

Three metal tool boxes are permanently installed. The Right Toolbox and Left Toolbox provide storage for a generator, tools, cables, guy wires, and all miscellaneous equipment required for the safe operation and maintenance of the trailer and tower.

The Relay/Power Equipment Box on the rear of the trailer contains an electrical subsystem to provide power to Data relay Electronics or RF communications equipment and an Aircraft Warning Light.

The primary power supply and storage system consists of 04 ea. 100 – 120 amp hour 12 volt DC deep cycle marine batteries connected in a parallel circuit.

A 25 amp battery charger is mounted in the electronics box and a 1000 watt generator is provided to power the battery charger. The Battery Charger is standard COTS equipment.

It can be powered by any 15 – 20 Amp 110 – 120 vAC 60 hz power supply.

Figure 1

I – 3

Dimensions & Capacities 31.0’

10.5’

23.3’

8.5’

Figure 2

Equipment Description

I – 4

Dimensions:

Overall Length: (Hitch Point to end of tower): 31.0’ Width: Outside Fender to Outside Fender: 8.5’

Outside Tire tread to outside tire tread: 8.0’ Height: Ground to top of stowed tower: 10.5’ Height: Ground to top of tower seat (transport ): 8.7’ Weight: Trailer & Tower fully loaded 7000 lbs

Tower Height Vertically nested: Top of Mast Head: 31’ Fully erect: Top of Mast Head: 97’

Mast Load Capacity Dead weight: Mast Head: 125 lbs Wind surface area: Mast Head: 18 sq. ft.

Tower Only Horizontal nested length: 26’ Weight: 340lbs (approx.)

Equipment Description (Tower Configuration)

Vertical Nested Position

Transit/Transport Configuration

Standard Travel Configuration

I – 5

SECTION II

PREVENTIVE MAINTENANCE

CHECKS and SERVICES

( PMCS )

PMCS is divided into Four basic categories. All of these checks, with few exceptions, must be conducted Before, During, a nd After operation.

• Trailer

• Tower

• Stowage Boxes – Tools & Ancillary Equipment

• Power Supply

Trailer:

1. Walk around: Inspect the Trailer for obvious signs of damage.

Bent, broken or missing components, loose or missing bolts.

a. Ensure 04 ea. Leveling Jacks and 02 ea. Outrigger Jacks are present and serviceable.

b. Ensure Hitch assembly is serviceable. Ensure Ball and hitch hardware to include safety pin are present and serviceable.

c. Ensure Fenders are securely mounted and tighten mounting bolts as required.

d. Check under trailer for damaged or loose hanging electrical wires.

e. Check Suspension Springs and mounting hardware.

2. Check Tire Pressure

a. Check tire pressure on all four tires and spare tire.

b. Inflate to Manufacturer’s recommended operating pressure.

3. Inspect tires and wheels

a. Inspect tire for signs of damage, weather checking, and excessive wear.

b. Inspect wheels for damage or excessive rust.

c. Check wheel bearing serviceability.

TRANSMASTER F78 – 14 – ST

Max Load @ 50 PSI: 1470 lb Normal Operating Pressure 45 PSI

Figure 3

II – 1

For safe/legal operation a tire must have at least 2/32” of tread remaining. Place a penny in several tread grooves.

If any portion of Lincoln’s head/hair is always hidden in the tread it has 2/32” or more of tread remaining.

3. Inspect tires and wheels ( continued )

d. Check tread depth: Refer to Figure 4.

PREVENTIVE MAINTENANCE

CHECKS and SERVICES

Trailer : ( continued )

Figure 4

4. Trailer Electrical System

a. Connect Trailer electrical system to Tow vehicle with 4 or 7 pin connector.

b. Electrical Towing connecting pigtails are stowed in TOW KIT .

c. Ensure Tail lights, Brake lights, and signal lights are operational.

II – 2

Tower:

1. Tower Mounting & Support Frame Assembly

a. Inspect Main Frame mounting points for cracks in welds. ( Figure 5 )

b. Check for loose or missing nuts or bolts. ( Figure 5 )

Figure 5 Check Lower left & right side

REAR SUPPORT BRACES

Check upper left & right side

REAR SUPPORT BRACES

Check Lower left & right side

REAR MAIN FRAME

Check Lower left & right side

FROMT MAIN FRAME

Tower : ( continued )

2. Telescoping Tower

a. Check cable for signs of stress. Fraying or bird cages ( Figure 6 ) or strand separation.

b. Inspect all pulleys and mounting hardware for signs of stress or damage. ( Figure 7 )

c. Check rigging attach points. ( Figure 8 )

d. Check tower structure for cracks in welds or damaged rungs.

II – 3

Figure 7

Figure 8

Frayed Bird Cage Figure 6

3. Tower Seat Mounting Bolts & Bushings ( Figure 9 )

a. Ensure shoulder bolts are not loose or missing.

b. Inspect mounting brackets for stress cracks

c. Ensure mounting bolts are not loose or missing.

d. Check bushings for excessive wear and proper installation ( Figure 10 ).

PREVENTIVE MAINTENANCE

CHECKS and SERVICES

Figure 9

II – 4

Figure 10

NOTE: Bushings should be installed oriented as shown in Figure 10. Installed in the Flange welded to the tower from the inside out with the collar of the bushing between the flange on the lower Tower Section and the Mounting bracket on the Tower support

NOTE

Viewing perspective in the pictures in Figures 12 & 13 is at the front of the trailer looking to the rear.

