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PAGE 53 OF 164

PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM

OPERATING INSTRUCTIONS

TP-5580101-A

FEBRUARY 2022

4.5.1

Mast Installation Specifications

Table 4-7 Mast Installation Specifications

P/N*

MODEL

inch

Heavy Duty Locking

906043

7-30

2134

68.3

1735

55.3

1405

906045

7-42

2337

68.4

1737

49.6

1260

906051

10-60

122

3099

101.1

2568

82.4

2093

Super Heavy Duty Locking

909959

9-50

110

2794

89.6

2276

66.5

1689

909426

10.3-60

125

3175

104.6

2657

81.5

2070

Ultra Heavy Duty

710991201

8-39

(2.4-12 m)

2413

74 11/16

1897

48 11/16

1237

710905700

11.3-59

(3.4-18 m)

135

13/16

3450

108 ¾

2762

13/16

2332

710992000

9.8-65.6

(3-20 m)

118

2997

91 ¾

2330

66 ⅜

1686

710908000

14.3-80

(4.4-24 m)

172

4363

153.74

3901

127.76

3245

* Part Numbers for clear anodized finish. Additional finishes are available.

Summary of Contents for 10-60 HDL

Page 1: ...rt Company 401 Collins Blvd Orrville OH 44667 USA Phone 1 330 684 4000 E Mail info willburt com Website www willburt com TP 5580101 A February 2022 2022 The Will Burt Company Original Instructions Aut...

Page 2: ......

Page 3: ...THE MANUFACTURE OR SALE OF ITS PRODUCTS NO EMPLOYEE DISTRIBUTOR OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THIS WARRANTY IN ANY WAY OR GRANT ANY OTHER WARRANTY ON BEHALF OF WILL BURT Claims for defects...

Page 4: ...acket Options 35 3 3 4 3 Shelf Bracket 40 3 3 5 Payload Platform and Stub Adaptor Options Sold Separately 40 3 3 6 Guy Line Options Sold Separately 43 3 3 7 Additional Accessory Options Sold Separatel...

Page 5: ...03 5 7 2 7 Complete Installation of the Internal Mounting Kit 104 5 8 Install the Control and Pneumatic Systems 108 5 8 1 Control and Pneumatic Systems Installation Quick Summary 108 5 8 2 Control and...

Page 6: ...9 Troubleshooting 147 10 References 149 10 1 Extended Glossary of Terms 149 10 1 1 General Terms and Abbreviations 149 10 1 2 Mounting Position Terms 151 10 2 Drawings 151 10 3 System Wiring Diagram 1...

Page 7: ...oided could result in death or serious injury CAUTION indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury or equipment damage It is also used to aler...

Page 8: ...powered up Do not move vehicle until mast has been securely nested and isolated from power Power up and operate mast only if the vehicle is stationary and securely parked with the parking brake prope...

Page 9: ...at have been classified as hazardous as defined in Article 500 of the National Electric Code or equivalent national standards Do not use in the presence of flammable gases or liquids such as paint gas...

Page 10: ...efore applying power and operating mast be certain there is sufficient clearance above and to all sides of the expected location of the fully extended mast and payload Keep all persons clear of mast a...

Page 11: ...system If mounted internally in a vehicle or structure direct the draining water to a suitable location Cover locking masts when not in use to limit water ingress Non locking masts stored outdoors sho...

Page 12: ...ovement does not occur as this could lead to injury Safety Instruction Lightning Lightning protection is not part of this system A proper means of electrical grounding should be provided Failure to ob...

Page 13: ...s than specified by the manufacturer Pipes should be marked to avoid hazards from incorrect connection The exhaust should be fitted with a silencer and be directed away from personnel When routing pip...

Page 14: ...o partially deploy the mast use the hold down leash to tether the tubes to the mast payload platform Do not use the hold down leash cable to secure mast sections to the base tube during operation This...

Page 15: ...and decommissioning System tip over could result in death or serious injury This symbol indicates a general warning In this unit this symbol indicates a frozen water hazard Water must be permitted to...

Page 16: ...PAGE 14 OF 164 PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM OPERATING INSTRUCTIONS TP 5580101 A FEBRUARY 2022...

Page 17: ...580101 A FEBRUARY 2022 2 Specification Compliance 2 1 CE Declaration of Conformity Refer to the Product page at www willburt com for the latest Declaration of Conformity The Pneumatic Mast with Remote...

Page 18: ...PAGE 16 OF 164 PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM OPERATING INSTRUCTIONS TP 5580101 A FEBRUARY 2022...

