DIY Installation Instructions

WEAR APPROPRIATE SAFETY GEAR

• Steel Toed Shoes
• Safety Glasses
• Work Gloves
• Hard Hat

DO YOUR HOMEWORK

• Mark pipes and electric cables before drilling or trenching
• Keep masts away from power lines, height +15ft

KEEP ALERT

• Always stand and work to the sides of the Cheek Plates
• Never stand or work under a mast being raised or lowered
• Inspect all tools, winch & accessories, cable, and ladder for wear or damage
• Don’t raise or lower mast in more than a gentle breeze
   

TOOLS REQUIRED

· (1) 120v Electric Winch with Cable 

· (1) Base Mounting Plate to Attach to Winch to Lower Tower/Mast 

· (1) 1-Ton Forged Lifting Hook/Safety Clip Attach to Bow Shackle (See Note and Configuration Top of Page 7) 

· (1) 5/16” Bow Shackle to Attach to Winch & Lifting Hook

· (1) 5” OD Pulley

· (1) Lifting Strap (See Configuration Top Page 7)

· (1) Strap Clamp with Buckle

· (2) 10” Spud Wrenches

· (1) Fish Tape 100’

· (1) Emergency Manual Winch Crank

· (2) Magnetic Spirit Levels

· (1) 24” Pipe Wrench (Aluminum if Available)

· (1) 24‐30” Steel Wrecking Bar

· (2) U‐Bolts

· (1) 10’ Heavy Duty Stepladder (not pictured)

· Equipment to Drill and Cement Base Section or Hire a Contractor To Complete This Portion (not pictured)

· Ethernet / Cat 5 or Cat 6 Cable & Strain Relief (Usually Provided by your ISP) (not pictured)

· Conduit (Only if preferred, but not necessary) (not pictured)

 LM-4 MAJOR PARTS SHIPPED

• (1) Base Section
• (1) 2nd Section
• (1) 3rd Section
• (1) 4th Section
• (1) 5th Section (Optional)
• (2) Cheek Plates & Bolts
• (1) Toggle & Bolts
   

(Purchase Not Necessary If You Already Have These Tools)

· Emergency Manual Winch Crank

· (2) U‐Bolts

· 120v Electric Winch with Cable 

· Base Mounting Plate to Lower Tower/Mast (attached to back of Winch)

· 5/16” Bow Shackle attached to Winch

· 1-Ton Forged Lifting Hook/Safety Clip 

· attached to Bow Shackle on Winch

· 5” OD Pulley

· Lifting Strap (See top of page)

· Strap Clamp with Buckle

The Above Items Are Subject To Change Without Notice
 

STEP 1 - SELECT A GOOD LOCATION

• Select A Good Location well away from power lines (mast height + 15’)
• Avoid Structures
• Mark Underground Utilities
• Consider Distance to POE point (<200')
• Use a Hand‐digger to check for obstructions before power drilling
• Separate sections in tower
  shipping bundle, layout and inspect 

STEP 2 - DRILL FOUNDATION HOLE

•  12” Diameter x 6 to 7' Deep
• 6' Minimum
• Clear out dirt to bottom       
   

STEP 3 - PLACE BOTTOM SECTION IN HOLE

• Use 8’ long 2x10 to Guide Bottom Section into hole
• Set base section against board
• Carefully walk base section up.  (May take 3 persons or use a loader.)
• Don’t stand under the Section
  while raising
• Center and Orient Bottom
  Section
• Mast folds down opposite
  Cheek Plates 

STEP 4 - PLUMB BASE SECTION & CEMENT

 4A - PLUMB BASE SECTION

• Now is the time to add the Conduit for Cat 6 if needed 

4B - CEMENTING

• Spirit Level to Plumb (both Directions) after 12" of Cement Fill 
• Check Plumb after each foot of fill 
• Be SURE of orientation and plumb—There is no adjustment later.  
• Double Check Conduit Section is appropriately in place.

4C- ALLOW CEMENT TO CURE

• Temperature affects curing time.
• Check premix bag for mix and cure details.
   

STEP 5 - INSTALL 2ND SECTION

• Check Base Section is Plumb
•  Using 10’ Stepladder, Install 5” Pulley
• Use Supplied 5/8” Bolt and Locknut
• Snug but do not over‐tighten Bolt
• Pulley should turn freely 
• Note position of step ladder is to the side of the Cheek Plates.

 STEP 6 - LIFT 2ND SECTION 

• Bottom of 2nd Section has three holes (See Picture Page 12)
• Place Winch opposite and below Cheek Plates
• Place Toggle on 2nd Section 7‐1/2’ from end with holes 
• Snug Grub Bolts
• Attach lifting strap near bottom (See Page 6 for Configuration.)
• Align 2 small holes horizontally with larger hole facing down
• Attach Lifting Strap and winch section into position between Cheek Plates
• Install ½” Bolt through cheek plates and bottom section through outer most hole
• Snug with ½” lock nut
   

STEP 7 - WINCH 2ND SECTION TO VERTICAL

• Reinstall 5/8” bolt, washers and lock-nut through Clevis and Toggle
• Relocate Lifting Strap to just below Toggle (See Picture Page 12)
• Toggle is 7.5’ above base of 2nd Section
• Winch 2nd section within about 4” of Pulley 