Right Side Stowage Box Left Side Stowage Box

Figure 12 Figure 13

Stowage Boxes: Equipment Inventory and Inspection

Guy Cables Hardware 100’ Tape

COAX

CABLES

Tool & Hardware boxes

TOW KIT

Hi Lift Jack & Sledge Hammer Pintle Hitch Hardware

Ground Rods Level

Antenna

Winch Cables

Figure 11

B A

T T

E R

IE

S

T-Posts 04 ea.

Leveling Jacks

Leveling Jacks

Leveling Jacks

II – 5

For detailed description and inventory of Tools and Ancillary Equipment see Appendix A: Tools and Equipment.

NOTE

ELECTRONICS POWER SUPPLY

The Rear Storage Box houses the power supply and charging system primarily designed for DFIRST 3.0 FlexTrain Systems. It provides continuous Power to Relay Electronics and the Aircraft Warning Light. The Power supply is also used to operate the Telescoping Tower winch.

The system can power a variety of equipment requiring 12v DC Power.

04 ea. Deep Cycle Marine Batteries connected in a parallel circuit ( Figure 14 ) provide 12v DC current with a storage capacity of 400 – 500 amp hours depending on which model of battery is currently in service.

Figure 14

13 2

1 Winch Power NEG - Connection

Winch Power POS + Connection

3 Battery Charger NEG – Connection Aircraft Warning light

Battery Charger POS + Connection Aircraft Warning light

Additional 12v DC Power cords should be connected to Terminals 3 and 4 or 5 and 6

Figure 15 Figure 16

5 6 7

Electrical Pass – Thru and Patch Panel

1. The 3” x 3” Cover ( Figure 15 – 1 ) can be removed to provide a 2” dia. egress

2. The 110v AC Wet Location Outlet ( Fig. 15 – 2 ) serves as a 110v AC Pass – Thru to power the 25 amp Battery Charger. The “Turn & Lock” Power cord is stowed in the Right side Stowage Box.

* Old Winch and Solar Panel connections no longer used…

II – 6

SECTION III

TOWER SET UP

AND

OPERATION

NORTH DAKOTA WISCONSIN

FLORIDA MINNESOTA

ALUMA TOWERS IN OPERATION

Deploying Relay Tower ( Set up )

Check list / Task list

1. Inspection, Inventory, and PMCS complete.

2. All task critical and safety deficiencies corrected

3. Position Trailer.

4. Set Wheel chocks & disconnect from tow vehicle

5. Deploy Leveling Jacks

6. Level Trailer

7. Deploy Out Riggers ( Do not use out riggers to level trailer )

8. Install Mast head assembly – antenna array

9. Install Ground Cable, Warning Light Cable, and Coax Cables

10. Attach cables to antenna array and stress relief points

11. Attach Guy cables to tower.

12. Raise Tower from Travel seat to vertically nested position

13. Plumb Tower ( Level )

14. Install Guy Anchor Posts and anchor plates

15. Attach Guy Cable assemblies to Anchor plates

16. Tighten bottom “ RED” guy cables

17. Pay out maximum slack on Green, Blue, and Yellow cables at anchor end.

18. VERIFY OPERATIONAL STATUS OF RADIOS, RELAY

ELECTRONICS, ETC.. BEFORE RAISING TOWER!!!

19. Raise Tower

20. Adjust Green, Blue, and Yellow guy cable assemblies

21. Attach CAUTION tape on guy posts and lower guy lines

22. Emplace grounding rods and attach cables

III – 1

1. Position Trailer on as level ground as is feasibl e within the site.

NOTE

When using one directional antenna pointing the trailer hitch in the direction of the signal source simplifies alignment.

Example: With the Tower in the stowed position you would aim the 2.4 Ghz antenna straight down at the hitch. When the tower is raised the antenna will be aligned with the transmitting source.

2. Disconnect from Towing vehicle

a. Lower Hitch Jack and lock in place

b. Position Wheel Chocks.

c. Disconnect Electrical connections, safety chains, and hitch ball latch/lock.

d. Raise tongue and free hitch from towing vehicle.

e. Move towing vehicle…

3. Install Leveling Jacks

a. Remove all six leveling jacks from stowage box or travel mounts.

b. Position Jacks at four positions front and rear and at two outriggers.

c. Position jack pads at all four leveling positions and two outrigger positions.

d. Crank leveling jacks to their lowest position and install on mounts. ( Figure 17 )

e. Remove pin from telescoping leg and allow jack foot to extend to pad.. ( Figure 18 )

f. Replace pin in holes that align at the longest setting.( Figure 19 )

g. Crank jack down until it makes positive contact with the pad. ( Figure 20 )

NOTE

Jack pads should be used on all surfaces with the e xception of concrete.

Leveling jacks will leave imprints in pavement in h igh temperatures and can sink into sod, soil, or gravel significantly o ver time. Jack pads are particularly important if rain is expected during d eployment.

Figure 17 Figure 18 Figure 19 Figure 20

III - 2

3. Level Trailer Chassis

a. Make rough adjustments to level trailer. ( Eye ball it to get it close )

b. Position the 4’ level across the rear of the trailer and raise or lower rear jacks until the rear is level. ( side to side )

c. Repeat procedure for front of the trailer.

d. Place level length wise on the trailer and raise or lower front or rear legs as required to level back to front.