Page 19: ...before performing any procedure outlined in this manual The views depicted in this manual are provided for clarification and are subject to change without notice Views are not to scale The Pneumatic M...

Page 20: ...ply input supply voltage or operate the mast system when the vehicle is in motion The mast shall remain in the powered down nested position during vehicle motion Contact The Will Burt Company with any...

Page 21: ...components of the mast system include Telescoping Mast Hardware Bag P N 902853 or 5032501 Drain Kit P N 902982 Magnetic Warning Kit Hold Down Leash Mast Top Cover P N 902989 or 5063501 Identification...

Page 22: ...mast is depressurized Has collars fitted to the top end of each tube except the top tube which is fitted with a top tube stop Has two rectangular keys along each tube except the base tube These keys...

Page 23: ...luminate an LED when the mast is pressurized 30 psi and when the locks are unlocked Above the base tube Unlock mechanically when contact is made between the latch lever and the guide plate from the lo...

Page 24: ...tra Heavy Duty masts ship standard with hardware bag P N 5032501 The contents of the hardware bag Figure 3 4 are used to Secure the base plate to the mast 4 Screw 16 x 1 Flathead Stainless Steel P N 2...

Page 25: ...lb Red Brass NPT P N 900522 Used for Heavy Duty Masts 1 Threaded Hex Bushing Inch NPT Brass P N 912293 Used for Super Heavy Duty Masts For Hardware Bag 5032501 1 x inch reducing bushing 125 lb red br...

Page 26: ...odically drained particularly after the mast has been exposed to rain in order to prevent damage The drain kit Figure 3 5 includes 1 Washer Inch ID x OD x 1 16 Thick P N 900555 1 Lock Nut Inch Brass P...

Page 27: ...switch assembly against the base tube Magnet which is cylindrical and covered with a wax like coating Switch assembly which is attached to a small rectangular casing Labels which are gray Flasher whic...

Page 28: ...ity 1 Clamp 1 2 Magnet Assembly 1 3 Switch Label 1 4 Notice Label 1 5 Warning Label 1 6 Flasher 1 7 Light 2 8 Relay 1 9 Carton Not Shown 1 Table 3 3 Magnetic Warning Kit Description Quantity 1 Notice...

Page 29: ...tension of the mast 3 3 1 5 Mast Top Cover P N 902989 or 5063501 The mast top cover Figure 3 7 comes standard with locking masts The mast top cover is A large bag with draw strings Pulled over the col...

Page 30: ...The label kit is used to identify potential hazards within the mast system Some of the labels come installed on the mast system Additional labels are provided with the operator s manual this document...

Page 31: ...r 5572604 30 ft Power Cable Assembly P N 5567501 30 ft Sensor Cable P N 5567601 30 ft 0 375 OD x 0 245 ID Air Hose P N 108768 30 ft 0 250 OD x 0 125 ID Air Hose P N 5558001 The control box Figure 3 9...

Page 32: ...PAGE 30 OF 164 PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM OPERATING INSTRUCTIONS TP 5580101 A FEBRUARY 2022 Figure 3 9 Control Box Not to Scale...

Page 33: ...switch on base tube air cylinders to the control box Figure 3 12 Sensor Cable Not to Scale 3 3 3 Pneumatic System Options Sold Separately The pneumatic system refers to a means of safely pressurizing...

Page 34: ...Rotatable Base Plates Rotatable Hardware Kits Non Rotatable Base Plate The non rotatable base plate is used to stabilize the mast and to provide a means of securing the mast to a mounting surface The...

Page 35: ...t to a mounting surface the rotatable base plate Figure 3 14 and turning handles Figure 3 15 enable the mast to be rotated The exact configuration of the rotatable base plate may vary In general the r...

Page 36: ...have four holes spaced 90 apart in the tube head where a customer supplied rod can be inserted to provide leverage to turn the mast Figure 3 16 Bottom of Rotatable Super Heavy Duty Mast P N 909426 Sh...

Page 37: ...brackets away from the support structure 2 Support bracket clamps which close around the base tube and are bolted together to hold the mast against the mounting structure Bearing strips attached insid...

Page 38: ...a Heavy Duty support brackets contain shims and a washer plate which are used to allow for slight variation between mast tubes Figure 3 19 Ultra Heavy Duty External Support Bracket P N 4989201 Shown F...

Page 39: ...s Customer supplied inch M6 bolts lock washers and hex nuts shall be used as fasteners Bolt length depends on the specific application and is to be determined by the customer Internal mounting kits fo...

