Will Burt Stiletto AL 4-Meter User manual

STILETTO AL OPERATING INSTRUCTIONS
(6-Meter Stiletto AL P/N: 711990692 Shown)
The Will-Burt Company Phone: [phone] TP-5418901-F, August 2020
401 Collins Blvd E-Mail: [email protected] © 2020 The Will-Burt Company
Orrville, OH 44667, U.S.A. Website: www.willburt.com Original Instructions
Authorized Representative:
GEROH GmbH & Co. KG
Fischergasse 25
D-91344 Waischenfeld, Germany

STILETTO AL OPERATING INSTRUCTIONS
TP-5418901-F Original Instructions i
August 2020
Warranty
Will-Burt warrants its Stiletto® AL 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; 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.

STILETTO AL OPERATING INSTRUCTIONS
ii Original Instructions TP-5418901-F
August 2020
Document History
Document Numbers
Dates
Remarks
TP-5418901-00
August 23, 2017
Initial Release
TP-5418901-A
May 24, 2018
Updated to reference the Roof Seal Kit
(Sections 1.6.4.3 and 2.6). Updated
Extension Nut cycles to 5,000.
TP-5418901-B
August 2, 2018
Updated Section 1.6.4.2 and the D-TEC
references throughout.
TP-5418901-C
January 21, 2019
Updated Section 5.4.2. Minor verbiage and
grammatical changes throughout manual.
TP-5418901-D
December 4, 2019
Updated Section 1.5, 1.6.1.2, 2.9, 3.1,
3.4.2.6, and 4.
TP-5418901-E
February 17, 2020
Update to Table 1-2. Minor grammatical
changes throughout manual.
TP-5418901-F
August 7, 2020, 2020
Update to Table 1-2. Minor grammatical
changes throughout manual. Add copy of
latest CE Certificate of Conformance.
Added optional EMI Filter information

STILETTO AL OPERATING INSTRUCTIONS
TP-5418901-F Original Instructions iii
August 2020
Table of Contents
Safety Summary......................................................................................................................vii
Signal Word Definitions............................................................................................................................vii
General Safety Instructions......................................................................................................................vii
Symbols....................................................................................................................................................xii
Section 1 Introduction & Intended Use................................................................................ 1-1
1.1 Specification Compliance.................................................................................................................1-2
1.2 Safety Precaution Notification..........................................................................................................1-3
1.3 Manual Organization........................................................................................................................1-3
1.4 Definitions of Terms .........................................................................................................................1-3
1.5 Specifications...................................................................................................................................1-4
1.6 Finishes............................................................................................................................................1-7
1.7 Major Components...........................................................................................................................1-8
1.7.1 Telescoping Mast......................................................................................................................1-9
Collars..............................................................................................................................1-11
Top Tube Ring .................................................................................................................1-11
Drive Assembly ................................................................................................................1-13
Support Bracket Assembly...............................................................................................1-15
Fully Extended Limit Switch (P/N: 913217) .....................................................................1-16
Motor and Brake Cable (P/N: 5433101 for 3M Cable).....................................................1-16
Mast Sensor Cable (P/N: 5433201 for 3M Cable) ...........................................................1-17
Fully Extended Limit Switch Cable (P/N: 5427901).........................................................1-17
EMI Filter (optional equipment)........................................................................................1-18
Power Cable Connector (P/N: 213075) .........................................................................1-18
Identification Plate (P/N: 451830xx)...............................................................................1-19
Crank Handle Assembly (P/N: A3209918) ....................................................................1-19
Grease Gun (P/N: 4288501)..........................................................................................1-20
Label Kit (English) (P/N: 5428301) ................................................................................1-20
1.7.2 Universal Control Box (P/N: 4453901)....................................................................................1-21
Display .............................................................................................................................1-23
UP/DOWN Switch............................................................................................................1-24
OVERRIDE Switch...........................................................................................................1-24
Bulkhead Connectors.......................................................................................................1-25
Printed Circuit Board........................................................................................................1-25
1.7.3 PC Interface............................................................................................................................1-26
1.7.4 Accessory Options (Sold Separately).....................................................................................1-27
Hand-Held Remote Control..............................................................................................1-27
D-TEC®.............................................................................................................................1-28
Additional Accessory Options ..........................................................................................1-30
Section 2 Installation............................................................................................................ 2-1
2.1 Pre-Installation Check......................................................................................................................2-1
2.2 Installation Equipment......................................................................................................................2-3
2.3 Installation Hardware .......................................................................................................................2-4
2.4 Installation Dimensions ....................................................................................................................2-5

