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Will Burt EXPEDITION RANGER MAST Operator's Manual

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R
ANGER
The Will-Burt Company
401 Collins Blvd
Orrville, OH 44667, U.S.A.
™ M
O
AST
PERATOR
Phone: +1 330 684 4000
E-Mail:
info@willburt.com
Website:
www.willburt.com
Authorized Representative:
Will-Burt Germany GmbH & Co. KG
Fischergasse 25
D-91344 Waischenfeld, Germany
'
M
S
ANUAL
TP-4549901-G, February 2024
© 2024 The Will-Burt Company
Original Instructions

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Summary of Contents for Will Burt EXPEDITION RANGER MAST

  • Page 1 ™ M ’ ANGER PERATOR ANUAL The Will-Burt Company Phone: +1 330 684 4000 TP-4549901-G, February 2024 401 Collins Blvd E-Mail: info@willburt.com © 2024 The Will-Burt Company Orrville, OH 44667, U.S.A. Website: www.willburt.com Original Instructions Authorized Representative: Will-Burt Germany GmbH & Co. KG Fischergasse 25 D-91344 Waischenfeld, Germany...
  • Page 3 ™ M ’ ANGER PERATOR ANUAL Expedition Series™ Ranger™ Mast Warranty Will-Burt warrants its Expedition Series™ Ranger™ Masts to be free from defects in material and workmanship for a period of two (2) years, with such time period running from the date of shipment by Will-Burt. Will-Burt shall not be responsible for any damage resulting to or caused by its products by reason of failure to properly install, maintain or store the product;...
  • Page 4 ™ M ’ ANGER PERATOR ANUAL Document History Document Dates Remarks TP-4549901-00 10/4/2010 Initial Release TP-4549901-A 2/15/11 Added reference to replacement kits (Section 4.2) TP-4549901-B 4/6/2011 Change to a caution and to step 39. TP-4549901-C 4/26/2011 Added Staging Guy Lines. TP-4549901-D 5/8/2012 Added cable weight note and height to...

  • Page 5: Table Of Contents

    ™ M ’ ANGER PERATOR ANUAL Table of Contents Section 1 Safety Summary .....................vii 1.1 Signal Word Definitions ........................vii 1.2 Safety Instructions ..........................vii 1.3 Symbols ............................. xiv Section 2 Introduction ......................2-1 2.1 Intended Use ............................ 2-2 2.2 Definitions ............................2-2 2.3 Mast Component Descriptions ......................
  • Page 6 ™ M ’ ANGER PERATOR ANUAL Table of Figures Figure 2-1 Telescoping Mast Parts (Not to Scale) ..................2-5 Figure 2-2 Tripod, Base Plate Assembly and Tripod Step ................. 2-5 Figure 2-3 Some Guy Bag Components (Not to Scale) ................2-6 Figure 2-4 Guy Collars ..........................
  • Page 7 ™ M ’ ANGER PERATOR ANUAL Figure 4-35 Lower to Ground ........................4-16 Figure 4-36 Stake the Base Plate ......................4-17 Figure 4-37 Tighten Guy Lines......................... 4-17 Figure 4-38 Lock the Upper Clamp and Unlock the Lower Clamp ............4-18 Figure 4-39 Insert Top Tube from the Top of the Tripod .................
  • Page 8 ™ M ’ ANGER PERATOR ANUAL Figure 4-79 Tighten Guy Lines......................... 4-31 Figure 4-80 Use the Hitch Pin to Attach the Step to the Tripod ............... 4-31 Figure 4-81 Unlock Winch Spool ......................4-32 Figure 4-82 Turn the Winch Handle Counterclockwise to Raise the Payload ......... 4-32 Figure 7-1 Periodic Inspections........................

