Will Burt QEAM TM-21 User manual

QEAM TM-21, TM-25, TM-30, AND TM-34
STRAP DRIVE MASTS OPERATING MANUAL
The Will-Burt Company Phone: [phone] TP-4619601-D, October 2023
401 Collins Blvd E-Mail: [email protected] © 2023 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

QEAM STRAP DRIVE MAST OPERATOR’S MANUAL
TP-4619601-D i
October 2023
Warranty
Will-Burt warrants its mast system 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; use of the product in a manner inconsistent with its
design; unauthorized service, alteration of products, neglect, abuse, accident, or
acts of God. This warranty does not extend to any component parts not
manufactured by Will-Burt; provided, however, Will-Burt’s warranty herein shall not
limit any warranties by manufacturers of component parts which extend to the
buyer.
THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, AND
NO REPRESENTATIONS, GUARANTEES OR WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING BUT NOT LIMITED TO, A WARRANTY OF
MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR NON-
INFRINGEMENT ARE MADE BY WILL-BURT IN CONNECTION WITH 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 in material and workmanship shall be made in writing to Will-
Burt within thirty (30) days of the discovery of defect. Failure to provide notice as
required hereby shall be conclusive evidence that the product was in conformity
with the warranty, and Will-Burt shall be released from any and all liability relating
to the product. Will-Burt may either send a service representative or have the
product returned to its factory at Buyer's expense for inspection. If judged by Will-
Burt to be defective in material or workmanship, the product will be replaced or
repaired at the option of Will-Burt, free from all charges except authorized
transportation.
THE REMEDIES OF BUYER SET FORTH HEREIN ARE EXCLUSIVE AND ARE
IN LIEU OF ALL OTHER REMEDIES. THE LIABILITY OF WILL-BURT WHETHER
IN CONTRACT, TORT, UNDER ANY WARRANTY, OR OTHERWISE, SHALL
NOT EXTEND BEYOND ITS OBLIGATION TO REPAIR OR REPLACE, AT ITS
OPTION, ANY PRODUCT OR PART FOUND BY WILL-BURT TO BE DEFECTIVE
IN MATERIAL OR WORKMANSHIP. WILL-BURT SHALL NOT BE LIABLE FOR
COST OF INSTALLATION AND/OR REMOVAL, OR BE RESPONSIBLE FOR
DIRECT, INDIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY
NATURE.

QEAM STRAP DRIVE MAST OPERATOR’S MANUAL
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October 2023
Document History
Document
Dates
Remarks
TP-5000901-00
4/3/2013
Initial Release
TP-4619601-C
12/2013
--
TP-4619601-D
10/23/2023
Updated to WB format

QEAM STRAP DRIVE MAST OPERATOR’S MANUAL
TP-4619601-D iii
October 2023
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 .................................................................................................................................... 2-1
2.2 Definitions ......................................................................................................................................... 2-2
2.3 Mast Component Descriptions ......................................................................................................... 2-2
Section 3 Technical Data ...................................................................................................... 3-1
Section 4 Installation ............................................................................................................ 4-1
4.1 Pre-Installation Check ...................................................................................................................... 4-1
4.2 Select a Suitable Mounting Location ................................................................................................ 4-1
4.3 Recommended Installation Tools ..................................................................................................... 4-2
4.4 Unpack the Mast System ................................................................................................................. 4-2
4.5 Deploy the Mast ............................................................................................................................... 4-3
Section 5 Retrieval ................................................................................................................ 5-1
5.1 Recommended Retrieval Tools ........................................................................................................ 5-1
5.2 Retrieve the Mast ............................................................................................................................. 5-1
5.3 Optional Stake Puller ....................................................................................................................... 5-6
Section 6 Transportation ...................................................................................................... 6-1
6.1 General Transportation .................................................................................................................... 6-1
6.2 Shipping ........................................................................................................................................... 6-1
Section 7 Maintenance and Disposal .................................................................................. 7-1
7.1 Pre-Maintenance Check ................................................................................................................... 7-1
7.2 Maintenance Equipment .................................................................................................................. 7-1
7.3 Spare Parts ...................................................................................................................................... 7-2
7.4 Periodic Maintenance ....................................................................................................................... 7-2
7.5 Strap Replacement Procedure ......................................................................................................... 7-4
7.5.1 Strap Visual Inspection Criteria................................................................................................. 7-4
7.5.2 Replace the Strap ..................................................................................................................... 7-8
7.6 Long-Term Storage ........................................................................................................................ 7-11
7.7 System Disposal ............................................................................................................................ 7-12
Section 8 Mast Recovery Procedures ................................................................................. 8-1
8.1 Removing the Winch from an Extended Mast - Winch Issues ......................................................... 8-1
8.2 Mast Jammed in Extended Position ................................................................................................. 8-2
8.2.1 Standard Procedures ................................................................................................................ 8-2
8.2.2 Emergency Procedure I ............................................................................................................ 8-3
8.2.3 Emergency Procedure II ........................................................................................................... 8-4
Table of Figures
Figure 2-1 Accessory Bag S/A #1 Contents .............................................................................................. 2-3

