Home Satellite TV Antenna (160-2508) Dish Assembly Faxback Doc. # 31426 Preparing The Mount For Dish Assembly 1. Loosen the mount's sleeve bolts and turn the mount so that the round hub plate points true south (toward the true-south marker you used during your site survey). Then, retighten the sleeve bolts. 2. Disconnect the upper end of the turnbuckle from the mount so that the turnbuckle hangs down by the post. WARNING: Have someone hold the feedboom during the next two steps. The feedboom and mount can drop sharply when you disconnect the turnbuckle and loosen the inclination adjustment bolts. 3. Loosen, but do not remove, the "inclination adjustment" bolts and tilt up the mount as near as possible to vertical. NOTE: Hold the inclination bolts on one side of the mount while you loosen the nuts on the other side. 4. Retighten the inclination bolts to hold the mount in the vertical position while you assemble the dish. Attaching The Dish Arms For this procedure, you need the 12 dish arms (System Box #1) and the 1/4-inch nuts and bolts (System Box #2). Using two of the 1/4-inch nuts and bolts for each arm, attach all 12 arms to the large square surface of the mount. NOTES: Insert the bolts from the top of the mount and attach the nuts underneath. Tighten these nuts/bolts only "finger tight." Do not tighten them securely until we tell you to (after the dish is completely assembled). ASSEMBLING AND MOUNTING THE FIRST PAIR OF DISH PANELS The 12 perforated dish panels you need for this procedure are in System Box #4 - the hardware is in System Box #2. 1. Remove two panels from the box and inspect the edges to be sure they are straight and smooth. If they are not, use the side of a 2 x 4 board to smooth the edges. 2. Place the two panels side-by-side and face down with narrower ends resting on a support that is about 17 inches high. You can use System Box #2 as this support. 3. Insert the tongue that sticks out at the wider end of the left panel behind the rim of the right panel. 4. Align the holes in the matching sides of the panels and use flanged nuts and bolts to connect the panels at the indicated three points (the three dimpled holes). NOTE: Tighten these nuts/bolts only finger tight. Do not securely tighten them until we tell you to. 5. Carefully lift the pair of panels above the dish arms and place the panels so that the common side of the two panels is at the right of an arm. NOTE: Be sure the outer side of each panel is also at the right of an arm. 6. Slide the narrower ends of the panels under the mount's round hub plate. 7. Using flanged bolts and nuts, attach the narrower ends of the panels to the round hub. (Insert the bolts from the top and attach the nuts underneath.) NOTE: Tighten these nuts and bolts only finger tight. Do not securely tighten them until we tell you to. 8. Using two sets of 1/2-inch nuts, washers, and bolts, attach the two larger holes on the common side of the two panels to the arm's larger holes. NOTES: Place the washer on the bolt first. Then, insert the bolt through the panels (from the right) and through the arm. Finally, attach the nut. Tighten these nuts and bolts only finger tight. Do not securely tighten them until we tell you to. 9. Use a flanged nut and bolt to connect the panels to the arm at the remaining smaller hole. ASSEMBLING AND MOUNTING THE REMAINING DISH PANELS Assemble and mount the remaining dish panels in pairs, as previously instructed. However, each time you mount a new pair of panels, you must also connect the new pair to the last pair you mounted. Begin by connecting the new pair of panels and the previously mounted pair of panels at the three dimpled holes. Then, attach the newly joined panels to the right side of the adjacent arm as previously instructed. When, you mount the last pair of panels, you must attach both sides of the last pair to previously mounted panels and to the arms, in addition to attaching the common side of the last two panels to an arm. Note: As before, tighten all nuts and bolts only finger tight. Do not securely tighten them until we tell you to. (If you're wondering, we're going to tell you to tighten them next. TIGHTENING THE DISH ASSEMBLY'S NUTS AND BOLTS Now that all 12 dish panels are loosely assembled, it's time to pull together the dish into the proper parabolic shape. Be sure to follow these instructions exactly so your dish has the proper shape to provide the best possible pictures and sound for your TV. 1. Securely tighten all 12 nuts/bolts at the position marked 1 in the above drawing. These are the bolts that join the narrowest parts of the panels. Work around the entire dish until you have tightened each bolt at this position. 2. Securely tighten all 12 nuts/bolts at the position marked 2. Work around the entire dish until you have tightened each bolt at this position. 3. Securely tighten all 12 nuts/bolts at the position marked 3. Work around the entire dish until you have tightened each bolt at this position. At this point, all the panels should be pulled together with no gaps at the seams. 4. Securely tighten all 24 nuts/bolts at the position marked 4. These are the nuts/bolts that secure the arms to the mount. Work around the entire dish until you have tightened each bolt at this position. 5. Securely tighten all 12 nuts/bolts at the position marked 5. Work around the entire dish until you have tightened each bolt at this position. 6. Securely tighten all 12 nuts/bolts at the position marked 6. Work around the entire dish until you have tightened each bolt at this position. 7. Securely tighten all 12 nuts/bolts at the position marked 7. Work around the entire dish until you have tightened each bolt at this position. 8. At the outer edge of the dish, use two flanged nuts/bolts to connect each panel's tongue to the adjacent panel. Insert the bolts from the outside and securely tighten the nuts from underneath. 9. Using the hand crank (located in System Box #2) move the dish to the east or west until the inclinometer reads about 10 to 15 degrees. DO NOT ALLOW THE DISH TO TOUCH THE GROUND. NOTE: If you move the dish too far to the side, the worm gear and large rack gear lose contact and you cannot move the dish. To fix this problem, lift up on the dish while someone else turns the hand crank. 10. With the dish still to one side, tighten the 12 nuts/bolts (marked 8) that attach the narrower ends of the panels to the round hub. ATTACHING THE DISH TRIM The push-on rubber trim in System Box #4 adds a finished look to the dish. Attach it as follows: 1. Using the hand crank, return to the dish to the center position (so that the pointer on the worm gear cover is aligned with the mark on the rack gear plate). 2. Begin pushing the rubber trim onto the edge of the dish, stretching the trim slightly as you go. NOTES: It is easier to start attaching the trim at the center of a panel. To reach the upper parts of the dish, you might have to use the hand crank to adjust the dish to its limits on each side. DO NOT ALLOW THE DISH TO TOUGH THE GROUND. If you move the dish too far to the side, the worm gear and large rack gear lose contact and you cannot move the dish. To fix this problem, lift up on the dish while someone else turns the hand crank. 3. When you have attached the trim all the way around the dish, cut off any excess with wire cutters. The two ends should butt together. (CS 3/19/96)