  • Page 9: Section 1 Safety Summary

    ™ M ’ ANGER PERATOR ANUAL Section 1 Safety Summary This section describes safety instructions for the Ranger™ Mast that personnel must understand and apply throughout all product activities such as transportation, handling, installation, deployment, disassembly, maintenance, storage, disposal and troubleshooting. Read and understand this entire document, and contact The Will-Burt Company with any questions, before performing any procedure outlined in this document.
  • Page 10 ™ M ’ ANGER PERATOR ANUAL Mast Tip Over Hazard! Mast tip over could result in death or serious injury. Before operation, be certain mounting structure is capable of resisting forces generated from all loading and environmental conditions, including, but not limited to, mast size and weight, payload and cable size and weight, payload sail area, wind speed, guy line arrangement, support bracket or roof line location, and base plate assembly.
  • Page 11 ™ M ’ ANGER PERATOR ANUAL Read Operating Instructions! Read and observe the operating instructions. Non-observance of the instructions, operation which is not in accordance with use as prescribed in the instructions, wrong installation or incorrect handling can seriously affect the safety of operators and machinery.
  • Page 12 ™ M ’ ANGER PERATOR ANUAL Crush Hazard - Mast Failure! Do not stand directly beneath mast or its payload. Be certain the payload is properly installed and secured. Entanglement Hazard! Tangled cables can cause equipment damage. Ensure payload cables, Nycoil®, trip lines, guy lines or other cables are not tangled and are free to pay out as mast is deployed.
  • Page 13 ™ M ’ ANGER PERATOR ANUAL Manual Retraction! For powered masts, make sure all power sources have been disconnected from the system prior to manually lowering mast to avoid unexpected start-up motion and/or damage to mast. Mast Lifting/Handling! Use extreme caution while lifting mast System and when mast System is suspended to avoid injury and equipment damage.
  • Page 14 ™ M ’ ANGER PERATOR ANUAL Frozen Water Hazard! Water freezing inside mast or air fittings may render mast inoperable and cause major equipment damage such as tube deformation. Ensure water is free to exit at the base of mast. Open drain cock when mast is not in operation. The drain cock shall be installed at the lowest position in the pneumatic system.
  • Page 15 ™ M ’ ANGER PERATOR ANUAL Mast Extension Hazard - Obstruction! Do not deploy the mast if power lines are less than 80 ft. (24.4 m) from the center of the deployment site. Mast Tip Over Hazard! Do not attempt to deploy or retrieve this mast when winds exceed 32 km/h / 20 mph.

  • Page 16: Symbols

    ™ M ’ ANGER PERATOR ANUAL 1.3 Symbols The following are symbols that are used with the system and their meaning. Contact The Will- Burt Company with any questions before performing any procedure outlined in this manual. This symbol indicates an electrocution hazard or hazardous voltage hazard. There is DC voltage present inside the mast and control box.

  • Page 17: Section 2 Introduction

    ™ M ’ ANGER PERATOR ANUAL Section 2 Introduction Thank you for selecting The Will-Burt Company for your critical payload elevation needs. These operating instructions describe transporting, handling, installing, disassembling, maintaining and storing procedures for the Ranger™ Mast. These procedures assume the use of standard mast systems.

  • Page 18: Intended Use

    ™ M ’ ANGER PERATOR ANUAL 2.1 Intended Use The Ranger™ Mast is intended for use by professionals in the fire/rescue/first responder/ security/towing/broadcast/cellular industries to provide elevated and directional emergency scene lighting and surveillance or communication capabilities. It is not intended for use by nonprofessionals.

  • Page 19: Mast Component Descriptions

    ™ M ’ ANGER PERATOR ANUAL 2.3 Mast Component Descriptions This section describes major components of a mast system assuming the use of standard catalog mast systems. Characteristics of components customized to meet customer-specific needs may vary. If necessary, contact The Will-Burt Company for additional details. The exact configuration of the mast may vary.

  • Page 20: Table 2-2 Mast Components With Ez Raze™ Option

    ™ M ’ ANGER PERATOR ANUAL Table 2-2 Mast Components with EZ Raze™ Option Accessory Bag Description Guy Stakes Guy Ropes Guy Bag Lift Puck Hammer Section tubes for 16’ Section tubes for 20’ Section tubes for 24’ Section tubes for 28’ Section tubes for 32’...