Page 40: ...r Heavy Duty Masts P N 910784 Shown Internal Mounting Kits for rotating Super Heavy Duty masts have the same components as the Internal Mounting Kits for non rotating masts but remove the O Ring and a...

Page 41: ...ing 1 O Ring 8 16x3 50 Bolts 16 x1 0 Flat Washers 8 16 Nyloc Nuts Note Included hardware is sized for a inch 6 35 mm roof If a thicker roof is present the customer must supply appropriate hardware Fig...

Page 42: ...the shelf bracket becomes the mounting surface for the base plate Figure 3 24 Shelf Bracket P N 4434101 Shown For more information on the shelf bracket options see www willburt com 3 3 5 Payload Platf...

Page 43: ...th through holes to allow for quick installation of customer payloads and without through holes to allow the customer to drill through holes to match payload specific mounting hole patterns Payload Pl...

Page 44: ...Burt Company for additional information on available payload platforms Table 3 4 Hold Down Platforms Description Part Number Hold Down Platform for 3 00 Top Tube 5545101 xxxx Hold Down Platform for 3...

Page 45: ...ler model masts Use of a guy line kit may be required for customer specific payloads or to achieve specific survival wind speeds Consult The Will Burt Company s engineering team Note Not all masts hav...

Page 46: ...01 Weatherize pneumatic masts in extremely harsh environmental conditions D TEC Safety System Provide overhead power line and above the mast illumination PositionIt Remotely pan and tilt a payload Cab...

Page 47: ...sts with Remote Locking Systems See Mast Wind Load Capacity Section 10 4 for wind load specifications for various masts If the mast model is not listed contact The Will Burt Company If payload extends...

Page 48: ...8 2 36 10 3 07 Approximate Mast Weight lb kg 125 57 235 107 330 150 Payload Capacity lb kg 200 90 7 200 90 7 300 136 1 Number of Sections 6 9 8 Tube Diameter Range in mm 6 75 3 171 76 9 3 229 76 9 3...

Page 49: ...vided are for reference only and are not intended for vehicle design purposes 3 Specifications may be subject to change without notice 4 Payload Capacity assumes 12 inch maximum offset payload from ma...

Page 50: ...ed Height ft m 9 15 2 79 10 4 3 18 Approximate Mast Weight lb kg 500 227 500 227 Payload Capacity lb kg 530 240 4 530 240 4 Number of Sections 8 8 Tube Diameter Range in mm 11 25 5 25 286 134 11 25 5...

Page 51: ...are for reference only and are not intended for vehicle design purposes 3 Specifications may be subject to change without notice 4 Payload Capacity assumes 12 inch maximum offset payload from mast ce...

Page 52: ...3 59 9 8 65 6 13 70 14 3 80 Extended Height ft m 50 13 15 28 39 3 12 59 18 65 6 20 70 21 3 79 9 24 35 Nested Height ft m 8 74 2 67 7 9 2 4 11 3 3 4 9 8 3 13 4 14 48 4 4 Approximate Mast Weight lb kg 6...

Page 53: ...are not intended for vehicle design purposes 3 Specifications may be subject to change without notice 4 Payload Capacity assumes 12 inch maximum offset payload from mast centerline Mast deployment an...

Page 54: ...Section 4 5 4 Support Bracket Assembly Installation Specifications Section 4 5 5 Internal Mounting Kit Installation Specifications Section 4 5 6 Shelf Bracket Assembly Installation Specifications Sec...

Page 55: ...337 68 4 1737 49 6 1260 906051 10 60 122 3099 101 1 2568 82 4 2093 Super Heavy Duty Locking 909959 9 50 110 2794 89 6 2276 66 5 1689 909426 10 3 60 125 3175 104 6 2657 81 5 2070 Ultra Heavy Duty 71099...

Page 56: ...PAGE 54 OF 164 PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM OPERATING INSTRUCTIONS TP 5580101 A FEBRUARY 2022 Figure 4 1 Mast Installation Specifications Not to Scale Drain Hole A B C...

Page 57: ...PAGE 55 OF 164 PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM OPERATING INSTRUCTIONS TP 5580101 A FEBRUARY 2022 Figure 4 2 Ultra Heavy Duty Mast Installation Specification P N 710991590 Shown...

Page 58: ...PAGE 56 OF 164 PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM OPERATING INSTRUCTIONS TP 5580101 A FEBRUARY 2022 Figure 4 3 Ultra Heavy Duty Mast Installation Specification P N 710908091 Shown...

Page 59: ...tion Specifications P N 902491 Shown Table 4 8 Non Rotating Base Plate Installation Specifications A B C D BCD P N Base Tube inch mm inch mm inch mm inch mm inch mm 902363 6 6 171 5 146 7 16 11 0 5 12...

