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.

STILETTO AL OPERATING INSTRUCTIONS
TP-5418901-F Original Instructions ix
August 2020
Fire Hazard! Cleaning solvent, used for maintenance, is flammable and can be explosive
resulting in death or serious injury. Do not smoke. Use cleaning solvent in a well-ventilated area.
Keep cleaning solvent away from ignition sources. Always store cleaning solvent in the proper
marked container.
Tip Over Hazard! Mast tip over could result in death or serious injury. Do not operate in high
winds. Be certain mast is level, stable, and secure before and during installation, operation,
maintenance, and transportation. Stand clear of mast and mast payload during operation.
Before operating, the base section shall be within:
•10° of vertical for models at or below 10M extended height
•5° of vertical for models above 10M extended height
Pinch Point Hazard! Moving parts can crush and cut resulting in death or serious injury. Keep
clear of moving parts while operating mast.
Mounting Structure Hazard! Before installation, ensure the mounting structure is capable of
resisting forces generated from all loading and environmental conditions, including, but not
limited to, Mast System size and weight, payload size and weight, vehicle dynamic loads, sail
size, wind speed, support bracket or roof line location and base plate assembly. The lower
structure at the base plate shall be sized to support all vertical loads from the mast and payload.
The support bracket is not intended to carry vertical loads. The support bracket mounting
structure and the base plate mounting structure shall be tied to the same vehicle structure/frame
(i.e. do not mount the support bracket to vehicle body and the base plate to the vehicle chassis
frame. This would put the vehicle suspension system between the mounting points). Mounting
the Mast System into a structure unable to resist the forces generated from the customer-specific
loading scenario could result in death or serious injury and could damage the Mast System.
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 Will-Burt
engineering.
Mast Extension Hazard! Extending mast into obstructions could result in death or serious
injury and could render the mast inoperable and partially extended. Before applying power and
operating the mast, be certain there is sufficient clearance above and to all sides of the
expected location of the fully extended mast and payload. Keep all persons clear of mast and
mast extension. Do not lean directly over the mast.

STILETTO AL OPERATING INSTRUCTIONS
xOriginal Instructions TP-5418901-F
August 2020
Safety Instruction –Observe Proper Lifting Procedures! Use extreme caution while lifting
the Mast System and when Mast System is suspended to avoid injury and equipment damage.
Be certain the Mast System is properly secured. All operators should be aware of and follow the
applicable local, regional, and national standards and codes of practice for slinging and
transporting equipment. Never lift Mast System over people. Ensure lifting equipment including,
but not limited to, lifting straps and hoist, are capable of handling the forces generated from
lifting the system. Observe manufacturer instructions on lifting equipment. Death or serious
injury could result if proper procedures are not followed.
Safety Instruction –Operation! For outdoor use only. Do not use in areas that have been
classified as hazardous as defined in Article 500 of the National Electric Code.
Safety Instruction –Potential Air Contaminants! If internally mounted in a vehicle, air from
the mast and any accumulated water will discharge into the vehicle. Appropriate drainage
location shall be defined by the installer.
Disconnect Power! Power must be disconnected before connecting or disconnecting any Mast
System connector. For example, power must be disconnected when connecting or
disconnecting J1, J2, J3, and J4 on the Control Box. Do not disconnect the power cable from J1
on the Control Box or from the power source while the mast is in motion (extending or
retracting). This could result in damage to the Control Box.
Equipment Damage –Control Box! Do not open the Universal Control Box. The Universal
Control Box is vacuum-sealed at the factory. Opening the Universal Control Box could cause
equipment damage and will void the warranty.
Equipment Damage –Forces! Before unloading the system, be certain the unloading region is
capable of resisting forces generated from unloading the system including but not limited to
system weight. Ensure the unloading region is level and has sufficient room and strength to hold
the system. If the unloading region is incapable of meeting the requirements of the system,
damage to the system and/or unloading region could occur.
Equipment Damage –Qualified Personnel! All persons installing and maintaining this
equipment should be suitably qualified and work to local, regional, and national standards and
codes of practice.
Equipment Damage –Support Bracket! Do not overtighten the mast support bracket.
Overtightening may damage the Base Tube causing the mast tubes to stick.