4. Position Outriggers

a. Remove pin and slide each outrigger from stowed position to deployed..

b. Replace pin and safety pin.

c. Install leveling jacks w/jack pads under feet.

d. Lower jacks but do not make adjustments until tower has been raised vertically nested position and adjusted

DO NOT USE OUTRIGGERS TO LEVEL TRAILER. THEY ARE P ROVIDED

FOR ADDITIONAL STABILITY WHEN TOWER IS RAISED.

Deploying Relay Tower ( continued )

Figure 21

III – 3

Figure 22

Leveling Points

Figure 21.1

( continued )

III – 4

5. Install Mast assembly & antenna array.

6. Feed Ground Cable, Aircraft Warning light Cable, & Coax Cables Through the Tubes of the Center “Yellow” Tower secti on. ( Figure 23 - 24 )

Feed Cables through Center section tubes while tower is in Horizontal “ Travel” position

Figure 23

7. Attach Cables to fixtures on mast head and stress relief points.

Figure 24

CAUTION

Ensure that Clevis pins ( bolts ) are tightened firmly into clevis body.

Loose pins can vibrate free in winds and guy failure can occur and cause damage or catastrophic tower failure

Figure 25

8. Attach Guy Cables to color coded flanges on top o f tower sections. ( Figure 25 - 26 )

Figure 26

CLEVIS

CLEVIS

PIN

Tighten Clevis Pins “Firmly” with Pliers

( continued )

9. Raise tower from Seated position to vertical nest ed position ,

a. Release and free restraint cable securing tower to front Travel Seat ( Figure 27 ).

b. Using hand crank tilting winch raise tower to vertical position ( Figure 28 ).

NOTE: Install inner adjusting nut on lug before tower is in full vertical position. ( Figure 28 / 29 )

WARNING

Keep personnel clear of area under tower while tilting to vertical position. If tilt winch cable fails personnel under tower or between tower and frame could be seriously injured.

10. Plumb Tower ( Adjust tower so it is straight up and down )

a. Use 4’ Level to ensure tower is Plumb front to back.( Figure 30 ) Use inner and outer adjusting nuts to adjust and lock into place. ( Figure 29 ).

b. Use 4’ Level to Ensure tower is Plumb side to side. ( Figure 31) Use Left and Right Rear Leveling Jacks to adjust. DO NOT USE OUTRIGGER JACKS TO LEVEL.

III – 5

Figure 30 Figure 31 Figure 32

11. Remove Tower lower transit restraint. ( Figure 32 )

a. Remove “Red Strap” or other bindings used to secure tower sections during movement.

Figure 28 Figure 29

Inner adjusting Nut.

Outer adjusting Nut

Figure 27

( Position Guy Anchors )

70 – 75 ft 70 – 75 ft

70 – 75 ft

12. Determine Guy Anchor Positions

The Basic rule of thumb for achieving the proper distance to achieve efficient support is a formula based on 75% of the Tower height. The actual overall height of the T100H

Series Tower is between 95 & 100 ft.

Guy anchors should be placed 70 – 75 ft from the center of the tower.

NOTE

a. Measure out approximately 73’. Sight back towards the tower and line up with the color coded flanges to determine the appropriate Angle. ( Figure 33 )

b. Mark the positions and emplace Guy anchors.

Figure 33

III - 6

Distance not to scale

( Emplace Guy Anchors & Grounding Rods )

13. Emplace Guy Anchors .

a. With the “T” facing away from the tower drive the T-Posts in 18 – 24”.

b. Drive the T- Post in at a 10°- 12°angle away from the tower. ( Figure 34 )

14. Attach Guy Anchor Plates to Guy anchors.

a. Slide bracket down over top of T-Post all the way to the ground.

b. Tighten mounting bolt on back side of post to compress bracket firmly on post.

15. Attach Guy Anchor assemblies to Anchor Plates.

a. Remove bolts from Guy Anchor Plate and attach guy cable turnbuckles.

b. Ensure guys are attached at the appropriate position ( Figure 35 ) and guy cables do not become twisted or intertwined between the guy anchor and tower attach points.

16. Prepare Guy Cables

a. Loosen 03 ea. Cable Clamps on each Red, Green, Blue, and Yellow Cable assembly.

b. Ensure turnbuckles are unscrewed to allow maximum adjustment

c. Pull Red cables tight at all three positions and tighten cable clamps.

d. Take up remaining slack in Red Cables by adjusting turnbuckles.

e. Tighten Lock nuts on Turnbuckles to prevent loosening.

f. Ensure cable clamps are loosely installed on Green, Blue, and Yellow cable assemblies and pay out maximum slack to allow raising of tower.

III – 7

Proper Cable Clamp Installation

Saddle

Yellow Sun Blue Sky Green Grass Lava or Red Clay

Color Code Memory Tool

Anchor Plate

Figure 35

NOTE: Where soil conditions such as sand or rock prevent using T-Posts in this fashion see Appendix C. Alternate Guying Techniques.

Figure 34

( Raise Tower )

A minimum of 04 personnel are required to raise the Tower safely and efficiently

CAUTIONS

Ensure the RED strap or other restraints have been removed from the lower rungs used during transit. Attempting to raise tower with restraint in place will damage the tower and/or rigging.