Page 60: ...a Heavy Duty Non Rotating Base Plate Installation Specifications P N 4995301 Shown Non rotating base plate P N 4995301 has a clear anodize finish Additional finishes are available 12 in 305 mm 13 5 in...

Page 61: ...b kg 902364 6 9 248 8 7 222 0 38 9 7 0 4 10 12 4 5 6 902344 9 12 305 11 279 0 38 9 7 0 4 10 20 5 9 3 909983 11 13 330 11 279 0 50 12 7 0 56 14 12 1 5 5 Part Numbers for the base plate only and does no...

Page 62: ...Specifications Table 4 10 Turning Handle Assembly Installation Specifications A P N Base Tube inch mm 914480 6 16 406 906813 9 18 457 Part Number is for the turning handles only and does not include...

Page 63: ...acket Assembly Heavy Duty Installation Specifications P N 4443601 Shown Table 4 11 Support Bracket Installation Specifications OD A B Est Weight P N Base Tube inch mm inch mm inch mm lb kg 4443605 6 7...

Page 64: ...Heavy Duty Installation Specifications P N 909984 Shown Note Part Number 909984 is for a black powder coat finish Additional finishes are available 8 inches 203 mm 16 34 inches 415 mm 19 68 inches 500...

Page 65: ...eavy Duty Installation Specifications P N 4894901 Shown Note Part Number 4894901 is for a black powder coat finish Additional finishes are available 5 38 inches 137 mm 12 75 inches 324 mm 15 inches 38...

Page 66: ...ernal Support Bracket Assembly Ultra Heavy Duty Installation Specifications P N 4989201 Shown External support bracket P N 4989201 has a black powder coat finish Additional finishes are available 6 5...

Page 67: ...l Mounting Kit Roof Flange and Roof Ring Installation Specifications A C D BCD P N Base Tube inch mm B inch mm inch mm inch mm 905734 6 9 248 8 1 9 48 3 0 25 6 4 8 222 905733 9 12 305 8 1 9 48 3 0 25...

Page 68: ...Hardware Stack Up BCD A B number of 5 16 inch 8 mm holes equally spaced on BCD Roof Flange Only Base Tube 5 6 9 C D Space for Roof Hardware Stack Up A BCD B number of 5 16 inch 8 mm holes equally spac...

Page 69: ...dimensions for the Ultra Heavy Duty s internal mounting kit P N 54761xx Figure 4 13 Internal Mounting Kit Ultra Heavy Duty Installation Specifications P N 5476101 Shown 15 25 in 387 mm BCD 16 5 in 41...

Page 70: ...late inch mm inch mm inch mm inch mm inch mm 4434101 6 NR 4 3 109 0 44 11 3 75 95 5 26 134 7 87 200 4454001 R 6 0 152 0 56 14 5 25 133 5 98 152 9 0 229 4454001 9 NR 6 0 152 0 56 14 5 25 133 5 98 152 9...

Page 71: ...plate mounting hole pattern shown Figure 4 14 has been simplified Actual shelf brackets may have multiple sets of base plate mounting holes in order to accommodate multiple mast types Use the set of b...

Page 72: ...A FEBRUARY 2022 4 5 8 Control Box Installation Specifications The control box Weighs approximately 11 8 lb Has the dimensions shown in Figure 4 15 Figure 4 15 Control Box Installation Specifications P...

Page 73: ...he entire installation procedure Only a properly trained and qualified certified electrician performs electric installations and maintenance The mounting structure is level and has sufficient room and...

Page 74: ...ction 5 3 16 AWG Stranded Wire For the Magnetic Warning Kit Hex Wrenches Equipment Compressed Air Supply Hoist Sling Strap Expendables Pipe Thread Sealant or PTFE Tape Rags Clean and Dry Silicone Seal...

Page 75: ...and 11 25 inch base tubes require eight sets of hardware Internal mounting kits for 5 0 inch base tubes require six sets of hardware The bolts should be sized to length to allow for the thickness of t...

Page 76: ...ructure any spacers and all mounting hardware e g flat washers lock washers and nuts HHRC Holder To the Mounting Structure 2 8 M4 Flathead Screws Customer The bolts should be sized to length to allow...

Page 77: ...47 use inch hardware Part Numbers for clear anodized finish only 4 Flat Washers Customer 4 Lock Washers Customer 4 Nyloc Nuts Customer Non Rotatable Base Plate To the Mast 4 16x1 Flathead Screws P N 2...