  • Page 21: Figure 2-1 Telescoping Mast Parts (Not To Scale)

    ™ M ’ ANGER PERATOR ANUAL Telescoping Mast (arrives disassembled): The telescoping mast is the structure used to raise the payload to an operational level. The mast consists of a base tube, intermediate tubes, and a top tube. If using the EZ Raze™ option, the mast consists of a winch/base tube, intermediate tubes, and a tip tube.

  • Page 22: Figure 2-3 Some Guy Bag Components (Not To Scale)

    ™ M ’ ANGER PERATOR ANUAL Guy Bag: Contains the guy line stakes (8), guy ropes (4), guy stub (1), lift puck (1), hammer (1). Figure 2-3 Some Guy Bag Components (Not to Scale) Guy Collars: Used to attach the guy lines to the top of the mast. Figure 2-4 Guy Collars Wheeled Bag: The wheeled bag is a carrier for the mast, tripod, guy bag, long bag, tube bag, short bag, and other components.

  • Page 23: Figure 2-5 Ez Raze™ Option Non-Deployed

    ™ M ’ ANGER PERATOR ANUAL EZ Raze™ (Optional): The EZ Raze™ option is a high-capacity winch, pulley and payload carriage system. Once the mast is installed, this optional system permits a single person to raise multiple antennas and equipment weighing up to 40 lb. / 18.1 kg (when evenly distributed) in a safe and controlled manner.

  • Page 24: Figure 2-7 Some Ez Raze™ Option Components

    ™ M ’ ANGER PERATOR ANUAL Figure 2-7 Some EZ Raze™ Option Components Payload Adaptors (Optional): Payload adaptors attach to the top of the mast and are used to secure and support the payload during operation. Payload adaptors come in varying sizes and configurations.

  • Page 25: Section 3 Technical Data

    ™ M ’ ANGER PERATOR ANUAL Section 3 Technical Data The model numbers listed in this section are for catalog masts with a black anodized finish only. Masts with other heights, capacities, and finishes are available. For more information on additional mast sizes, capabilities, and finishes, see www.willburt.com.

  • Page 26: Table 3-1 Ranger™ Mast Specifications

    ™ M ’ ANGER PERATOR ANUAL Table 3-1 Ranger™ Mast Specifications Ranger™ Mast Specifications Optional EZ Raze™ System Rated Model EZ Weight w/ Payload Model Weight Height Payload Raze EZ Raze Capacity Capacity * 56 lb. 12 ft. 40 lb. 714071200 26 kg 3.7 m...

  • Page 27: Section 4 Installation

    ™ M ’ ANGER PERATOR ANUAL Section 4 Installation This section provides instructions for installing the mast system and provides the general procedures that must be followed to ensure a successful installation. Be sure to read and understand the entire installation procedure and the Safety Summary (Section 1) before beginning installation.

  • Page 28: Recommended Installation Tools

    ™ M ’ ANGER PERATOR ANUAL 4.3 Recommended Installation Tools Table 4-1 lists recommended tools and materials for installation. Table 4-1 Tools and Materials Required for Installation Tools and Materials Safety Glasses Safety Shoes Nitrile or Vinyl Gloves Hearing Protection Hard Hat or Helmet Safety Gloves / Work Gloves Level (Optional)

  • Page 29: Figure 4-2 Open The Guy Bag

    ™ M ’ ANGER PERATOR ANUAL 7. Open the guy bag. Figure 4-2 Open the guy bag 8. Open the short bag. Short Bag with EZ Raze™ Short Bag Option Figure 4-3 Open the short bag 9. Open the tube bag. Figure 4-4 Open the tube bag The Will-Burt Company recommends keeping the shipping container for transporting the mast, for example if shipping the mast back to the factory for refurbishment.

  • Page 30: Set Up The Tripod

    ™ M ’ ANGER PERATOR ANUAL 4.5 Set Up the Tripod Set up the tripod as follows: 1. There are five clamps on the tripod. Three clamps are on the tripod legs and two clamps are in the center of the tripod. To unlock a clamp, push the lever towards the open position away from the locking tab.

  • Page 31: Figure 4-9 Stand Up Tripod

    ™ M ’ ANGER PERATOR ANUAL 11. Lift the tripod and unlock the upper clamp. This unlocks the tripod. Figure 4-9 Stand Up Tripod Figure 4-10 Unlock 12. Open the tripod by pushing down on the center collar, keeping fingers away from the pinch points.