STEP 8 - ATTACHING TOGGLE

• Note installer’s position is to the side of Cheek Plates (See Picture Page 13)
• Snug Strap Clamp with Buckle around Base and Second Sections about 18” below Pulley (See Page 6 for Configuration)
• Remove 5/8” Bolt and Pulley
• Loosen Toggle and lower into clevis at top of 1st Section
• Reinstall 5/8” bolt, washers and locknut through clevis and Toggle
• Strap Clamp may be moved up or down to align holes
• Tighten all four toggle bolts
• Note that 2nd section remains bolted to Cheek Plates outermost holes
   

STEP 9 -  TOGGLE CONNECTION COMPLETED

• Toggle in place with 5/8” bolt, washers and lock-nut  (See Picture Page 14)
• Snug up Locknut to the point where washers can’t be turned by hand
• Tighten 4 x ½” Grub Bolts on toggle 

STEP 10 - LOWERING 2ND SECTION

• Move Winch to just below Cheek Plates on opposite side (See Picture Page 14)
• Place Lifting Hook/Safety Clip through large hole in 2nd Section as shown
• Check Winch is ready
• Remove ½” Bolt through Cheek Plates and 2nd Section
• The load is now on the Winch 
• Reinstall ½” Bolt through bottom Cheek Plate holes
• Pull cable out to lower top of 2nd Section
• Note position of installers to sides of Cheek Plates
   

 STEP 11 - INSTALL 3RD AND SUBSEQUENT SECTIONS 

• Locate 3rd Section (2‐7/8” OD) Mark a line 24” from bottom
  (end without Grub Bolts)
• Set ladder to side of 2nd Section, within reach of Grub Bolts. Loosen Grub Bolts several turns 
• Insert end of 3rd Section into 2nd Section to 2’ line and tighten Grub Bolts (About 40 ft‐lbs)
• Adjust Winch to facilitate insertion of next Section(s) 
• 4th Section is 2‐3/8” OD 

STEP 12 - RUNNING CABLE AND GROUND

• Optionally, Ethernet Cable may be run inside tower/mast
• Push Fish Tape through tower/mast from terminal end to pull cable and ground through
• Install Strain Relief at top of tower/mast to support Ethernet Cable (See Picture Page 16)

 STEP 13 - INSERT RADIO AND SECURE CABLE 

• Adjust Azimuth to approximate Final Compass Bearing
• Note Drip Loop (See Picture Page 16)

STEP 14 - RAISING & SECURING THE TOWER/MAST

• Winch tower/mast to vertical. Tower/mast will bow quite a bit while near horizontal
• Stop Winch when 2nd section enters between Cheek Plates. Don’t over pull.
• If necessary, use wrecking bar to align bottom of second section between Cheek Plates
• If necessary, use Strap Clamp to pull section fully into position between Cheek Plates
• Install ½” x 4‐½” Bolt through outermost Cheek Plate holes as shown to secure 2nd Section (Don’t disconnect winch before this step is complete) (See Picture Page 17)
• NOTE – No bolts pass through 2nd Section
• The bottom Cheek Plate Bolt is centered below 2nd Section (See Picture Page 17)

 STEP 15 - ADJUSTING AZIMUTH

• Using stepladder, loosen the four Grub Bolts on the Toggle. (See Picture Page 18)
• There will be an audible “click” as the 2nd section drops to rest on the 1/2” x 4.5” center (lower cheek plate bolt.)
• 2nd Section is now resting on the bottom ½” bolt through the Cheek Plates, and is free to rotate.
• Use 24” Pipe Wrench to engage 2nd Section above Cheek Plates, and rotate the section as needed to maximize signal strength
• Re‐tighten the 4 Grub Bolts on the Toggle (30 ft‐lbs)
• Install 2 each ½” x 1‐ ½’ Bolts nearest the Base Section and
  snug (Do not over tighten)

 STEP 16 -  PREPARING TO SERVICE THE RADIO; CENTER LIFT HOLE

• Inspect winch for damage and wear; install beneath cheek plates.
• Check to be sure lift hole is centered between cheek plates and facing out.
• If not, loosen 2 rear (nearest base section) grub bolts on cheek plates.
• Loosen 4 grub bolts on toggle.
• Using a pipe wrench, rotate 2nd Section to center lift hole.
• Re-tighten 4 grub bolts on toggle, and connect winch hook. 
• Before lowering mast, always insure that 4 Grub Bolts on Toggle are tight!

STEP 17 -  LOWERING TOWER/MAST TO SERVICE RADIO 

• Check that large hole in 2nd Section is centered and facing out between Cheek Plates so that Lifting Hook can be inserted (See Page 6 Picture for Configuration)
• If not, loosen Toggle Grub Bolts and rotate 2nd Section as needed to center large hole between Cheek Plates
• Re‐tighten Toggle Grub Bolts
• Before lowering tower/mast, always insure that 4 Grub Bolts on Toggle are tight
• Connect winch hook through lift hole.
• Remove outboard (farthest from base) ½” bolt through cheek plates.
• Let out a few inches of winch cable
• Use pry bar to push base of 2nd section out until cable is tight.
• Let cable out and rest mast terminal end on sawhorse.