STILETTO AL OPERATING INSTRUCTIONS
iv Original Instructions TP-5418901-F
August 2020
2.4.1 Mast Installation Dimensions ....................................................................................................2-6
2.4.2 Support Bracket Assembly Dimensions....................................................................................2-8
2.4.3 Universal Control Box Dimensions ...........................................................................................2-9
2.4.4 EMI Filter Dimensions (optional equipment)...........................................................................2-11
2.5 Power Supply Requirements..........................................................................................................2-11
2.6 Mast System Installation ................................................................................................................2-12
2.6.1 Installation Quick Summary ....................................................................................................2-12
2.6.2 Installation Detailed Instructions.............................................................................................2-12
Select a Suitable Mounting Location................................................................................2-13
Unpack the Mast System.................................................................................................2-14
Secure the Support Bracket Assembly............................................................................2-15
Secure the Base of the Mast............................................................................................2-16
Finalize Physical Installation of the Mast.........................................................................2-16
Secure the Universal Control Box....................................................................................2-18
Electrically Install the Mast System..................................................................................2-19
Connect Power to the Mast System.................................................................................2-21
2.7 Additional Accessory Installation....................................................................................................2-23
2.8 Test the Installation........................................................................................................................2-24
2.9 Install Payload................................................................................................................................2-25
Section 3 Operation.............................................................................................................. 3-1
3.1 Pre-Operation Check .......................................................................................................................3-1
3.2 Operation Equipment .......................................................................................................................3-3
3.3 Controls............................................................................................................................................3-4
3.3.1 Universal Control Box (Powered Operation).............................................................................3-4
3.3.2 PC Interface (Powered Operation)............................................................................................3-4
3.3.3 Crank Handle Assembly (Manual Operation) ...........................................................................3-4
3.4 Universal Control Box Operation......................................................................................................3-5
3.4.1 Detailed Instructions .................................................................................................................3-5
Prepare the System for Powered Operation......................................................................3-5
Extend the Mast with UP/DOWN Switch............................................................................3-6
Extend the Mast with OVERRIDE Switch (Emergency Operation) ...................................3-7
Retract the Mast with UP/DOWN Switch...........................................................................3-8
Retract the Mast with OVERRIDE Switch (Emergency Operation)...................................3-9
Access the Cycle Count and Temperature with UP/DOWN Switch ................................3-10
3.5 PC Interface Operation ..................................................................................................................3-10
3.6 Crank Handle Operation ................................................................................................................3-11
3.6.1 Quick Reference .....................................................................................................................3-11
3.6.2 Detailed Instructions ...............................................................................................................3-12
Prepare the System for Manual Operation ......................................................................3-12
Extend the Mast with Crank Handle Assembly................................................................3-13
Retract the Mast with Crank Handle Assembly ...............................................................3-14
Section 4 Transportation...................................................................................................... 4-1
4.1 General Transportation ....................................................................................................................4-1
4.2 Shipping ...........................................................................................................................................4-2