  • Page 32: Deploy The Mast

    ™ M ’ ANGER PERATOR ANUAL Partially Raise the Tripod Legs: 13. Partially raise the tripod leg to ensure that the tripod is at a comfortable working height for attaching any accessories (including the carrier if using the EZ Raze option) and the payload in the later steps.

  • Page 33: Manual Deployment

    ™ M ’ ANGER PERATOR ANUAL 4.6.1 Manual Deployment To deploy the mast manually: 4.6.1.1 Install the Top of the Mast Insert the Top Tube 1. Stand in the operator’s quadrant. This area is next to the winch holder and in front of one of the levels.

  • Page 34: Figure 4-15 Lower Top Tube Until There Is One Hand Width From The Bottom Of The Tube And Lock The Lower Clamp

    ™ M ’ ANGER PERATOR ANUAL 3. Lower the top tube until there is one hand width from the bottom of the tube and lock the lower clamp. Lock Hand Width Figure 4-15 Lower Top Tube Until There is One Hand Width from the Bottom of the Tube and Lock the Lower Clamp 4.

  • Page 35: Figure 4-17 Lock The Guy Collar Clamps

    ™ M ’ ANGER PERATOR ANUAL 7. Lock the guy collar clamps. If accessories are not going to be installed, go to Step 17. Lock Lock Figure 4-17 Lock the Guy Collar Clamps Install Accessory Arm Collar 8. Slide the arm collar onto the top tube. Accessory Slide Arm Collar On Arm Collar...

  • Page 36: Figure 4-20 Pin Arm In Place

    ™ M ’ ANGER PERATOR ANUAL 10. Pick an angle for the arm, line up the arm hole with the arm collar hole, and pin the arm in place by pressing the pin button. Pick an Angle Line up Arm Figure 4-20 Pin Arm in Place 11.

  • Page 37: Figure 4-22 Place Guy Collar Onto Top Tube

    ™ M ’ ANGER PERATOR ANUAL Install the Accessory Guy Collar 14. Unlock the top and bottom clamps of the accessory guy collar and place the guy collar onto the top of the top tube. If a second guy collar and lines are wanted for additional support, place both collars onto the top tube.

  • Page 38: Complete Tripod Installation

    ™ M ’ ANGER PERATOR ANUAL 4.6.1.2 Complete Tripod Installation Fully Raise the Tripod Legs 19. As a team, unlock the leg clamps, step on the leg bases, and lift the tripod until the nested legs drop and are fully extended. Lock the leg clamps. Lift Up Lock Unlock...

  • Page 39: Raise The Mast

    ™ M ’ ANGER PERATOR ANUAL Stake the Tripod Safety Instruction! Be careful of buried cables and utilities when staking the mast. 23. Remove the stakes and hammer from the guy bag. Stake the base plates of each leg by driving a stake(s) in the two stake points aligned with the shaft of the hitch pin using the hammer.

  • Page 40: Figure 4-28 Attach Base Plate To Base Tube

    ™ M ’ ANGER PERATOR ANUAL Set Aside the Base Tube 24. So that the base tube does not get confused with the other mast tubes, it is best to place the plate on the base tube now. The base tube has the rounded plate adapter at the bottom.

  • Page 41: Figure 4-30 Drive Each Stake Into The Ground At A 45° Angle

    ™ M ’ ANGER PERATOR ANUAL 27. Drive each stake, with the hammer provided, into the ground at a 45° angle away from the tripod. Ensure that the stake is driven into the ground up to the eyelet of the stake and that the eyelet is facing the tripod.

  • Page 42: Figure 4-32 Place A Tube Into The Bottom

    ™ M ’ ANGER PERATOR ANUAL Breech Load Tubes 30. Place a tube (but not the base tube) into the bottom with the white button up and in the notch in the other tube. Push Tube Up Button in Notch Line Up Figure 4-32 Place a Tube into the Bottom 31.

