Hilomast Telescopic Masts OPERATING INSTRUCTIONS PNEUMATIC MASTS & ACCESSORIES MKII RANGE Issue 3 South Midlands Communications Issue 3 S.M.House, School Close, Chandlers Ford Ind. Est. Eastleigh, Hampshire, England. SO53 4BY Tel: (+44)0 23 8024 6200 Fax: (+44)0 23 8024 6206 Email: sales@smc-comms.
CONTENTS Page Masts General Information………………………………………………………………………….3 Head Load and Guy Radii…………………………………………………………………..4 Safety………………………………………………………………………………………….5 Operating Instructions……………………………………………………………………….6 Maintenance and Repair…………………………………………………………………….8 Dismantling the Mast………………………………………………………………………...9 PTFE and Piston Replacement…………………………………………………………...12 Nylon Key Replacement…………………………………………………………………...13 Magnetic Switch…………………………………………………………………………….
IMPORTANT INFORMATION Before using the mast carefully read the operating instructions herein. DO NOT use the mast unless it is fully extended. DO NOT drive vehicle with the mast extended (ensure isolating magnetic switch is installed) DO NOT attempt to rotate the mast unless fitted with a rotating system. (NRB/229R) Beware of overhead cables. DO NOT exceed 30p.s.i maximum mast pressure (Ensure safety relief – valve is installed) Only use Superfluid and Kilfrost as recommended by SMC/Hilomast LLC.
MASTS GENERAL INFORMATION Telescopic masts are considered to be temporary structures and should not be expected to withstand all weather conditions indefinitely. The table on page 4 specifies the wind speed that each mast will withstand. For wind speeds in excess of those stated it is essential for the life of the mast and the safety of the operating personnel, to retract the mast. Pneumatic masts operate at low pressures, normally between 1kg/cm and1.75kg/cm (14 and 25p.s.i.
LOADINGS – WIND SPEEDS – GUY RADII FOR HILOMASTS Mast NH5 NH7 NH9 NK6 NK9 NK11 NK16 NL8 NL9 NL10 NL12 NL16 NL22 NX8 NX10 NX14 NX18 NX25 NX30 NY7 NY10 NY12 NY14 NY18 NY21 Vertical headload Maximum wind speed unguyed Maximum wind speed with top guys Top guy reference number kgs 18 15 Kph 180 135 Kph 180 160 NUG/1 NUG/1 27 22 18 20 32 35 27 25 23 14 50 50 35 30 20 14 120 100 90 70 50 40 164 114 96 65 140 130 110 95 78 56 155 120 92 70 52 44 150 126 90 80 83 67 164 137 125 112 140 130 120 110 102 92
SAFETY At times be aware of overhead obstructions especially power lines (we recommend use of the Sigalarm, high voltage power line proximity warning system. Please call for further details). Note that in the interest of safety and reducing mast wear, the Sigalarm and air supply system must be arranged so as to dump air from the mast in the event of triggering the Sigalarm or any similar device.
OPERATING INSTRUCTIONS NH/NK/NL/NX Series Hilomasts (1) Close the mast exhaust valve by turning in a clockwise direction until finger tight. (2) All locking collars, with the exception of the top one, should be securely tightened by turning the thumbscrew in a clockwise direction. The locking collars are situated immediately above the guide collars at the top of each section. (3) Connect the air supply to the mast (see maximum air pressures in safety section).
Note: The locking collars are adjusted during assembly. However, if any locking collar is not clamping the section securely when fully tightened, if should be released and the socket screw or thumbscrews adjusted until the clamping action is sufficient. As a guide the gap on each side of the locking collar should be equal when that locking collar has been tightened. If one side is closed too much, the mast section may not release properly.
MAINTENANCE AND REPAIR Mast maintenance Inspect and lubricate mast sections at four-week intervals or every 200 operations, whichever occurs first. If the mast has been used in a dusty environment resulting in a build up of contaminants and old lubricant on the surface of the tubes, then this must be removed. This can be done by wiping each section with an oil soaked cloth. SMC build the masts using Hilomast lubricant oil (SMC Part No. 000055500).
To correct this, stand the mast at a vertical position and inject some Hilomast lubricating oil, allowing it to drain down inside the tubes. Then pull out each section in turn and thrust downward (with the air release valve closed). This forces the lip of the seal back to its original position against the wall of the tube. DISMANTLING THE MAST If possible, lay the mast horizontally and pull out the sections to full extension.