STILETTO AL OPERATING INSTRUCTIONS
TP-5418901-F Original Instructions v
August 2020
Section 5 Maintenance ......................................................................................................... 5-1
5.1 Pre-Maintenance Check...................................................................................................................5-1
5.2 Maintenance Equipment ..................................................................................................................5-3
5.3 Spare Parts ......................................................................................................................................5-3
5.4 Preventative Maintenance Checks and Services (PMCS)...............................................................5-3
5.4.1 Schedule...................................................................................................................................5-4
5.4.2 Lubricate the Drive Screw.........................................................................................................5-6
5.4.3 Special Instructions...................................................................................................................5-8
Corrosive Environments.....................................................................................................5-8
Mast Damage.....................................................................................................................5-8
Section 6 Long-Term Storage .............................................................................................. 6-1
Section 7 Mast System Disposal.......................................................................................... 7-1
Section 8 Troubleshooting................................................................................................... 8-1
8.1 Error Conditions ...............................................................................................................................8-1
8.2 Error (Fault) and Warning Codes.....................................................................................................8-4
8.2.1 Error (Fault) Codes ...................................................................................................................8-5
8.2.2 Warning Codes .........................................................................................................................8-9
Section 9 Reference.............................................................................................................. 9-1
9.1 Extended Glossary of Terms............................................................................................................9-1
9.1.1 General Terms and Abbreviations............................................................................................9-1
9.1.2 Mounting Position Terms ..........................................................................................................9-2
9.2 Guying..............................................................................................................................................9-3
9.3 Drawings ..........................................................................................................................................9-3
Table of Figures
Figure 1-1 Mast (6-Meter Stiletto AL P/N: 711990692 Shown) ................................................................1-9
Figure 1-2 Drain Hole (Base of 6-Meter Stiletto AL P/N: 711990692 Shown)........................................1-10
Figure 1-3 Collars (Collars from the 6-Meter Stiletto AL P/N: 711990692 Shown) ................................1-11
Figure 1-4 Top Tube Ring (Top Tube Ring for 6-Meter Stiletto AL P/N: 711990692 Shown)................1-12
Figure 1-5 Drive Assembly (Not to Scale)...............................................................................................1-13
Figure 1-6 Support Bracket Assembly (Not to Scale).............................................................................1-15
Figure 1-7 Fully Extended Limit Switch...................................................................................................1-16
Figure 1-8 Motor and Brake Cable..........................................................................................................1-16
Figure 1-9 Sensor Cable.........................................................................................................................1-17
Figure 1-10 Fully Extended Limit Switch Cable......................................................................................1-17
Figure 1-11 EMI Filter .............................................................................................................................1-18
Figure 1-12 Power Cable Connector ......................................................................................................1-18
Figure 1-13 Identification Plate (P/N: 4518302 Shown)..........................................................................1-19
Figure 1-14 Crank Handle Assembly......................................................................................................1-19
Figure 1-15 Grease Gun.........................................................................................................................1-20
Figure 1-16 Universal Control Box..........................................................................................................1-21
Figure 1-17 Universal Control Box Components ....................................................................................1-22
Figure 1-18 Hand-Held Remote Control.................................................................................................1-27

STILETTO AL OPERATING INSTRUCTIONS
vi Original Instructions TP-5418901-F
August 2020
Figure 1-19 D-TEC (P/N: 5354901 Shown) ............................................................................................1-28
Figure 2-1 Mast Installation Dimensions (Not to Scale)............................................................................2-7
Figure 2-2 Support Bracket Assembly Bolt Hole Pattern..........................................................................2-8
Figure 2-3 Universal Control Box Installation Dimensions (Measurements in Inches)...........................2-10
Figure 2-4 Drain Hole Location...............................................................................................................2-13
Figure 2-5 Shipping Crate.......................................................................................................................2-14
Figure 2-6 Ground Stud Locations..........................................................................................................2-17
Figure 2-7 Universal Control Box Ground Location................................................................................2-18
Figure 2-8 Stiletto AL Wiring...................................................................................................................2-19
Figure 2-9 Universal Control Box Schematic (Revision M).....................................................................2-20
Figure 2-10 Emergency Stop Switch Kit .................................................................................................2-21
Figure 2-11 Power Cable Connector Wiring ...........................................................................................2-22
Figure 2-12 Flat Spots on Collars ...........................................................................................................2-23
Figure 2-13 Mounting Hole Pattern.........................................................................................................2-26
Figure 3-1 UP/DOWN Switch Up Position................................................................................................3-6
Figure 3-2 OVERRIDE Switch Engage Position and UP/DOWN Switch Up Position..............................3-7
Figure 3-3 UP/DOWN Switch Down Position............................................................................................3-8
Figure 3-4 OVERRIDE Switch Engage Position and UP/DOWN Switch Down Position .........................3-9
Figure 3-5 Manual Override....................................................................................................................3-13
Figure 5-1 Grease Port .............................................................................................................................5-6
Figure 9-1 Lay Out Guy Lines...................................................................................................................9-3
Table of Tables
Table 1-1 Catalog Mast Part and Model Numbers....................................................................................1-4
Table 1-2 Stiletto AL Mast System Specifications ....................................................................................1-4
Table 1-3 D-TEC Specifications..............................................................................................................1-29
Table 1-4 Additional Accessory Options.................................................................................................1-30
Table 2-1 Equipment Recommended for Installation................................................................................2-3
Table 2-2 Installation Hardware................................................................................................................2-4
Table 2-3 Mast Installation Dimensions....................................................................................................2-6
Table 2-4 Support Bracket Assembly Bolt Hole Pattern Dimensions.......................................................2-9
Table 2-5 Circuit Breaker Specifications.................................................................................................2-11
Table 3-1 Equipment Recommended for Operation.................................................................................3-3
Table 5-1 Equipment Recommended for Maintenance ............................................................................5-3
Table 5-2 Preventative Maintenance Schedule........................................................................................5-4
Table 8-1 Troubleshooting Error Conditions.............................................................................................8-1
Table 8-2 Error (Fault) Codes...................................................................................................................8-5
Table 8-3 Warning Codes.........................................................................................................................8-9