QEAM STRAP DRIVE MAST OPERATOR’S MANUAL
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Figure 2-2 Accessory Bag S/A #2 Contents .............................................................................................. 2-4
Figure 2-3 Accessory Bag S/A #3 Contents .............................................................................................. 2-4
Figure 2-4 Accessory Bag S/A #4 Contents .............................................................................................. 2-5
Figure 2-5 Accessory Bag S/A #5 Contents .............................................................................................. 2-5
Figure 2-6 Accessory Bag S/A #6 Contents .............................................................................................. 2-6
Figure 4-1 Shipping Crate (Not to Scale) ................................................................................................... 4-2
Figure 4-2 Orient Base Plate at Center of Site and Anchor with Four Base Plate Stakes ........................ 4-3
Figure 4-3 Unwind Radius Rope in Direciton of Slot-Opening in Base Plate ............................................ 4-4
Figure 4-4 Hammer Guy Stakes at 60° Angle at Each Loop of Radius Rope ........................................... 4-4
Figure 4-5 Guying Diagrams ...................................................................................................................... 4-6
Figure 4-6 Place the Base of the Mast on the Base Plate ......................................................................... 4-7
Figure 4-7 Insert Tupe A into Tube B ......................................................................................................... 4-7
Figure 4-8 Slide the Legs into the Roller Frame ........................................................................................ 4-7
Figure 4-9 Place Gin Pole Center Apprx. 3 ft From Center of Base Plate ................................................. 4-8
Figure 4-10 Place Lift Winch Directly Opposite the Mast .......................................................................... 4-8
Figure 4-11 Stake Lift Winch Bracket in Place........................................................................................... 4-8
Figure 4-12 Tip Gin Pole Back Towards Lift Winch ................................................................................... 4-9
Figure 4-13 Connect Cable from Lift Winch to the Winch Shackle ............................................................ 4-9
Figure 4-14 Tension the Lines Lightly by Placing Guy Tensioner Hook Over Double Guy Lines ........... 4-10
Figure 4-15 Lift the Lift Winch Up by its Carry Handle and Rotate Crank Handle Clockwise ................. 4-10
Figure 4-16 Attach Remaining Guy Lines ................................................................................................ 4-11
Figure 4-17 Install the Manual Position or Top Tube Stub ...................................................................... 4-11
Figure 4-18 Raise Mast to Vertical ........................................................................................................... 4-12
Figure 4-19 Adjust Four Base Guy Lines Using Bubble Level ................................................................. 4-12
Figure 4-20 Detach Positive Retraction Reel ........................................................................................... 4-12
Figure 4-21 Install Winch Bracket to Side of Mast ................................................................................... 4-12
Figure 4-22 Place Strap Winch Handle Over Strap Winch Post .............................................................. 4-13
Figure 4-23 Secure Winch at Desired Position ........................................................................................ 4-13
Figure 4-24 Attach Positive Retraction Reel to Strap Winch ................................................................... 4-13
Figure 4-25 Feed Strap from Mast Around Winch Idler Arm and Onto Strap Reel ................................. 4-13
Figure 4-26 Place Strap Reel on Square Winch Shaft ............................................................................ 4-14
Figure 4-27 Attach Crank Handles to the Strap Winch at the Desired Reduction Shafts and 180° apart ... 4-
14
Figure 4-28 When Using Cordless Drill to Extend Mast, Set Drill to Lowest Torque that Will Operate Mast
................................................................................................................................................................. 4-15
Figure 4-29 When Guy Lines are Being Tensioned, Stand at Base of Mast and Site Mast for Vertical.. 4-16
Figure 5-1 Attach Crank Handles to the Crank Handle Input Shafts on the Winch ................................... 5-1
Figure 5-2 Remove the Pin Attaching the Positive Retraction Reel to the Strap Winch............................ 5-2
Figure 5-3 Remove Pin from the Square Winch Shaft ............................................................................... 5-2
Figure 5-4 Remove the Positive Retraction Reel from the Strap Winch .................................................... 5-2
Figure 5-5 Remove Pin Connecting the Strap Winch to the Strap Winch Bracket .................................... 5-3
Figure 5-6 Remove Strap Winch from Winch Post of Mast ....................................................................... 5-3
Figure 5-7 Remove Strap Winch Bracket .................................................................................................. 5-3
Figure 5-8 Add the Positive Retraction Strip and Pin in Place ................................................................... 5-3
Figure 5-9 Position Gin Pole in Place with Its Center 3 Feet from Base of Mast ...................................... 5-4