STILETTO AL OPERATING INSTRUCTIONS
TP-5418901-F Original Instructions xi
August 2020
Safety Instruction –Roof Access! If mast will be mounted to a vehicle, the operator must
provide safe means to access the roof of the vehicle during installation and maintenance.
Safety Instruction –Mast Access! The operator must provide safe means to access the top of
the mast during installation and removal of the payload.
Lifting Hazard –Manually Lifting! 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. Equivalent regulations exist in other
EU states.
Entanglement Hazard! Tangled cables can cause equipment damage. Ensure payload cables,
are not tangled and are free to pay out as mast is extended.
Frozen Water Hazard! Water freezing inside mast may render mast inoperable and cause
major equipment damage such as tube deformation. Ensure the mast drain at the base plate is
not obstructed.
The following list contains reasonably foreseeable misuses of the mast system according to EN
ISO 12100 5.3.2. These uses shall be avoided:
•Operating the mast with an obstruction in the functional space that prevents full
extension or retraction
•Operating the mast near overhead power lines
•Operating the mast without the mast and operating space visible to the operator
•Driving the vehicle with the mast in a deployed position (any height above the nested
position) or powered-up or without opening venting the mast to atmosphere
•Operating the mast or leaving deployed in wind speeds higher than the specified
maximum velocity
•Operating the mast on a non-level surface greater than the specified maximum angle
•Installing a payload greater than the maximum rated payload (weight and sail area) of
the mast

STILETTO AL OPERATING INSTRUCTIONS
xii Original Instructions TP-5418901-F
August 2020
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. Do not operate
mast near electrical lines or during lightning events. Contact with high
voltage will result in death or serious injury.
This symbol indicates a pinch point hazard. Keep fingers and hands clear of
moving parts.
This symbol indicates a tip-over hazard. The mast must be properly
supported during transport, installation, maintenance and operation. System
tip-over could result in death or serious injury.
This symbol indicates a general warning. In this unit, this symbol indicates a
frozen water hazard. Do not block the mast drain port at the base of the unit.
Water must be permitted to exit the mast to avoid ice damage to the mast.
This symbol is used to remind users to read and understand the operator’s
manual before operating the Mast System. Failure to follow operating
instructions could result in death or serious injury. Read and understand
operator’s manual before operating or installing the mast system.
This symbol indicates a hard hat is required when working under the mast
operating area. Failure to wear a hard hat could result in death or serious
injury.
This symbol indicates an electrical ground connection point.
This symbol is used to indicate the center of gravity (COG) of a fully nested
mast.

STILETTO AL OPERATING INSTRUCTIONS
TP-5418901-F Original Instructions 1-1
August 2020
Section 1 Introduction & Intended Use
Review this manual in its entirety. Contact The Will-Burt Company with any questions before
performing any procedure outlined in this manual. The views depicted in this manual are
provided for clarification and are subject to change without notice. Views are not to scale.
This manual describes installation, operation, transportation, maintenance, storage, and
troubleshooting procedures for the Stiletto AL Mast System. These procedures assume the use
of standard catalog Mast Systems. Procedures and characteristics for Mast Systems
customized to meet customer-specific needs may vary.
This manual is for the following Stiletto masts:
•4-Meter Stiletto AL
•6-Meter Stiletto AL
•8.54-Meter Stiletto AL
•10-Meter Stiletto AL
•15-Meter Stiletto AL
This manual is not for the following masts:
•Stiletto (3, 4, 6, 10 or 15-Meter)
•Stiletto HD (4, 6, or 10-Meter)
See www.willburt.com for information on these and other Will-Burt products.
A typical Stiletto AL Mast System consists of:
•A telescoping mast with a 28 VDC Drive Assembly and a Support Bracket Assembly
•Universal Control Box
•Optional Accessories
The Stiletto AL mast system is intended to be installed and operated by trained professionals to
elevate critical payloads. It is not intended for use by non-professionals. The Stiletto AL mast is
designed to lift a specific payload for lighting, surveillance, or communication use only. Do not
use the mast to lift personnel. The mast is intended for stationary use. Contact The Will-Burt
Company with any questions on the intended use, special on-the-move use for military
applications only, or available training programs for installation and operation.