Ensure cable bundle does not become kinked, entangled or otherwise restricted while raising tower. Cables can be damaged and rendered inoperative.

WARNINGS

PERSONNEL WORKING NEAR THE TOWER DURING RAISING OR LOWERING MUST

WEAR PROTECTIVE HEAD GEAR. FALLING DEBRIS, LOOSE HARDWARE OR TOOLS

CAN CAUSE SERIOUS INJURY.

DO NOT RAISE OR LOWER THE TOWER IF GUSTS OR CONSTANT WINDS

EXCEEDING 10 - 15 MPH ARE EXPECTED.

DO NOT RAISE OR LOWER IF LIGHTENING OR THUNDERSTORMS HAVE BEEN

REPORTED WITHIN 18 – 20 MILES OF THE SITE.

MAINTAIN SITUATIONAL AWARENESS AT ALL TIMES. DON’T GET IN A HURRY

AND DON’T TAKE CHANCES. PUT SAFETY FIRST

1. Prepare Winch for Operation

a. Remove protective cover.

b. Connect Winch Power Cable ( Figure 36 )

NOTE: Winch Power cable and Winch Control Cables are stowed in Electronics Box.

There are some variations in the mounting location of power connections on the Winch and in the Electronics box, but they are easily recognizable.

Figure 36

III – 8

4. Raise Tower

a. Move toggle switch on winch control down to pay in cable and raise tower. ( Figure 38 )

b. Watch and listen for warnings from Guy Tenders.

c. Stop periodically and check to ensure cables are not tangled or binding.

d. Raise tower until the second section ( Green ) is still nested in the Bottom ( Red ) section approximately 2.5 to 3 rungs. ( Figure 39 ).

e. Ensure Mechanical Safety is in place and gently lower tower till it just rests on safety.

f. Ensure winch cable remains taut and is supporting the tower weight.

2. Prepare Winch for Operation ( continued )

a. Connect Winch Control Cable

b. Align white witness marks as shown. ( Figure 37 ).

Deploying Relay Tower ( Raise Tower )

Figure 37 Winch Control

3. Organize Personnel

a. Supervisor: Operate Winch and coordinate actions of Guy Tenders.

b. Guy Tenders: Tend cables and guy wires as tower is raised.

Tighten and adjust Guy wires as directed by Supervisor.

c. Position Personnel:

( 1 ) Position one Guy Tender to guide cable bundle and ensure it doesn’t get tangled kinked or hung up as it passes up into the center of Tower.

( 2 ) Assign the other Guy Tenders to observe the Tower and Cables as the tower is raised to ensure guy cables don’t become tangled or hung up on tower.

Figure 38 Figure 40

Figure 39

III – 9

III – 10

5. Adjust Green, Blue, and Yellow Guy cables.

a. Position a Guy Tender at each guy anchor.

b. Coordinate simultaneous adjustment of guy cables starting with Green and working your way up.

c. Site up the backbone of the Tower ( Figure 41 ) and up one side. Direct Guy Tenders to make adjustments to ensure tower is straight and true.

Deploying Relay Tower ( Raise Tower )

Figure 41

Guy Tenders should ensure all cable clamps are loosened and pull on the running end of the cables with the approximate effort required to lift 60 – 75lbs of dead weight

Tighten one of the cable clamps and move to the next cable up when directed by the Supervisor.

The Supervisor should sight up the backbone and side of the tower, walk around to the guy points making spot checks, and direct the Guy Tenders to make adjustments according to tower orientation.

Only the Red Cable should be tight with little or no slack. The Green, Blue, and Yellow lines should have a visible “droop” in the upper ¼ of the line.

If tower is leaning one way or the other DO NOT over tighten one side to straighten it. Loosen the side it is leaning to instead.

When the Supervisor is satisfied that the tower is straight and true, tighten the remaining cable Clamps and mark the Guy Posts and Red Cables with Caution tape

6. Emplace Grounding Rods ( Figure 42 )

a. Drive one Ground Rod to connect the ground wires from the Mast & Trailer.

b. Drive one Ground Rod to connect to the Grounding lug on the Patch Panel.

c. Drive 5’ Ground Rods in approximately 4’.

To Patch Panel

Mast & Trailer

Figure 42

Periodic Safety and Maintenance Checks

ENVIRONMENTAL CONDITIONS WILL IMPACT TOWER STABILIT Y

High winds and rain are of particular concern and s pecial attention should be given to guy anchors, anchor assemblies, and guy cables to ensure they remain in tact and properly adjusted .

Periodic Checks

Guy anchors Guy anchor assemblies Guy Cable Tension

Leveling Jacks and Jack pad stability Tower Support Frame

Aircraft Warning light operation

Power supply

Generator

Checks should be conducted every two or three days and more often if environmental conditions dictate.

Generator, Power supply, and electronics packages s hould be checked as often as is required to maintain full mission ca pability.

Maintenance Checks can be conducted quickly and wil l prevent costly mission down time.