QEAM STRAP DRIVE MAST OPERATOR’S MANUAL
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Figure 5-10 Crank Winch Counterclockwise .............................................................................................. 5-4
Figure 5-11 Remove All Guy Lines Except Two on the Base Tube .......................................................... 5-5
Figure 5-12 Hit Each Guy Stake on Each Edge and Use Hammer to Pry Under the Guy Line Hook Rib 5-5
Figure 5-13 Press Blue Button Then Insert the Pin to Connect Handle .................................................... 5-6
Figure 5-14 Use the Cutouts that Best Fit Your Stake ............................................................................... 5-6
Figure 5-15 Place Wide or Widest Cutout Over the Stake ........................................................................ 5-6
Figure 5-16 Push Down on Stake Puller Handle ....................................................................................... 5-7
Figure 5-17 Place Narrow Cutout Over the Stake ..................................................................................... 5-7
Figure 5-18 Push Down on Stake Puller Handle ....................................................................................... 5-8
Figure 5-19 Lift Up on Handle .................................................................................................................... 5-8
Figure 7-1 Periodic Inspections.................................................................................................................. 7-2
Figure 7-2 New Strap will be Joined to Old Strap ...................................................................................... 7-8
Figure 7-3 Create a Butt Splice .................................................................................................................. 7-8
Figure 7-4 Test the Splice .......................................................................................................................... 7-8
Figure 7-5 Remove Pulley Covers ............................................................................................................. 7-9
Figure 7-6 Feed New Strap Without Twisting or Folding ........................................................................... 7-9
Figure 7-7 Pull Loop of the Strap Out of the Largest Collar ....................................................................... 7-9
Figure 7-8 Pull Out the Top Stub Cap ...................................................................................................... 7-10
Figure 7-9 Pull Strap Out of the Top of the Mast ..................................................................................... 7-10
Figure 7-10 Secure Strap Pin in Place ..................................................................................................... 7-11
Figure 8-1 Clamp Aluminum Clamp Block Over Strap .............................................................................. 8-1
Figure 8-2 Crank Winch in Reverse Direction ............................................................................................ 8-1
Figure 8-3 Once Load has Been Fully Transferred to the Clamp Block, Winch can be Removed ............ 8-2
Figure 8-4 Crank Winch in Reverse Direction to Transfer Load from Winch to Clamp Block ................... 8-3
Figure 8-5 Put 1/8” Allen Wrench into Each Access Hold and Release Each of the Four Latches ........... 8-5
Table of Tables
Table 3-1 Mast Specifications ................................................................................................................... 3-1
Table 4-1 Tools and Materials Required for Installation ........................................................................... 4-2
Table 5-1 Tools and Materials Required for Installation ........................................................................... 5-1
Table 7-1 Equipment Recommended for Maintenance ............................................................................ 7-1
Table 7-2 Fraying Level of the Strap .......................................................................................................... 7-4

