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Will Burt 3.3-10 Operator's Manual

Pneumatic internally wired mast
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P
NEUMATIC
The Will-Burt Company
401 Collins Blvd
Orrville, OH 44667, U.S.A.
I
NTERNALLY
O
'
PERATOR
S
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
W
M
IRED
AST
M
ANUAL
TP-5443101-07, March 2025
© 2025 The Will-Burt Company
Original Instructions

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  • Page 1 NEUMATIC NTERNALLY IRED ’ PERATOR ANUAL The Will-Burt Company Phone: +1 330 684 4000 TP-5443101-07, March 2025 401 Collins Blvd E-Mail: info@willburt.com © 2025 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 ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL Pneumatic Internally Wired Mast Warranty Will-Burt warrants its Pneumatic Internally Wired 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: Document History

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL Document History Document Dates Remarks Revision 5 February 2015 TP-5443101-F January 24, 2017 Update to Section 1.4. Added Section 5. Updated formatting and minor changes throughout. TP-5443101-07 March 20, 2025 Updated Safety Summary. Added long-term storage and disposal info.

  • Page 5: Table Of Contents

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL Table of Contents Section 1 Safety Summary ...................... v 1.1 Signal Word Definition ......................... v 1.2 General Safety Precautions ........................ v 1.3 Specific Safety Precautions ....................... vi 1.4 Symbols .............................. ix Section 2 Introduction ......................2-1 2.1 Safety Precautions ...........................
  • Page 6 ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 5.3 Tools and Materials Recommended/Required ................. 5-2 5.4 Cleaning and Lubrication ......................... 5-2 5.5 Corrective Maintenance ........................5-4 5.5.1 Replacing Seals – Standard Duty ..................... 5-4 5.5.2 Replacing Collar Bearing Strips ....................5-7 5.5.3 Replacing Wear Rings ......................5-8 5.5.4 Replacing Internal Bumpers ......................

  • Page 7: Section 1 Safety Summary

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL Section 1 Safety Summary 1.1 Signal Word Definition Per the ANSI Z535.4 standard, the following signal words and definitions are used to indicate hazardous situations: DANGER indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

  • Page 8: Specific Safety Precautions

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL Safety Instruction - Trained Personnel Only! Death or serious injury could result if proper inspection, installation, operation and maintenance procedures are not observed. Installation, operation and maintenance to be performed by trained and authorized personnel only. Proper eye protection should be worn when servicing the mast.
  • Page 9 ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL Lifting Hazard! The mast is intended to lift a specific payload for lighting, surveillance or communication use only. Any other use without written consent is prohibited and could cause death or serious injury. Do not use mast to lift personnel.
  • Page 10 ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL Safety Instruction – Control Valve! Improper positioning and operation of Control Valve can result in moderate injury or equipment damage. Control valve must be mounted in a location such that the operator has full view of the mast, but does not make contact with the mast during operation. Use only a Hold-To-Run type control valve.

  • Page 11: Symbols

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 1.4 Symbols The following are symbols that may be 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 12 ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL TP-5443101-07 March 2025...

  • Page 13: Section 2 Introduction

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL Section 2 Introduction Thank you for selecting The Will-Burt Company for your critical payload elevation needs. These operating instructions describe handling, installing, operating, maintaining, and troubleshooting procedures for Pneumatic Internally Wired Masts. These procedures assume the use of standard mast systems.

  • Page 14: Definitions

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 2.3 Definitions The following terms are used throughout this manual: Mast: refers to the telescoping Pneumatic Internally Wired Mast • Mast System: refers to the entire Pneumatic Internally Wired Mast System (telescoping • mast, pneumatic system, controller, mounting hardware, and additional accessories) Payload: refers to the object or equipment being extended by the mast to an operational •...

  • Page 15: Hardware Bag

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 2.4.2 Hardware Bag The hardware bag is a plain cloth bag that includes screws for attaching mast mounting hardware to the mast. Because of the varied installation circumstances, the hardware required to attach the mast to a vehicle or structure must be supplied by the installer. The hardware bag also contains a safety valve, for protection from over pressurization, and brass fittings for water drainage and connecting the mast to the air supply line.

  • Page 16: Non-Rotatable Base Plate

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 2.4.6 Non-Rotatable Base Plate The non-rotatable (NR) base plate is a square aluminum plate used to stabilize the mast and to provide a means of securing the mast to a mounting structure. Countersunk holes in the NR base plate match threaded holes on the base mast section.

  • Page 17: Pneumatic System

    See Section 3.7.2 for additional information on a pneumatic system. 2.5 Reference Data Table 2-1 Standard Pneumatic Internally Wired Mast Part & Model Numbers Part Number Model Number 4825401 3.3-10 4825301 4.3-15 914431 5.4-17 914428 6-20...