STILETTO AL OPERATING INSTRUCTIONS
1-2 Original Instructions TP-5418901-F
August 2020
1.1 Specification Compliance

STILETTO AL OPERATING INSTRUCTIONS
TP-5418901-F Original Instructions 1-3
August 2020
1.2 Safety Precaution Notification
Refer to the Safety Summary for precautions to be observed while installing, operating, or
maintaining this equipment.
1.3 Manual Organization
This manual is organized into the following sections:
Section 1 Introduction
Section 2 Installation
Section 3 Operation
Section 4 Transportation
Section 5 Maintenance
Section 6 Long-Term Storage
Section 8 Troubleshooting
Section 9 Reference
1.4 Definitions of Terms
Throughout this manual, the following terms are used:
•“Mast” to refer to the mechanical telescoping mast
•“Mast System” to refer to the entire Stiletto AL Mast System (telescoping mast, Universal
Control System, and additional accessories)
•“Payload” to refer to the object or equipment being raised by the mast to an operational
height
See Section 9.1 for an Extended Glossary of Terms used within this manual. The Extended
Glossary of Terms includes:
•General Terms and Abbreviations (Section 9.1.1)
•Mounting Position Terms (Section 9.1.2)

STILETTO AL OPERATING INSTRUCTIONS
1-4 Original Instructions TP-5418901-F
August 2020
1.5 Specifications
This section describes specifications for the Mast System. The specifications listed in this
section are for catalog masts only. Masts with other heights, capacities, and finishes are
available. For more information on additional mast sizes, capabilities, and finishes, see
www.willburt.com.
Table 1-1 Catalog Mast Part and Model Numbers
Part Number*
Model Number
711990491
4-Meter
711990692
6-Meter
711990890
8.54-Meter
711991010
10-Meter
711991591
15-Meter
* Part Numbers listed are for standard catalog
masts only. Additional options are available.
Table 1-2 Stiletto AL Mast System Specifications
Specifications*
4-Meter
6-Meter
8.54-Meter
10-Meter
15-Meter
Physical Characteristics
Fully Extended Height
(+50 / -50 mm)
(+2.0 / -2.0 inches)
4 m
6 m
8.54 m
10 m
15 m
13.1 feet
19.6 feet
28 feet
32.8 feet
49.2 feet
Fully Nested Height
(+2.0 / -5.0 mm)
(+0.08 / -0.2 inches)
1.28 m
1.58 m
1.88 m
2.10 m
2.65 m
50.4 inches
62.2 inches
74.02
inches
82.68
inches
104.4
inches
Rated Payload Capacity
(center of gravity within 300
mm of mast centerline)
181 kg
181 kg
181 kg
181 kg
158 kg
400 lb.
400 lb.
400 lb.
400 lb.
350 lb.
Approximate Mast
System Weight (Including
the Support Bracket
Assembly, Control Box, and
Cables)
120.2 kg
142.2 kg
165.2 kg
179.2 kg
229.2 kg
265 lb.
313.5 lb.
364.2 lb.
395 lb.
505.3 lb.
Approximate Mast
Weight (Without the
Support Bracket Assembly,
Control Box, or Cables)
105 kg
127 kg
150 kg
164 kg
214 kg
232 lb.
280 lb.
330 lb.
360 lb.
472 lb.
Approximate Universal
Control Box Weight
2.5 kg
5.5 lb.
Mast Footprint
446 x 284 mm
17.56 x 11.18 inches
Continued