A few minutes a day can prevent serious and expensi ve breakdowns

III – 11

SECTION IV

TOWER RECOVERY

AND

PREPARATION

FOR

MOVEMENT

Check list / Task list

1. Power Down Electronics and disconnect Coax & Power Cables

2. Relieve Guy Cable Tension

3. Lower Tower to Vertical Nested Position

4. Disconnect Rear Guy anchor assembly from anchor

5. Lower Tower to Horizontal position

6. Disconnect Ground Cable, Warning Light Cable, and Coax Cables from Mast Head assembly

7. Detach Guy Cables from tower.

8. Attach Tower front saddle transport restraint.

9. Disassemble and Remove equipment from Mast Head

10. Remove Coax cables, Warning light power cable, and ground cable from top section legs and coil for storage.

11. Remove and stow Outrigger Jacks and stow outriggers.

12. Remove and stow Leveling Jacks

13. Disassemble and Stow Guy Cable assemblies

14. Remove and stow grounding rods

15. Remove and stow guy anchor T-posts

16. Secure all tools and equipment in appropriate stowage configuration

17. Check Tire condition and pressure IAW Section II PMCS

18. Connect to Towing vehicle and ensure trailer lights are operational.

TOWER RECOVERY

and

PREPARATION FOR MOVEMENT

CAUTION

Do not attempt to raise tower to release safety latch for lowering without relieving tension on Yellow, Blue, and Green Guy Cables. Raising tower against operational guy tension will over stress tower cable and rigging hardware.

This can cause serious damage to rigging hardware that could result in a Catastrophic Tower failure.

IV – 1

( Lower Tower )

NOTE: When lowering the tower temporarily to the Vertical or Horizontal Nested positions it is helpful to place a witness mark on the cable bundle before lowering. ( Figure 43 )

When “re-raising” the tower it will be easier to determine the previous position and lessen the amount of work required reapplying guy cable tension.

Figure 43

Red tape applied as witness mark

1. Connect Winch Power ( Figure 44) and Control (Figure 45) Cables.

Figure 44

Figure 45

Winch Control

2. Position Personnel

a. Supervisor should operate the winch and direct the actions of Guy Tenders.

b. Position a Guy Tender at each of the three anchor points.

A MINIMUM OF FOUR PERSONNEL ARE REQUIRED TO SAFELY AND

EFFICIENTLY CONDUCT THIS TASK.

IV – 2

3. Disengage Mechanical Safety

a. Relieve Green, Blue, and Yellow Guy Cable tension

b. Direct Guy tenders to loosen turn buckles to relieve tension.

c. Loosen three cable clamps at the guy anchor assemblies and pay out a modest amount of slack if turn buckles are already in the fully extended position.

d. Pull on mechanical safety release ( Figure 46 ) and raise tower a few inches slowly until Safety lock can be released. ( Figure 47 )

Figure 46

IV – 3

TOWER RECOVERY

( Lower Tower )

CAUTION

After tension on Green, Blue, and Yellow guy cables is released tower stability is compromised.

The tower should be lowered expeditiously.

The upper tower sections may become jammed or be in a bind from uneven guy cable tension or wind gusts. If the Winch cable becomes slack. Immediately release the safety latch line and move the winch control toggle switch down to make the winch line taut again.

Investigate the cause and apply immediate action.

WARNINGS

PERSONNEL WORKING NEAR THE TOWER DURING RAISING OR LOWERING MUST

WEAR PROTECTIVE HEAD GEAR. FALLING DEBRIS, LOOSE HARDWARE OR TOOLS

CAN CAUSE SERIOUS INJURY.

DO NOT RAISE OR LOWER THE TOWER IF GUSTS OR CONSTANT WINDS

EXCEEDING 10 - 15 MPH ARE EXPECTED.

DO NOT RAISE OR LOWER IF LIGHTENING OR THUNDERSTORMS HAVE BEEN

REPORTED WITHIN 18 – 20 MILES OF THE SITE.

MAINTAIN SITUATIONAL AWARENESS AT ALL TIMES. DON’T GET IN A HURRY

AND DON’T TAKE CHANCES. PUT SAFETY FIRST

Figure 47

4. Lower Tower

a. Continue to pull on Mechanical Safety release. ( Figure 48 )

b. Push toggle switch on Winch Control up (Figure 49) to pay out cable and lower tower.

c. Position a tender to mind the cable bundle as it lowers to keep the slack pulled out of the center of the tower to prevent it from piling up and being trapped between tower section rungs.

d. Continue lowering tower until it is fully nested. ( Figure 50 )

TOWER RECOVERY

( Lower Tower )

NOTE: If Tower doesn’t lower and winch cable becomes slack, one of the upper sections is most likely in a bind or one of it’s legs are resting on a roller on an outer section rung.

Raise the tower a few inches then sight up the backbone of the tower and direct the Guy tenders to pull on the Blue and Yellow guy cables to straighten the tower.

It may be necessary to “jiggle” the upper sections to free it from the bind.

USE DISCRETION AND MAINTAIN SITUATIONAL AWARENESS.

BE SURE TO KEEP THE MECHANICAL SAFETY DISENGAGED UN TIL TOWER IS

COMPLETELY NESTED IN THE VERTICAL POSITION.

Figure 48 Figure 49 Figure 50

NOTE: In special cases, such as when a Di pole antenna is mounted on the upper portion of the Blue section, the tower can’t be lowered to fully nested until the Antenna assembly is removed.

Tower must be lowered to horizontal to remove Di pole mounting hardware and then tilted back up to vertical in order to lower to fully nested before attaching Transport Strap or Binding to bottom rungs.

IV – 4

( Prep for Move )

Inner adjusting Nut.