Page 78: ...ess of the control box feet support structure any spacers and all mounting hardware e g flat washers lock washers and nuts HHRC Holder To the Mounting Structure 2 8 M4 Flathead Screws Customer The bol...

Page 79: ...Bolts P N 5431 TheWill Burt Company Included with internal mounting kit Included hardware is sized for a inch 6 35 mm roof If a thicker roof is present the customer must supply appropriate hardware 1...

Page 80: ...re 5 2 Shipping Crate HHRC Holder To the Mounting Structure 2 8 M4 Flathead Screws Customer The bolts should be sized to length to allow for the thickness of the HHRC support structure any spacers and...

Page 81: ...itioning the mast Hoist and slowly lift the mast until just free of the mast saddles Lower the mast and adjust the sling as necessary to balance the mast Hoist the mast free from the crate and careful...

Page 82: ...pressure to the air cylinders when lifting Lifting with weight on the air cylinders could damage the mast Figure 5 3 Hoist the Mast The Will Burt Company recommends keeping the shipping crate for tran...

Page 83: ...ast Installation External Mount This section describes installation of an externally mounted mast Figure 5 4 The external mounting instructions assume the use of an external support bracket For inform...

Page 84: ...1 Select a Suitable Mounting Location Section 5 6 2 1 2 Install the Shelf Bracket Optional Section 5 6 2 2 3 Attach the Base Plate to the Mast Section 5 6 2 3 4 Position the Mast Section 5 6 2 4 5 Ins...

Page 85: ...system is to be attached Reinforce as necessary Note High forces to the mounting structure may result depending on the payload wind load and if the mast is guyed or not The mounting surface to which t...

Page 86: ...ture 3 If necessary use washers or short spacers made of inch 6 35 mm pipe to level out any irregularities that exist in the support structure 4 Secure the shelf bracket to the support structure using...

Page 87: ...the countersunk holes are facing away from the mast 3 Heavy Duty and Super Heavy Duty Secure the base plate to the mast with the 4 16x1 flathead screws P N 2772 from the hardware bag Apply Loctite 24...

Page 88: ...ve a clear view of them while operating the masts 5 6 2 5 Install the External Support Bracket This section describes installation of the external support bracket for the Heavy Duty and Super Heavy Du...

Page 89: ...olts Figure 5 5 External Support Bracket P N 4894901 Installation 3 If necessary use the external support bracket as a template to drill holes in the desired support structure Ensure the mast system i...

Page 90: ...forces generated over the support bracket clamp flange To secure the mast in the external support bracket 1 Determine the desired location for the external support bracket The external support bracke...

Page 91: ...adjusted properly It is necessary to check the mast in two places 90 apart when leveling b Secure the right side of the support bracket clamp to the support bracket weldment with the hardware from th...

Page 92: ...e left support bracket clamp flange and push it towards the support bracket weldment Figure 5 8 Looking at the gap between the support bracket weldment and the support bracket clamp estimate how many...

Page 93: ...between the support bracket clamp and the washer plate The shims should be inserted so that the bottom of the shims hangs down below the bottom of the support bracket clamp Figure 5 9 Shims Inserted...

Page 94: ...ly loosening the hardware To adjust the location of a shim i Push up on the shim from the bottom until the bottom of the grooves in the shim touch the bolts Figure 5 11 Figure 5 11 Push Up Shim ii Pul...

Page 95: ...ize and grade 5 6 2 6 Secure the Base Plate to the Mounting Surface To secure the base plate to the mounting surface 1 If necessary use the base plate as a template to drill holes through the mounting...

Page 96: ...dles 2 Secure the band clamp halves together around the mast with 2 20x1 50 Hex HD Bolts P N 2000 2 20 Nyloc Nuts P N 1930 Tighten the turning handle bolts just enough to allow the turning handles to...

Page 97: ...t Installation Internal Mount This section describes installation of an internally mounted mast Figure 5 13 These internal mounting instructions assume the use of an internal mounting kit Section 3 3...

Page 98: ...nting Location Section 5 7 2 1 2 Begin Installation of the Internal Mounting Kit Section 5 7 2 2 3 Lower Mast through the Internal Mounting Kit Section 5 7 2 3 4 Attach the Base Plate to the Mast Sect...

Page 99: ...the forces required by the bolts Check the strength and rigidity of the mounting structure e g vehicle body where the mast system is to be attached Reinforce as necessary The area underneath the mast...

Page 100: ...erly align with the hole in the roof when the roof liner or ceiling panels are reinstalled 3 Center the ceiling plate from the internal mounting kit Figure 5 14 Figure 5 15 or Figure 5 16 over the hol...