STILETTO AL OPERATING INSTRUCTIONS
TP-5418901-F Original Instructions vii
August 2020
Safety Summary
This section describes safety precautions for the Stiletto AL. These are recommended
precautions that personnel must understand and apply throughout many phases of installation,
operation, transportation, maintenance, storage, and troubleshooting. Be sure the read and
understand the entire manual, and contact The Will-Burt Company with any questions, before
performing any procedure outlined in this manual.
Signal Word Definitions
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.
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.
General Safety Instructions
The following are general safety precautions that are not related to any specific procedures.
These are recommended precautions that personnel must understand and apply throughout
installation, operation, transportation, maintenance, storage, and troubleshooting. Additional
precautions that apply to specific procedures and steps may be listed with the procedure or step
to which they apply.
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. Be sure to allow
sufficient clearance on all sides of the mast to allow for side sway. Do not operate mast in
lightning. Be certain electrical cables are undamaged and properly terminated. Always
disconnect power before performing service, repair or test operations.
Relocation/Driving Hazard! Do not relocate the system during operation or while the mast is
extended to any height above the nested position or powered up. Do not move vehicle until the
mast has been securely nested and isolated from power. Power-up and operate the mast only if
the vehicle is stationary and securely parked with the parking brake properly applied. Do not
move vehicle without the vehicle interlock circuit installed to confirm the mast is nested.

STILETTO AL OPERATING INSTRUCTIONS
viii Original Instructions TP-5418901-F
August 2020
Relocating the system during operation or after mast is extended could result in death or serious
injury. Contact Will-Burt Engineering for special on-the-move situations for military only use.
Safety Instruction –Read Manual! Failure to follow operating instructions could result in death
or serious injury. Read and understand the operating instructions before using the mast.
Resuscitation! Personnel working with or near high voltages should be familiar with modern
methods of resuscitation. Such information may be obtained from the Bureau of Medicine and
Surgery.
Trained Personnel Only! Only trained and qualified personnel should perform installation,
operation, and maintenance procedures. Death or serious injury could result if proper
procedures are not observed.
Safety Equipment! Helmets or hard hats, eye protection, gloves, and safety shoes shall be
properly worn while working in the deployment area. Improperly secured payload components,
ice formations, etc. could be dislodged from the mast and fall. Death or serious injury could
result if proper safety equipment is not properly worn.
Crush Hazard –Mast Failure! Do not stand directly beneath the mast or its payload. Be certain
the payload is properly installed and secured. Death or serious injury could result if mast fails
suddenly.
Equipment Damage –Lock Mechanism! Do not modify the mast lock mechanism or lock
housing or attach any components to the lock housing. Do not remove the locks with the mast
extended. Equipment damage and dangerous mast collapse could occur if the lock mechanism
is modified. Do not let the payload control/power cables get between the lock housing and the
lock post during retraction. Pinching the cable with the lock during nesting can result in an
unsafe operating condition or damaged to cables.
Equipment Damage –Submerged! Do not submerge the mast in liquid or operate the vehicle
in a fording situation that would result in a submerged mast.
Health and Safety Hazard! Solvent used to clean parts is potentially dangerous. Follow solvent
manufacturer’s safety procedures and recommendations. Avoid inhalation of fumes and also
prolonged contact to skin. Death or serious injury could occur if solvents are not handled
properly.