32/40' Expando Class Broadcast TV Trucks

Expand Your Imagination

TV Pro Gear engineers work closely with Gerling engineers to create the CAD layout drawings for the vehicles. In addition, the companies’ technical staffs work hand-in-hand to design and specify HVAC, electrical distribution, storage bays, consoles, racks, wall, floor and ceiling treatments. Of course, during this process, the client has final approval.

A “Rack Ready” vehicle is one that has all of the HVAC, electrical distribution, equipment consoles and equipment racks installed. Once the “rack ready” vehicle is completed at Gerling & Associates factory in Sunbury, Ohio, it is moved to one of TV Pro Gear’s System Integration facilities in New York or Los Angeles.

TV Pro Gear’s wiring technicians and engineers install all of the video, audio and transmission equipment. Only the highest quality wire and connectors are utilized. All wires get labels at both ends indicating source, destination and CAD reference number. Wires are dressed in and secured according to military and NASA specifications.



After the equipment is installed and wired, TV Pro Gear’s engineers perform System Configuration on such items as the switcher, router, intercom, replay and camera base stations. Next, TV Pro Gear Quality Assurance Engineers begin a lengthy testing procedure. Every input and output is repeatedly tested for continuity and signal quality. In addition, the QAE staff verifies that the “As Built” CAD drawings conform to reality. Finally, all equipment manuals are bound together along with a CD-ROM copy of the manuals.