  • Page 18: Figure 2-1 Standard Pneumatic Internally Wired Mast

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL Figure 2-1 Standard Pneumatic Internally Wired Mast Table 2-3 Entry Level Pneumatic Internally Wired Mast Part & Model Numbers Part Number Model Number 913835 4.7-10 914382 5.7-13 914383 6.7-16 Table 2-4 Reference Data – Entry Level Duty Pneumatic Internally Wired Mast Payload Extended Nested...

  • Page 19: Section 3 Installation

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL Section 3 Installation This section provides instructions for installing the Pneumatic Internally Wired Mast 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 before beginning installation.

  • Page 20: Unpacking And Handling

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 3.3 Unpacking and Handling Lifting Hazard! Manually lifting over 55 lb. (25 kg) is prohibited. In the UK, all lifting equipment must be thoroughly examined annually by a competent person according to the Lifting Operations and Lift Equipment Regulations 1998.

  • Page 21: Select A Suitable Mounting Location

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 3.4 Select a Suitable Mounting Location To select a suitable location for the mast in a vehicle consider the following: The mounting area must have sufficient room to mount the mast system. The roof area •...

  • Page 22: Internal Mounting Installation

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 3.5 Internal Mounting Installation If doing an external installation, go to Section 3.6. Mounting Structure Hazard! Mounting mast into a structure unable to resist the forces generated from customer- specific loading scenario could result in death or serious injury and could damage the mast.
  • Page 23 ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 2. Lower the mast through the internal mounting kit: a. Use a hoist to slowly lift the mast above the roof. b. Align the base of the mast with the center hole of the internal mounting kit. c.

  • Page 24: External Mounting Installation

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 3.6 External Mounting Installation If doing an internal installation, go to Section 3.5. Mounting Structure Hazard! Mounting mast into a structure unable to resist the forces generated from customer- specific loading scenario could result in death or serious injury and could damage the mast.

  • Page 25: Complete Mast System Installation

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 9. The weep hole drain kit, intended to protect the interior of a vehicle from damage due to water drainage, is not required for externally mounted masts. However, the elbow from the kit may be used to shield the weep hole from blow sand, dust and other debris. Refer to point 2 in Section 3.7.1 for instructions on installing the elbow.

  • Page 26: Weep Hole Drain Kit Installation

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 3.7.1 Weep Hole Drain Kit Installation The intended use of the weep hole drain kit is to route water, from inside the mast, outside a vehicle or enclosure. The weep holes on each mast section are located to facilitate the drainage of water during periods of extension.

  • Page 27: Pneumatic System Installation

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 3.7.2 Pneumatic System Installation Safety Instruction – Installation! At all times while using pipe and hose during installation, recognize that: 1. Pipe and hose should be routed, mounted and restrained to protect from damage; 2.
  • Page 28 ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 3. Air Supply – The compressor should have adequate ventilation to provide at least 10 SCFM of clean dry air at the air intake at all times. The recommended temperature range for inlet air is 32° F (0° C) to 95° F (35° C), so it works best when located in a heated compartment.

  • Page 29: Mast Extension Magnetic Warning Kit Installation

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 3.7.3 Mast Extension Magnetic Warning Kit Installation The vehicle should be equipped with a mast extension warning system. The mast extension magnetic warning kit includes items to install a system for warning against moving a vehicle while the telescoping mast is partially or completely extended.

  • Page 30: Figure 3-4 Magnetic Warning Kit

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 5. Attach the “NOTICE” label in a visible area on the mast base tube. NOTE: Do not mount the relay any closer than 6 inches (15 cm) from the switch assembly that is clamped to the mast. When energized, the relay produces an electromagnetic field that could affect the performance of the reed switch if the relay is mounted closer than inches (15 cm).

  • Page 31: Section 4 Operation

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL Section 4 Operation This section describes the operation of the mast system. Be sure to read and understand the entire operation procedure and Safety Summary before beginning operation. 4.1 Pre-Operation Check Before operating the mast system, ensure: •...
  • Page 32 ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL Pinch Point Hazard! Moving parts can crush and cut resulting in death or serious injury. Keep clear of moving parts while operating mast. Relocation Hazard! Relocating the mast during operation or after extension could result in death or serious injury.

  • Page 33: Operation Equipment

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 4.2 Operation Equipment Table 5-1 lists recommended equipment for operation. Table 4-1 Equipment Recommended for Operation Recommended Equipment Safety Glasses Work Gloves Nitrile or Vinyl Gloves Hearing Protection Hard Hat or Helmet Safety Shoes Depending on the national and local standards and codes of practice, and the environment, additional personal protective equipment may be necessary.