(1) Loosen the lower pan head screw on the stainless straps (if fitted with locking collars). Remove any sealing compound from screw holes to reveal screws. Loosen the socket set screws “A” from the collar, except the one securing the Nylatron key “B”. Note there are two screws in each hole. The outer screws are shorter and used to lock main screws. (2) Holding the collar onto its tube, pull out all the remaining sections (keeping them together as one unit) until the tube stop “C” is against the collar.
(5) Clean the tubes with a cloth and examine the tube surfaces. If there are dents or sufficient surface damage to affect the seals, then the section will not function correctly and should be replaced. (6) Remove the faulty seal; in most cases the damage is imperceptible. Having oiled or greased the new seal, fit into the piston groove using only the fingers, DO NOT USE METAL TOOLS. The PTFE slide ring “E” should be replaced at this stage if necessary (see separate instructions at 6a over page).
PTFE Slide Ring Replacement (6a) The Teflon rings should be examined for scuffing and wear. If replacement is necessary they should be fitted before the seals. A length of Teflon should be cut so that there is a small gap between the ends when it is wrapped around the piston groove. The piston should then be pushed into the receiving tube over its entire length of travel.
NYLON KEY REPLACEMENT Tools required: 3mm Allen key and screwdriver, a fine file may also be needed. (1) For this operation, dismantle as described on page 9 onwards, but only the mast collars need be removed, the tubes may be left in their nested position. Mark the base tube with a pencil so that the collar is assembled at the same place. (2) When the collars have been removed from the end of the tube, the green nylon key can be seen in its slot inside the main collar.
FITTING INSTUCTIONS Magnets (1) Grease O-ring on magnet housing. (2) Remove mast cap and insert the magnets in their housing into the top tube, O-ring first. The housing should be a tight fit but if too tight the O-ring should be trimmed with a sharp knife. (3) Push the unit down to the bottom of the tube with a rod and replace the cap. DO NOT hammer the rod to make sure that the unit is fully down, since this could disturb the piston on which the magnet housing is sitting.
MAST MOUNTINGS There are several mounting arrangements available for the installation of masts. They can be mounted either internally or externally to a vehicle or building. For erecting masts on open ground, base guy assemblies are available; they are the strongest for field mounting. For the NH, NK, NL and NX series, field stands have been designed specifically for the purposes, up to extended height of 18m.
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17 Mast A Dia B Dia NH5 89 38 NH7 89 38 NH9 89 38 NK6 102 50 NK9 102 50 NK11 102 38 NK16 102 50 50 127 NL8 50 127 NL9 50 127 NL10 50 127 NL12 50 127 NL16 50 127 NL22 50 152 NX8 50 152 NX10 50 152 NX14 50 152 NX18 50 152 NX25 50 152 NX30 NY7 238 150 NY10 238 150 NY12 238 150 NY14 238 150 NY18 238 150 NY21 238 150 Note: All dimensions in mm C 1161 1586 2043 1361 2026 2026 3736 1368 2033 2033 2033 3743 3743 1375 2040 2040 3850 3850 4040 1381 2026 2026 2026 3756 3756 D 252 252 252 277 277 340 277 403 407 470
NH NK NL NX FM VEHICLE BEARINGS (1) Select a suitable horizontal location for the roof bearing. Maximum and minimum installation dimensions are shown on pages 16 and 17. (2) Cut a hole in the outer skin equal to the internal diameter of the bearing tapping plate. (3) Clamp the outer flange centrally over the hole and using as a template, drill six holes 6.
NY VEHICLE BEARINGS As can be seen on the drawing below, this mounting is constructed differently from the other vehicle bearing kits before, and therefore needs slightly different fitting. There is no Teflon bearing, as the mast itself makes no contact with the roof bearing or tapping plate. Rotation is supported and guided by the mast-clamping shroud, which fits snugly over the bearing and is lubricated with grease through the nipple provided.
(1) Select a suitable horizontal location for the roof bearing. Maximum and minimum installation dimensions are shown on pages 16 and 17. Ensure that there are no obstructions for the base plate on the floor. (2) Cut a hole in the outer skin equal to the internal diameter of the tapping plate. (3) Clamp the bearing centrally over the hole and using it as a template, drill eight holes 6.5mm diameter.