Figure 51

Outer adjusting Nut

5. Tilt Tower to Horizontal Travel position.

a. Disconnect Rear Guy Assembly from Guy Anchor

b. Remove Outer adjusting nut. ( Figure 51 )

c. Pay out some slack on the tower tilting winch.( Figure 52 )

Figure 52

NOTE: After tower is tilted forward slightly remove both inner and outer adjusting nuts and stow in Tool box. Nuts WILL vibrate off during travel and be lost if left on vertical adjusting Lug.

6. Tilt Tower to Horizontal Travel position. ( continued )

a. Direct Tender to grasp tower near the bottom and pull away from Base Frame until

Tilt winch cable is engaged and weight of tower causes it to tilt forward.

b. Install “Red Strap” or other binding to secure bottom rungs of all four sections together

c. Remove and stow inner and outer adjusting lugs.

d. Slowly crank tilting winch and lower tower onto front tower seat.

WARNING

Stand to the side and clear of the Tower when pulling it away from Base Frame.

Load on Mast head can cause it to kick out quickly and injure any personnel behind it in it’s swing path.

IV – 5

IV – 6

( Prep for Move )

7. Attach front Travel restraint. ( Figure 53 )

Figure 53

8. Remove Guy Cables from top of Tower.

a. Remove Clevis Pins and remove from flanges on tower

b. Leave Clevis on Cable thimble and replace Clevis pin to prevent loss.

9. Disconnect Coax Cables, Ground Cable, & Power Cable s.

10. Disassemble and remove Mast Head Assembly

11. Pull Cables out of center section tubes from rea r.

12. Remove and stow Out rigger Jacks.

13. Put Outriggers in stow position and install reta ining and safety pins

14. Remove and stow leveling Jacks

15. Disassemble Guy Cable assemblies and stow.

a. Remove Turnbuckles from Anchor Plates and coil cables ( Lariat Style )

b. Place coiled Cable assemblies in appropriate color coded storage bags

16. Conduct checks IAW Section II.

17. Connect to towing vehicle and ensure trailer lig hts are operational.

Note: Ensure tower is centered on front seat and resting on rubber pads before locking down restraint latch

APPENDICES

APPENDIX A: TOOLS & EQUIPMENT

Hand Tools Tools and Equipment Hi Lift Jack Manual ( Extract ) Operate Grounding Rod Puller

APPENDIX B: EF1000is YAMAHA GENERATOR

APPENDIX C: ALTERNATE GUYING TECHNIQUES

APPENDIX D: TRAILER TRANSPORT CONFIGURATION

APPENDIX E: MARKINGS, DECALS, & SIGNS

APPENDIX F: REFERENCES

APPENDIX A

Tools and Equipment

HAND TOOLS

TOOLS & EQUIPMENT

HI LIFT JACK MANUAL ( Extract )

OPERATE GROUND ROD PULLER

( Hand Tools )

5 6 – 7

21 3 4

8 9

A1

The Tool Box is stowed in the left side Stowage Box. It is not limited to, but at a minimum should contain the hand tools shown on this page.

A2

The Tools and hardware shown on this page are stowed in the Left side Stowage Box.

Tools and hardware are not limited to, but should consist of the following at a minimum.

10 11 a b c

A3

Tools, Hardware & Equipment shown below, with the exception of 04 ea. T-Posts, are stowed in the right side Stowage Box. T-Posts are stowed between the rear tower frame and the Electronics Box.

32 5 76

CANVAS

STOWAGE

BAGS

03 ea. Red Cables 78’ Length

03 ea. Green Cables 87’ Length

03 ea. Blue Cables 101’ Length

03 ea. Yellow Cables 116’ Length

130’ LMR 400

COAX CABLE

X 03

130’ Ground Cable

130’ 12v DC Light

Power Cable

915 Mhz & ACW Light Assembly

2.4 Ghz

Antenna Assembly

5’ Copper Grounding Rods

4’ Level 100” Measuring Tape

130’ 120v AC Power Cable

EXTRACT

EXTRACT

A4

A5

( Hi Lift Jack )

A6

A7

A8

A9

( Operate Grounding Rod Puller )

Pulling Grounding Rods

1. Attach Ground rod puller to eyelet on Hi lift Jack with D-ring. ( Figure 1 )

2. Position Jack base plate a few inches from Grounding Rod. ( Figure 1)

3. Open Puller Jaws and position on Grounding Rod. ( Figure 2 )

4. Push rod retaining lever on Puller forward over lug. ( Figure 3 & 4 )

5. Lift jack and engage in lift mode.

6. Operate Jack handle till Grounding Rod is free. ( Figure 4 )

Figure 1 Figure 2

Figure 3 Figure 4

A10

APPENDIX B

Yamaha Generator

( EF 1000is )

STARTING INSTRUCTIONS

1. Disconnect all electrical devices

2. Turn ECON Switch to OFF

3. Open Fuel Cap Vent

4. Turn Fuel Knob to ON

5. Turn Engine switch to ON

6. Pull Choke knob out

7. Pull recoil starter

8. Push Choke knob in

B1

CHECK – CHANGE OIL

Check Oil before Operating Fill with 30 W Engine Oil

Oil should be observed at the lip of the fill spout.

NOTE: Be ready to replace plug quickly. Oil may run out when removed.