  • Page 34: Lowering The Mast

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 4.5 Lowering the Mast To lower the mast: 1. Before lowering the mast, rotate the mast or top load to allow for enough clearance in the stowed position. 2. Using the control valve, exhaust air from the mast. The mast will retract by its own weight and the weight of the payload.

  • Page 35: Section 5 Maintenance And Service

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL Section 5 Maintenance and Service This section describes maintenance and service 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, see Section 5.8 for troubleshooting. Disconnect power to any devices mounted to the mast and pneumatic systems with lock-out tagout procedures as appropriate before performing mast maintenance.

  • Page 36: Pre-Maintenance Check

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 5.2 Pre-Maintenance Check Before performing maintenance procedures, ensure: All operators read and understand the entire maintenance procedure and are properly • trained. The payload is removed prior to performing maintenance on the system. • The system is level and secure.
  • Page 37 ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL To clean and lubricate the mast: 1. Remove top load from the mast. This will allow the sections of a non-locking mast to more easily be extended from smallest to largest. See Step 3. On locking masts, the sequence of extension can be controlled by the locking collars.

  • Page 38: Corrective Maintenance

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 5.5 Corrective Maintenance This section describes corrective maintenance for the system. Depending on the mast system configuration and the conditions of the mast system, all corrective maintenance procedures may not be required. Follow the appropriate instructions for your mast system. Prior to performing corrective maintenance, remove the: •...

  • Page 39: Figure 5-1 Seal Replacement -- Standard Duty

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 9. As necessary, refer to the appropriate section(s) for replacement steps for the following: a. Replacement of Collar Bearing Strips (Section 5.5.2) b. Replacement of Wear Rings (Section 5.5.3) c. Replacement of Internal Bumpers (Section 5.5.4) d.
  • Page 40 ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 15. Ensure that the seal is in correctly. If not, the mast will eventually leak air. If the seal has not been inserted into the receiving tube correctly, remove the mast section and repeat the process.

  • Page 41: Replacing Collar Bearing Strips

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 5.5.2 Replacing Collar Bearing Strips This section describes replacement of collar bearing strips. Inspect the bearing strip (Figure 5-2) and the machined keyways of the collar for wear. If the keyways of the collar are badly worn, the collar should be replaced. If the bearing strips are worn down to the metal collar, they should be replaced.

  • Page 42: Replacing Wear Rings

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 5.5.3 Replacing Wear Rings Wear rings are preformed split synthetic bearings that fit around the butt plate above the seal on each interior mast section. Wear rings can be replaced when the mast is disassembled for seal replacement.

  • Page 43: Replacing Internal Bumpers

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 5.5.4 Replacing Internal Bumpers The internal bumper, which looks like an O-ring, is located on the top edge of the stop panel on each internal mast section. When the mast is disassembled, check the condition of the internal bumper.

  • Page 44: Replacing External Bumpers

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 5.5.5 Replacing External Bumpers The external bumper is a flat rubber ring cemented to the top of each mast collar. Check the condition and the adhesion of each external bumper. If the external bumpers become loose, they can usually be reused unless they have been damaged.

  • Page 45: Long-Term Storage

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 5.6 Long-Term Storage When putting the system into long-term storage, ensure the: Mast is fully nested (Section 4.5). • Drain cock is open to eliminate the possibility of inadvertent mast extension. • • Mast is stored in a clean and dry environment. Mast is stored vertically when storing for more than six months with provisions to keep •...

  • Page 46: Troubleshooting

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL 5.8 Troubleshooting Problem Possible Cause(s) Possible Solutions 1. Mast Base Section not drained 1. Wrap warming blankets around collar Mast frozen in routinely. Typically freezes until ice melts. Use heat gun or 500W extended around collar area.

  • Page 47: Section 6 Mast Parts

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL Section 6 Mast Parts 14 13 20 22 20 22 Base Section (5.0") Intermediate Section (4.5") Intermediate Section (4.0") Intermediate Section (3.5") Top Section (3.0") Coil Cord Light Duty Collar Assembly (5.0") Light Duty Collar Assembly (4.5") Light Duty Collar Assembly (4.0") 10.

  • Page 48: Figure 6-2 Entry Level Pneumatic Internally Wired Mast (Images Not To Scale)

    ’ NEUMATIC NTERNALLY IRED PERATOR ANUAL Base Section (4.0") Intermediate Section (3.5") Top Section (3.0") Coiled Cord Strain Relief Bushing Light Duty Collar Assembly (4.0") Light Duty Collar Assembly (3.5") Top Tube Stop IWM Locker 10. Tube Adaptor 11. Tube Head 4.0" IWM-VLT LC 12.

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