  • Page 43: Figure 4-36 Stake The Base Plate

    ™ M ’ ANGER PERATOR ANUAL Stake the Base Plate 33. Stake the base plate of the base tube by driving the stake, with the hammer provided, at a point aligned with the shaft of the hitch pin. The stake should be driven at an angle toward the center of the mast.

  • Page 44: Deployment With Ez Raze™ Option

    ™ M ’ ANGER PERATOR ANUAL 4.6.2 Deployment with EZ Raze™ Option Note: If installing the mast at maximum load (40 lb. / 18.1 kg total, 20 lb. / 9 kg per arm), three people are required. This allows enough people to raise the payload and to steady the payload arms as the mast is being guyed.

  • Page 45: Figure 4-40 Lower Top Tube Until There Is One Hand Width From The Bottom Of The Tube And Lock The

    ™ M ’ ANGER PERATOR ANUAL 3. Lower the top tube until there is one hand width from the bottom of the tube and lock the lower clamp. See Section 7.5 to check that the clamps are sufficiently tight. Lock Hand Width Figure 4-40 Lower Top Tube until There is One Hand Width from the Bottom of the Tube and Lock the Lower Clamp...

  • Page 46: Figure 4-42 Tip Tube

    ™ M ’ ANGER PERATOR ANUAL Install Tip Tube 5. Retrieve the tip tube from the tube bag. The tip tube is the tube has an integrated pulley and guy collar. Insert the tip tube from the top of the tripod with the white button in the notch of the top tube.

  • Page 47: Figure 4-46 Side Bracket

    ™ M ’ ANGER PERATOR ANUAL Install the Carriage Arms 7. Remove the two side brackets from the small bag. There are two long pins and two short pins on each bracket. Put the brackets on the inside of the carriage and secure with the two long pins from the back of the bracket so the pin loops will not snag on the cable that is installed later.

  • Page 48: Figure 4-52 Cup Holder

    ™ M ’ ANGER PERATOR ANUAL 10. If a cup holder is required, on the end of the extension arm, connect the cup holder to the carriage with one front pin. Ensure that the top of the cup holder is open (bottom is closed).

  • Page 49: Figure 4-54 Connect Cable To The Carriage

    ™ M ’ ANGER PERATOR ANUAL Connect the Carriage 12. Take more slack from the winch cable to allow for feeding the cable through the tip tube. 13. Connect the cable to the carriage by pushing the snap hook on the winch cable through the hole in the tripod collar.

  • Page 50: Complete Tripod Installation

    ™ M ’ ANGER PERATOR ANUAL Connect to Guy Collar 15. Remove the four guy line spools from the guy bag. Connect the single-line, hook ends from the bottom, to the four larger, guy plate holes at 90° angles. Figure 4-57 Guy Lines Figure 4-58 Hook to Guy Plate Figure 4-59 Single Line to Collar 16.

  • Page 51: Figure 4-61 Adjust Legs As Needed And Consult Bubble Level To Ensure Tripod Is Level

    ™ M ’ ANGER PERATOR ANUAL Level the Tripod 39. Check the front level. If the tripod is not level, unlock one of the adjacent leg clamps and lower one of the legs. Relock the leg clamp. Leveled Tripod Levels Figure 4-61 Adjust Legs as Needed and Consult Bubble Level to Ensure Tripod is Level 40.

  • Page 52: Raise The Mast

    ™ M ’ ANGER PERATOR ANUAL 4.6.2.3 Raise the Mast Set Aside the Winch Tube 17. So that the winch tube does not get confused with the other mast tubes, it is best to place the plate on the winch tube now. The winch tube has the rounded plate adapter at the bottom.

  • Page 53: Figure 4-65 Drive Each Stake Into The Ground At A 45° Angle

    ™ M ’ ANGER PERATOR ANUAL 45. Drive each stake into the ground at a 45° angle away from the tripod. Ensure that the stake is driven into the ground up to the eyelet of the stake and that the eyelet is facing the tripod.

  • Page 54: Figure 4-68 Prepare Guy Lines

    ™ M ’ ANGER PERATOR ANUAL Stage the Guy Lines 20. For masts 44 ft / 13.4 m to 60 ft / 18.3 m tall, prepare the guy lines for a tube to be breech loaded by loosening a maximum of 5 ft / 1.5 m of guy line from each tensioner. SINGLE LINE SIDE DOUBLE...