BASE GUY ASSEMBLY This arrangement is generally the easiest method of erecting a mast on open ground. The kit is complete with the mast fittings, 3 guys, adjusters, base plate, ground stakes and pegs. Foundation bolts are also supplied for mounting on concrete foundations. The base plate incorporates a PTFE disk to permit rotation of mast and thumbscrew for locking in any azimuth direction. NH and NK kits have polyester guy ropes with adjusters.
TRIPOD STAND FOR NH MASTS Fitting instructions Before the tripod stand can be used, the top bearing must be fitted to the mast as follows: (1) The top locking collar must be securely clamped in position at 728mm from the base of the mast, as shown in the sketch. (2) Remove inlet valve so that the upper bearing can now slide up to meet the top locking collar, ensuring that the Teflon rings are in position.
Erecting Instructions (1) Place the stand in position on the ground and hinge the three legs out into horizontal position. (2) Place the mast into the lower bearing, ensuring that the PTFE disk is in position. (3) Remove the three struts from their stored position in the legs and fit them into the holes provided in the upper bearings. Push the three attached R clips into holes in struts. (4) Lower the adjustable feed just sufficiently to prevent the stand from rocking and to set the mast vertically.
FIELD STAND (N4L/102) FOR NK MASTS (1) Remove inlet valve with box spanner provided. (2) On the NK16 masts only, fit the first split collar approximately 2m up from the base of the mast. All other masts split collar should be fitted up against the base collar. (3) Slide mast through the stand collar. (4) Position the second split collar close under the stand collar, with sufficient clearance to allow it to rotate. (5) Refit inlet valve. DO NOT over tighten split collars.
COMPRESSORS GENERAL INFORMATION Hilomast compressors are air cooled, oil-less electric motors of the diaphragm type enclosed in a steel case. All models incorporate a pressure controlled switched to maintain the correct mast working pressure. They are quiet, maintenance free and assembled from components that have a proven reliability over many years. Compressor Type NC1 NC2 NC3 Approximate Rate of Mast Extension (Metres per Minute) NH Series NK Series NL Series NX Series NY Series 7.2 4.2 2.6 1.7 13.5 8.
TYPES OF COMPRESSORS Type NC1 Single unit Output: 17 litres/minute at 0.7kg/cm² Fuses: 12VDC = 10A, direct switching 24VDC = 5A, direct switching 240VAC = 1A, direct switching Manual exhaust valve. Type NC2 Twin unit Output: 34 litres/minute at 0.7kg/cm² Fuses: 12VDC = 20A, relay 24VDC = 10A, relay 240VAC = 3A, relay Solenoid exhaust valve. Type NC3 Single unit Output: 65 litres/minute at 0.7kg/cm² Consumption: 12VDC = 30A, relay 24VDC = 15A, relay 240VAC = 5A, relay Solenoid exhaust valve.
OPERATING INSTRUCTIONS NC1 Unit (1) Connect compressor to suitable power supply. (2) Connect airline to mast inlet valve. (3) Close exhaust valves at the base of the mast and compressor. (4) Switch on compressor to extend mast. (5) To lower mast, check compressor is switched off. Open either the exhaust valve at the base of the mast or that at the compressor. Opening both valves will allow a more rapid retraction but this can loosen or even damage antennas.
SETTING COMPRESSOR PRESSURE Setting Pressure Switch in the Compressor Set pressure switch only when pressure is applied to the system. A gauge must be fitted in order to check pressure. (1) Unscrew stop “A” with screwdriver. (2) The maximum switching pressure must be adjusted first, this is done by rotating knob “B” (clockwise raises the pressure). (3) To adjust minimum switching pressure, depress knob “B” and rotate as before. (4) Screw in stop “A”. (5) Enter cut-in and cutout valves on label.
USE OF THIRD PARTY COMPRESSORS When using third party compressors, ensure that the tank pressure is set to a maximum of 25 p.s.i. To ensure proper operation of the mast use SMC lubricant (Part No. 000055500) in the compressor system.
South Midlands Communications Issue 3 S.M.House, School Close, Chadlerds Ford Ind. Est. Eastleigh, Hampshire, England. SO53 4BY Tel: (+44)0 23 8024 6200 Fax: (+44)0 23 8024 6206 Email: sales@smc-comms.