QEAM STRAP DRIVE MAST OPERATOR’S MANUAL
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QEAM STRAP DRIVE MAST OPERATOR’S MANUAL
TP-4619601-D vii
October 2023
Section 1 Safety Summary
This section describes safety instructions for the QEAM Strap Drive 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. Keep this document
during the entire duration of use of the device. Pass this document along to trained and qualified
end users.
1.1 Signal Word Definitions
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.
WARNING indicates a potentially hazardous situation that, if not avoided, could result in death
or serious injury.
CAUTION indicates a potentially hazardous situation that, if not avoided, may result in minor or
moderate injury. It is also used to alert against unsafe practices.
1.2 Safety Instructions
Electrocution Hazard! Contact with high voltage will result in death or serious injury. Observe
general safety precautions for handling equipment using high voltage. Do not locate or operate
mast near electrical lines, cables or other unwanted sources of electricity. Allow sufficient
clearance on all sides of mast to allow for side sway. Do not operate mast during an electrical
storm. Be certain electrical cables are undamaged and properly terminated. Do not touch live
wires. Follow OSHA or other national safety regulations when working near energized power
lines. Personnel working with or near high voltages should be familiar with methods of
resuscitation.
Disconnect Power for Service! Always disconnect all power sources following proper lock-out
tag-out procedures before performing service, repair or test operations. Remove the tethered
hand held control where applicable for added protection during maintenance.

QEAM STRAP DRIVE MAST OPERATOR’S MANUAL
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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. Do not operate in wind speed conditions exceeding the
maximum rated wind speed. Do not operate on slopes exceeding the maximum deployment
angle. Do not install a payload that exceeds the maximum payload lifting capacity of mast. Do
not install a payload with the center of gravity offset from mast centerline exceeding the
maximum allowed offset. Stand clear of mast and mast payload during operation. Be certain
mast is level and secure before and during installation, operation, and maintenance.
Falling Objects from Mast Hazard! Wear a protective hard hat when working on mast or
situated near mast operating area while mast is extending, retracting or deployed in any position
above the nested position. Improperly secured payload or mast components, ice formations,
etc. could be dislodged from mast and fall. Be sure the payload is properly installed and
secured.
Relocation/Driving Hazard! Do not relocate the system during operation or while mast is
extended to any height above the nested position or 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 properly applied. Do not put
mast in service or operate without the vehicle interlock warning circuit or magnetic warning kit
installed to provide confirmation mast is nested prior to moving the vehicle. Contact The Will-
Burt Company Engineering for special on-the-move situations for military only use on
specialized products.
Burst Hazard! For pneumatically operated masts, do not operate without the over-pressure
safety valve installed. Keep personnel clear of safety valve exhaust direction. Do not exceed the
maximum rated pressure of mast. If the mast air pressure is not fully discharged prior to
removing air hoses, a rapid release of air pressure will occur requiring hearing and eye
protection.
Payload Lifting Hazard - Intended Use! 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. Do not
exceed specified payload capacity. Large payload wind sail areas can reduce payload capacity.
Consult The Will-Burt Company engineering.