Page 101: ...of one gasket 6 For Heavy Duty Masts a Line up the holes of the roof the gasket with silicone sealant applied and the roof flange Figure 5 14 Ensure the gasket is between the roof and roof flange b R...

Page 102: ...appropriate for its size and grade Note that the weather bonnet and o ring are not yet installed Figure 5 14 e Clean off any silicone sealant that may have squeezed out the hole cut for the mast f Sli...

Page 103: ...asket Figure 5 14 and Figure 5 16 against the inside of the roof This gasket does not need sealant It will be held in place by the ceiling plate Fit the ceiling plate in place and ensure all holes ali...

Page 104: ...hold down leashes to lugs on opposite sides of the base tube collar and connect the hold down leashes to the hoist Depending on the environment and equipment available other methods may work better U...

Page 105: ...vided with the operator s manual and should be installed where the operator will have a clear view of them while operating the mast 5 7 2 6 Secure the Base Plate to the Mounting Surface To secure the...

Page 106: ...installation instructions for your configuration Non Rotatable Heavy Duty Masts To complete installation slide the weather bonnet with the o ring in the notch down the mast and over the roof flange I...

Page 107: ...ng hardware Torque all hardware as appropriate for its size and grade Figure 5 19 Fasten Assembly Together Once the mast is installed see Section 5 8 for information on installing the pneumatic system...

Page 108: ...he flashing halves to rest on the internal mount 2 Raise the flashing halves inch 3 mm 3 Ensure there will be no obstructions with the sealant or roof line when the mast rotates and mark the top of th...

Page 109: ...ogether around the mast with 2 20x1 50 Hex HD Bolts P N 2000 2 20 Nyloc Nuts P N 1930 Tighten the turning handle bolts just enough to allow the turning handles to turn the mast without slipping Overti...

Page 110: ...r supply should be regulated not to exceed the maximum operating pressure of 35 psi 241 kPa for the mast at any time 5 8 1 Control and Pneumatic Systems Installation Quick Summary The following is a q...

Page 111: ...pneumatic system 2 Locate the air inlet port to be used When installing the pneumatic system only use one air inlet port To use the air inlet port with the plastic plug a Remove the plastic plug This...

Page 112: ...nage Figure 5 20 Pneumatic System Installation 4 Attach the safety valve to the brass cross Apply PTFE Tape to all threaded joints 5 Attach the drain cock to the brass cross Apply PTFE Tape to all thr...

Page 113: ...ficient amount of clean dry air at the air intake at all times The air supply should not be operated without the air filters in place Drain and Relief Fittings A drain cock and safety valve must be in...

Page 114: ...aust the Mast Optional Sensor Cable to the Air Cylinders Power Cables from the Power Supply HHRC Optional Installation If desired the control box feet can be rotated 90 before installation To reorient...

Page 115: ...ntrol box If routing the air hose through a structure The Will Burt Company recommends the use of a grommet or equivalent to protect the air hose Note If the system shipped with a 12 mm hose P N 58259...

Page 116: ...th 5 Connect the air hose P N 108768 to the drain and relief fittings The air hose will use a close nipple part of the hardware bag Section 3 3 1 1 to connect to the brass cross Apply PTFE Tape to all...

Page 117: ...ommends the use of a grommet or equivalent to protect the sensor cable It may be possible to use the same grommet used to route the inch air hose P N 5558001 12 Secure the sensor cable to the reed swi...

Page 118: ...ct the HHRC to the Control Box Optional Installation If desired the mast can be operated using an HHRC instead of directly through the control box To connect the HHRC plug the HHRC into the REMOTE plu...

Page 119: ...the HHRC holder 1 Use the holder as a guide to drill two holes on the mounting structure 2 Secure the holder in place with two 8 M4 flathead screws Note To use the HHRC to control the mast it will be...

Page 120: ...er be certain to observe any local codes or regulations See Section 10 3 for the system wiring diagram To connect customer power to the control box 1 Plug 20 gauge power cable P N 5567501 into the POW...

Page 121: ...f extension The drain kit is designed to route water from inside the mast to outside of the vehicle or enclosure The drain kit is intended to protect the interior of a vehicle or other water sensitive...

Page 122: ...ptor to contact the moving intermediate tube Figure 5 29 Ultra Heavy Duty Drain Kit Installation 3 Drill a hole in the vehicle or enclosure to route the water outside 4 Fasten the bulkhead fitting Fig...