Change Engine Oil every 100 hours of operation

Generator is not equipped with an hour meter so ope rating hours must be tracked manually.

Change oil at the end of each mission.

If it is apparent Oil change was neglected ( Oil th in and Black ) change oil.

CHANGING OIL TOO OFTEN WILL NOT HARM THE ENGINE

NOT CHANGING IT OFTEN ENOUGH WILL!!

B 2

Figure 1

APPENDIX C

Alternate Guying Techniques

When soil conditions prevent the use of single T-Post driven 18 – 24 inches in the ground if may require using a field expedient method.

1. In sandy soil a double post technique can be used.

a. Drive the front post in the normal distance from the center of the tower.

b. Drive the second post in behind it at a distance allowing use of a turnbuckle ( Figure 1 )

c. Chain, rope, or heavy gauge steel wire can also be used to lash to the rear post.

2. In extremely hard soil or rock the pallet and/or weighted basket can be used. ( Figure 2 )

a. Attach a chain, rope, or cable with a combined working load rating of no less then 1000lbs to the center 2 x 4 skid in the middle of the pallet.

b. Load sand bags on the pallet to achieve a weight of 800 – 1000 lbs.

c. Adding side boards or some other technique to keep sand bags from sliding off may be required during longer deployments.

Figure 2

NOTE: In wooded areas a live tree with a trunk diameter of 4” or more can also be used as an anchor using field expedient methods to attach the Guy anchor assembly.

CAUTION

DO NOT USE AN ANCHOR THAT YOU

ARE NOT CERTAIN CAN SUPPORT

A WORKING LOAD OF 800 LBS OR MORE.

C1

APPENDIX D

Trailer

Transport Configuration & Flat Bed Loading

The Transport Configuration reduces the overall height of the trailer to allow hauling on a standard flat bed trailer.

Height in Standard Travel configuration: 10.5 ft.

Height in Transport configuration: 8.7 ft.

Length in Standard Travel configuration: 31.0 ft.

Length in Transport configuration: 27.0 ft.

Two towers can be hauled on a 48’ Trailer with some overhang and overlap of the trailer tongues.

53’ flat bed shown in the figure above.

Hitch to end of tower

The process of putting the Tower in Transport configuration or from Transport Configuration back to Standard Travel configuration can be accomplished with a light duty fork lift and a minimum of 02 personnel.

Loading on, or unloading from, a flat bed trailer can be accomplished using a standard or variable reach forklift with a working lift capacity of no less than 10,000 lbs.

D1 a d bc

APPENDIX D

Transport Configuration

1. Prepare Tower for removal

a. Remove coax, ground, and power cables from inner section.

b. Remove or put Mast head in stow position. ( Figure 1 a. )

c. Disconnect Tilting Winch Cable Pulley from bottom of Tower (Figure 1b & 2).

d. Disconnect tower trailer light connection and solar panel cable if equipped and secure wiring harnesses. (Figure 1c – 3 & 4).

e. Remove front travel restraint ( Figure 1 d. )

Tower Trailer Light connector

Solar Panel Power cable

Trailer light connection

High or

Low

Tilt Winch Cable Anchor

2. Remove Tower Mounting shoulder Bolts & secure bac k in tower flanges ( Figure 5 ).

NOTE:

Inspect bushings and take care to secure bolts, washers & bushings in the Tower flanges to prevent losing them.

D2

Figure 1

Figure 2 Figure 3

Figure 4 Figure 5

Transport Configuration

3. Position fork lift

a. Use guide to position forklift

b. Green rectangles in Figure 6 indicate approximate lift point for forks.

c. Lift the tower a few inches and test balance before moving. Adjust forklift position as required.

4. Lift Tower

a. Lift the tower just high enough to ensure mounting flanges clear the rear frame.

b. Move forklift back from trailer and lower forks/tower and maneuver to align for insertion through rear support brace ( Figure 7 ).

CAUTION

WARNING

DO NOT RUSH. Use guides and spotters to ensure personnel are in safe positions when lifting, lowering, and maneuvering forklift and tower into position. Maintain situational awareness and be wary of possible safety hazards.

DO NOT RUSH. Take care not to damage tower when positioning forklift or guiding it through the rear support Brace. Clearance is tight and care must be taken not to bind the tower and bend or damage aluminum tubes.

Figure 6

D3

Figure 7

Transport Configuration

NOTE: Terrain and maneuver room will dictate how y ou must maneuver the tower into position. Once you maneuver the tow er to the rear of the Trailer one person can push the tower from the bott om end while another person guides the top of the tower into the Rear su pport frame.

It will be necessary for the person at the base of the tower to lift the tower slightly to slide the mounting flanges on the tower over the forklift forks.

5. Position Tower and secure for transport.

a. Slowly and carefully slide tower through rear Brace and through front brace.

b. Slide tower in until the winch is a few inches from the rear support frame upright.

Support Frame upright

Figure 8

View from Rear looking forwardView from Front looking rearward

Figure 9 Figure 10

D4

6. Install transit restraint hardware assemblies.

a. Shift tower back or forward to ensure assemblies can be installed on tower and cross members at 2 points front and rear.

NOTE: Use a 4 – 6” Piece of 1½” Heater hose to protect the Aluminum from metal on metal contact as shown in Figure 11 a/b.