STILETTO AL OPERATING INSTRUCTIONS
TP-5418901-F Original Instructions 1-5
August 2020
Table 1-2 Stiletto AL Mast System Specifications Continued
Specifications*
4-Meter
6-Meter
8.54-Meter
10-Meter
15-Meter
Universal Control Box
Footprint
311 x 203 mm
12.23 x 8.0 inches
Mast Type
Electro-Mechanical
Drive System
SSTL Drive Screw
Emergency Operation
Manual Hand-Crank
Collar Type
Auto Self-Locking with Integrated Icebreakers
Number of Sections
5
6
7
7
8
Tube Outside Diameter
Range (Base Tube to Top
Tube)
250 to 170
mm
250 to 150
mm
250 to 130
mm
250 to 130
mm
250 to 110
mm
9.84 to 6.69
inches
9.84 to 5.91
inches
9.84 to 5.12
inches
9.84 to 5.12
inches
9.84 to 4.33
inches
Number of Keys
1
Tube Material
Aluminum
Height Readout
Meters or US Customary
(Request when ordering. Defaults to meters.)
Electrical Characteristics
Operating Voltage Range
18.1-33 VDC
Optimal Voltage
(MIL-STD-1275)
28 VDC
Steady State Current
Draw (Maximum Operating
Conditions)
15-40 Amps
Inrush Current (Maximum
Operating Conditions)
160 Amps
Wind Performance
Deployment Wind Speed
64 km/h
64 km/h
56 km/h
56 km/h
48 km/h
40 mph
40 mph
35 mph
35 mph
30 mph
Survival Wind Speed
209 km/h
185 km/h
153 km/h
129 km/h
100 km/h
130 mph
115 mph
95 mph
80 mph
62 mph
Rotational Accuracy
(Twist)
±1°
Continued

STILETTO AL OPERATING INSTRUCTIONS
1-6 Original Instructions TP-5418901-F
August 2020
Table 1-2 Stiletto AL Mast System Specifications Continued
Specifications*
4-Meter
6-Meter
8.54-Meter
10-Meter
15-Meter
Extension and Retraction Performance (See Note Below)
Approximate Extension
Time (Powered, 28 VDC)
< 35
seconds
< 60
seconds
< 85
seconds
< 100
seconds
< 150
seconds
Approximate Extension
Time (Manual)
< 110
seconds
< 180
seconds
< 270
seconds
< 320
seconds
< 740
seconds
Approximate Retraction
Time (Powered, 28 VDC)
< 35
seconds
< 60
seconds
< 85
seconds
< 100
seconds
< 150
seconds
Approximate Retraction
Time (Manual)
< 110
seconds
< 180
seconds
< 270
seconds
< 320
seconds
< 740
seconds
Maximum Tilt From Vertical (See Note Below)
Operational
10°
10°
10°
10°
5°
Maximum Altitude Above Sea Level
Operational
4572 m
(15,000 feet)
4572 m
(15,000 feet)
4572 m
(15,000 feet)
4572 m
(15,000 feet)
4572 m
(15,000 feet)
Temperature Performance (See Note Below)
Operating Temperature
Range
-51°C to 60°C (-60°F to 140°F)
Storage Temperature
Range
-51°C to 70°C (-60°F to 158°F)
Airborn Noise Emissions (measured according to EN ISO 3744:2010)
Deploying & Retracting
A-weighted sound pressure level: 71 dB(A)
C-weighted instantaneous pressure level: 72 dB
A-weighted sound power level: 79 dB(A)
Guying
Is guying required?
No
Is guying an option?
Yes. Consult factory.
Continued
* Note:
•Dimensions and specifications are provided for reference only and are not intended for vehicle design
purposes.
•Specifications may be subject to change without notice.
•Maximum payload weight will impact other performance specifications. Consult The Will-Burt Company
for additional information.
•Manual extension and retractions times assume estimated manual crank speed of 1.5 meters per minute
•Maximum Tilt from Vertical assumes the rated payload.
•Typical Payload Sail Area (CD = 1.5) is as follows:
o4-meter Stiletto AL: 1.58 square meters (17 square feet)
o6-meter Stiletto AL: 1.11 square meters (12 square feet)
o8.54-meter Stiletto AL: 1.02 Square meters (11 square feet)
o10-meter Stiletto AL: 1.02 Square meters (11 square feet)
o15-meter Stiletto AL: 0.74 square meters (8 square feet)
Consult factory for larger sail areas, as the payload and wind capacities may be reduced.