Page 123: ...attery terminal should be connected to the ignition switch so the lights will only illuminate when the mast is extended and the ignition is on The operator should always visually confirm that the mast...

Page 124: ...bly that is clamped to the mast When energized the relay produces an electromagnetic field that could affect the performance of the reed switch in the magnetic switch assembly if the relay is mounted...

Page 125: ...d wire customer supplied to connect the flasher lights and relay to the wires exiting the magnetic switch assembly Figure 5 33 and Figure 5 24 Figure 5 33 Wire the Magnetic Switch Assembly Kit Custome...

Page 126: ...net assembly is located the lights will stop flashing The vertical sensing range should be about 1 to 3 inches 2 5 to 7 5 cm 13 Tighten the band to clamp the switch assembly within the sensing range e...

Page 127: ...lation Follow all precautions while testing the mast system installation The mast may operate better with a payload on it For procedures on installing a test payload see Section 5 13 To test the insta...

Page 128: ...1 Ensure the air supply is disconnected and the drain cock is opened while installing the payload to eliminate the possibility of inadvertent mast extension 2 If necessary remove the mast top cover N...

Page 129: ...hinder mast system function are removed The mast system and payload are properly installed When using a vehicle the vehicle is not moving and is on level terrain Masts extended up to 60 feet 18 2 m c...

Page 130: ...ppropriate operation procedures for your mast system Operation of the mast system is described as follows Prepare the Mast System for Operation Section 6 3 1 Extend the Mast Section 6 3 2 Stow the Mas...

Page 131: ...yment and retraction wind speeds are payload dependent however the mast can typically be deployed and retracted in winds speeds up to 25 mph 40 km h assuming 12 inch maximum offset payload from mast c...

Page 132: ...Note that masts with 6 75 inch base tubes only have and require one hold down leash For partial extension applications 1 Install the hold down platform on top of the mast 2 Secure a hold down leash t...

Page 133: ...e in line with the lug on the hold down platform During mast extension the sections between the connection points will be prevented from fully extending and settle once air is exhausted Figure 6 1 Hol...

Page 134: ...tion 5 13 4 If guy lines are used attach the guy lines to the payload platform or appropriate collar lugs 5 Prior to extending the mast The Will Burt Company recommends laying out any guy lines so the...

Page 135: ...isconnect the air hose at the base of the mast c Connect a hand pump to the base of the mast d Use the hand pump to pressurize the mast e Skip to Step 12 9 Select HOLD The HOLD EXHAUST switch is a mai...

Page 136: ...straight and is not bending too far towards one side Figure 6 3 Adjust the appropriate guy line as necessary to keep the mast plumb vertically Check one day after initial install Check periodically af...

Page 137: ...MOTE switch on the control box If operating manually typically an emergency operation when power is not available a Ensure all electrical circuits are de energized and properly tagged to prevent injur...

Page 138: ...drain cock when exhausting the mast to drain off any accumulated water 8 Once the mast is fully retracted select the middle position with the UP DOWN switch 9 If guy lines are used remove the guy lin...

Page 139: ...d should be removed and the mast top cover fitted over the mast and secured in place Note If transporting the mast in the horizontal position the mast sections must be secured to prevent them from acc...

Page 140: ...2 As necessary prepare the mast system for transportation Section 7 1 3 As necessary uninstall the mast system from the mounting structure Section 5 4 Secure the mast system in the shipping crate a Ca...

Page 141: ...Section 1 while performing these procedures If the system does not perform as required see Section 9 Disconnect power to any devices mounted to the mast and pneumatic systems with lock out tag out pr...

Page 142: ...lity Knife Wrenches Rubber Mallet Saw Plumb Bob Equipment Compressed Air Supply Hoist Sling Strap Ratchet Straps Saw Horses or Similar Supports Expendables Acetone Alcohol or other solvent Pipe Thread...

Page 143: ...pections Frequency Inspection Action As Needed In salt water or sandy environments clean the mast every 3 months Inspect to ensure the mast system is kept clean and free from foreign material Dirt gre...

Page 144: ...process Signs cleaning and lubrication might be needed can be A noticeable gritty film on the exterior surfaces of the tubes Erratic extension or retraction of the mast Noisy operation of the mast Sti...

Page 145: ...icant P N 900600 into the weep hole of the exposed tube The weep holes are located between 1 and 3 feet 30 and 91 cm below the collar on each tube except the top tube Do not lubricate the exterior of...

Page 146: ...N 4725801 Will Burt Non Toxic Pneumatic Mast Antifreeze P N 473801 can also be purchased by the gallon The Pneumatic Mast Antifreeze Kit includes 2 Flush Caution Labels P N 4770001 1 Gallon Will Burt...