Figure 11bFigure 11a

D5

APPENDIX D

Transport Configuration

CAUTION

DO NOT OVERTIGHTEN U-BOLT NUTS. ALUMINUM TUBING WILL BE

DAMAGED BY OVER TIGHTENING. TIGHTEN NUT UNTIL SPRING

LOCK WASHER IS COMPRESSED AND THEN APPLY A SECOND NUT

AS A LOCK TO PREVENT HARDWARE FROM VIBRATING LOOSE

DURING TRANSIT

7. Reattach tilt winch cable.

a. Attach clevis to eye bolt on cross member.( Figure 12 )

b. Take up slack in winch cable and apply a moderate amount of tension.

Figure 12

Transport to Travel Configuration

1. Remove Tower from Transport position

a. Remove Restraint hardware from front and rear and stow. ( Figure 13 )

b. Disconnect tilt winch clevis. ( Figure 13 )

c. Remove shoulder bolt assemblies from flanges and set aside.

CAUTION

WARNING

DO NOT RUSH. Use guides and spotters to ensure personnel are in safe positions when lifting, lowering, and maneuvering forklift and tower into position. Maintain situational awareness and be wary of possible safety hazards.

DO NOT RUSH. Take care not to damage tower when positioning forklift or guiding it through the rear support Brace. Clearance is tight and care must be taken not to bind the tower and bend or damage aluminum tubes.

NOTE: With one person positioned on the trailer and one on the ground the tower is easily balanced on the rear support brace as the Forklift is repositioned.

Figure 14

D6

Figure 13

c. Position forklift behind Trailer as shown in Fi gure 14.

d. Slightly lift and slide tower rearward out of Tower support assemblies.

e. Have two personnel support tower and reposition forklift until tower is clear and lift balance is accomplished.

2. Position Tower on Tower support seats.

a. Position Tower with forklift and carefully lower onto tower seats.

b. Refine Tower position and align mounting flanges on tower inside of mounting brackets on support frame crossbar ( Figure 16 )

APPENDIX D

Transport to Travel Configuration

Figure 15

Figure 17

NOTE: Use a short length of 2 x 4 lumber to align flanges when inserting shoulder bolts.

DO NOT PRY ON CENTER

CROSS BRACES OR RUNGS.

Figure 16

3. Attach Tower to Rear Support Frame

a. Align mounting Flanges on Tower with mounting brackets on cross member.

c. Install shoulder bolts and associated hardware as shown in Figure 17.

Tower Flange

Tower Flange

1: Shoulder Bolt 2: Thin Washer 3: Bushing 4: Hex nut w/nylon

23 4

D7

Transport to Travel Configuration

3. Attach Tilt winch pulley anchor

a. Attach tilt winch pulley to “I” Bolt on cross member with clevis ( Figure 18 ).

b. Secure front seat Travel restraint ( Figure 19 ).

Figure 18

Figure 19

END OF TASK

D8

Loading Tower

Two towers can be loaded and transported on a 48’ Flatbed trailer in the Transport Configuration.

A Heavy Duty Forklift with a minimum working load capacity of 10,000lbs is required.

The tower can be lifted sling fashion using cargo straps attached to the lifting eyes on the left and right front and rear or lifted from under the frame.

WARNING / CAUTION

This procedure should only be conducted by trained and experienced personnel. There are many factors involved that can cause serious injury to personnel and damage to equipment.

Sling load method using 04 ea. 3300lb cargo straps and variable reach forklift.

Regardless of the method used stage equipment so movement to the Flat bed is limited.

When lifting under the frame a forklift with 5.5 to 6.0 ft or longer forks must be used.

Position forks approximately as shown below and apply cribbing to distribute weight and maximize lift balance.

With forks level and the right fork, if lifted from left slide as shown, touching the spring mount between the wheels apply cribbing at the points shown in the figure below before lifting.

Cargo straps should also be attached from the far side to the fork header for additional stability

Figure 20

Figure 21

D9

Deploy Front Leveling Jacks when tower is loaded on trailer for transit.

Extreme load applied to chain Bindings will cause damage to Tongue Jack if Front Leveling Jacks are not deployed.

CAUTION

APPENDIX E

MARKINGS, SIGNS, &

DECALS

E1

Relay Trailer Identification #s A numerical designator has been assigned to each Relay Tower.

It is stenciled on the Right front and rear of the trailer frame.

The Manufacturers Data Plate is on the Left front of the Frame.

Corresponding State FlexTrain Home Station designation:

System #1 – CA – Camp Roberts: RT 1 System #1 – CA – Camp Roberts: RT 2 System #2 – ID – Gowen Field: RT 3 System #3 – KY – WHFRTC: RT 4 System #4 – MS – Camp Shelby: RT 5 System #5 – MN – Camp Ripley: RT 6 System #6 – Unassigned: RT 7 System #7 – Unassigned: RT 8 FLOAT: 60’ Aluma Tower: RT 9

E2

APPENDIX E

MARKINGS, SIGNS, &

DECALS

Manufacturer’s Data Plate Left Front

APPENDIX E

References

Aluma Tower Company Website: www.alumatower.com/

EF 1000iS Yamaha Generator Operator’s Manual: www.yamahagenerators.com/

Hi lift Jack Operator’s Manual: www.hi-lift.com/hi-lift-jacks/instruction-manual.html

Super Winch 1000 Operator’s Manual: www.superwinch.com/UserFiles/File/89_10865.pdf

INDEX