  • Page 55: Figure 4-71 Line Up

    ™ M ’ ANGER PERATOR ANUAL Breech Load Tubes 22. Place a tube into the bottom with white button up and aligned with the notch in the other tube. Figure 4-71 Line Up Figure 4-72 Push Tube Up Figure 4-73 Button in Notch 23.

  • Page 56: Figure 4-76 Lock J-Hook

    ™ M ’ ANGER PERATOR ANUAL Install Winch as Base Tube 24. Once the desired height is reached, remove the winch from the winch holder. Insert the winch tube into the bottom tube with the white button up and in the notch of the other tube.

  • Page 57: Raise The Payload

    ™ M ’ ANGER PERATOR ANUAL Tighten the Guy Lines Note: When tightening the guy lines, do not over-tighten the guy lines. Tighten the lines to the point that the mast is stabilized, sway is minimized, and the mast is stable during winds. Over- tightening the guy wires causes an additional or unlevel load on the mast and reduces the overall load capacity of the mast.

  • Page 58: Figure 4-81 Unlock Winch Spool

    ™ M ’ ANGER PERATOR ANUAL Unlock the Winch Spool Safety Instruction! There is no brake on the EZ Raze™ Option. Ensure that the safety latch is properly functioning to ensure that when the payload is raised, it cannot fall freely. If the winch cable ever breaks, quickly get away from the tripod because the payload will drop freely.

  • Page 59: Section 5 Disassembly

    ™ M ’ ANGER PERATOR ANUAL Section 5 Disassembly This section provides instructions for disassembling the mast system and provides the general procedures that must be followed to ensure a successful disassembly. Be sure to read and understand the entire installation procedure and the Safety Summary (Section 1) before beginning disassembly.

  • Page 60: Disassemble The Mast With Ez Raze™ Option

    ™ M ’ ANGER PERATOR ANUAL 5.2 Disassemble the Mast with EZ Raze™ Option To disassemble the mast with the EZ Raze™ option, proceed as follows: 1. Unlock the winch, lower payload, and remove the devices from the mast. 2. Slightly loosen the guy ropes to relieve any tension or binding that may exist between the mast tubes.

  • Page 61: Section 6 Transportation

    ™ M ’ ANGER PERATOR ANUAL Section 6 Transportation Before transporting the mast system, the mast system needs to be secured. The exact procedures for transportation will vary based on the mast system configuration. The process described in this manual represents a possible method of transporting the mast. Depending on the environment and equipment available, other methods may work better.
  • Page 62 ™ M ’ ANGER PERATOR ANUAL TP-4549901-G February 2024...

  • Page 63: Section 7 Maintenance

    ™ M ’ ANGER PERATOR ANUAL Section 7 Maintenance This section describes maintenance procedures required to keep the mast system operational. Use care to understand and follow all precautions while performing these procedures. If the system does not perform as required, contact The Will-Burt Company. Disconnect power to any devices mounted to the mast with lock-out tagout procedures as appropriate before performing mast maintenance.

  • Page 64: Spare Parts

    ™ M ’ ANGER PERATOR ANUAL 7.3 Spare Parts To order spare or replacement parts, always refer to the mast model number and serial number. This information is included in the operator’s manual supplied with each mast. The mast serial number is stamped at the bottom of the base tube.

  • Page 65: Checking And Adjusting Clamp Tightness

    ™ M ’ ANGER PERATOR ANUAL Monthly Inspect the tripod for uneven wear. Replace unevenly worn-out component or tripod. Contact The Will-Burt Company. As every use Inspect all clamps for tightness Tighten clamps if lose. Follow when locked. Section 7.5 for correct procedure.

  • Page 66: Long-Term Storage

    ™ M ’ ANGER PERATOR ANUAL 4. To ensure that the clamp is tight, by hand, turn the nut in the “+” direction shown on the nut. The clamp is tight when the nut cannot be tightened further by hand. Do not use tools to tighten.

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