Page 147: ...justed 4 Slide the reed switch to the left then slowly move it towards the right until the light illuminates Stop moving the reed switch as soon as it illuminates 5 Secure the reed switch into place T...

Page 148: ...PAGE 146 OF 164 PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM OPERATING INSTRUCTIONS TP 5580101 A FEBRUARY 2022...

Page 149: ...oz Will Burt Antifreeze P N 4735801 where the top of the collar and intermediate tube meet There is ice buildup on the exterior of the mast Follow the Instructions for Clearing Ice Buildup on the Exte...

Page 150: ...l bumper Depressurize mast Remove the collar and lift the tube to check the internal bumper If necessary order replacement Collar inserts tight Depressurize and disassemble mast File or lightly grind...

Page 151: ...collars where tubes make contact with each other Butt Plate refers to the bottommost plate on each intermediate tube CFM stands for Cubic Feet per Minute Collar Inserts refer to machined pieces of pla...

Page 152: ...r equipment being raised by the mast to an operational height PSI stands for pound force per square inch PSIG stands for pound force per square inch gauge PSIG refers to a gauge that has been calibrat...

Page 153: ...surface to which the base plate is secured When installing inside a vehicle this will likely be the floor Roof the horizontal surface to which the internal mounting kit is secured This term applies to...

Page 154: ...PAGE 152 OF 164 PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM OPERATING INSTRUCTIONS TP 5580101 A FEBRUARY 2022...

Page 155: ...the assumptions at the bottom of each graph If your payload application exceeds any of these assumption values contact The Will Burt Company s Engineering for the wind load capacity for your specific...

Page 156: ...m guying radius Kevlar Guy Lines 4 Arrowhead Anchors Survival Wind Speed Assumptions Payload Weight 200 lb 90 7 kg Payload Coefficient of Drag 1 3 Payload centroid is on mast axis and 12 304 8 mm abov...

Page 157: ...m guying radius 3 16 steel guy lines 4 6 Screw Anchors Survival Wind Speed Assumptions Payload Weight 200 lb 90 7 kg Payload Coefficient of Drag 1 3 Payload centroid is on mast axis and 12 304 8 mm ab...

Page 158: ...29 m Guying Radius 3 16 steel guy lines 4 6 Screw Anchors Survival Wind Speed Assumptions Payload Weight 300 lb 136 1 kg Payload Coefficient of Drag 1 3 Payload centroid is on mast axis and 12 304 8...

Page 159: ...15 24 m Guying Radius 3 16 steel guy lines 4 6 Screw Anchors Survival Wind Speed Assumptions Payload Weight 530 lb 240 4 kg Payload Coefficient of Drag 1 3 Payload centroid is on mast axis and 12 304...

Page 160: ...0 ft 21 34 m Guying Radius 3 16 steel guy lines 4 6 Screw Anchors Survival Wind Speed Assumptions Payload Weight 530 lb 240 4 kg Payload Coefficient of Drag 1 3 Payload centroid is on mast axis and 12...

Page 161: ...15 24 m Guying Radius 3 16 steel guy lines 4 6 Screw Anchors Survival Wind Speed Assumptions Payload Weight 980 lb 444 5 kg Payload Coefficient of Drag 1 3 Payload centroid is on mast axis and 12 304...

Page 162: ...ft 18 83 m Guying Radius 3 16 steel guy lines 4 6 Screw Anchors Survival Wind Speed Assumptions Payload Weight 1 200 lb 544 3 kg Payload Coefficient of Drag 1 3 Payload centroid is on mast axis and 1...

Page 163: ...ft 17 8 m Guying Radius 1 4 steel guy lines 4 6 Screw Anchors Survival Wind Speed Assumptions Payload Weight 530 lb 240 4 kg Payload Coefficient of Drag 1 3 Payload centroid is on mast axis and 12 304...

Page 164: ...STL Guying Kit WB P N 5365901 2 level 4 way guying to platform and 8 25 collar 70 ft 21 34 m Guying Radius 1 4 steel guy lines 4 6 Screw Anchors Survival Wind Speed Assumptions Payload Weight 1 200 lb...

Page 165: ...A FEBRUARY 2022 11 Document History Table 11 1 Document History Document Revision Date Change Details Changes Backward Compatible with Previous Manual Version TP 5580101 00 1 14 2019 Initial Release T...

Page 166: ...PAGE 164 OF 164 PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM OPERATING INSTRUCTIONS TP 5580101 A FEBRUARY 2022...

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