Will Burt 7-30 HDL User manual

Pneumatic Mast with Remote Locking System
Operating Instructions
(Heavy Duty, Super Heavy Duty, and Ultra Heavy Duty Models)
The Will-Burt Company
401 Collins Blvd
Orrville, OH 44667, USA
Phone: [phone]
E-Mail: [email protected]
Website: www.willburt.com
TP-5580101-A, February 2022
© 2022 The Will-Burt Company
Original Instructions
Authorized Representative:
Will-Burt Germany GmbH & Co. KG
Fischergasse 25
D-91344 Waischenfeld, Germany
(2.7-15m UHD RLS P/N: 710991590 Shown)

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PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM
OPERATING INSTRUCTIONS
TP-5580101-A
FEBRUARY 2022
Warranty
Will-Burt warrants its Pneumatic Mast with Remote Locking 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 NONINFRINGEMENT 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.

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PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM
OPERATING INSTRUCTIONS
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Contents
1 Safety Summary................................................................................................... 5
1.1 Signal Word Definitions............................................................................................. 5
1.2 Safety Instructions .................................................................................................... 5
1.3 Symbols Used on Product Labels........................................................................... 13
2 Specification Compliance ................................................................................. 15
2.1 CE Declaration of Conformity ................................................................................. 15
3 Introduction........................................................................................................ 17
3.1 Intended Use........................................................................................................... 18
3.2 Definition of Terms and Abbreviations .................................................................... 18
3.3 Major Components.................................................................................................. 19
3.3.1 Telescoping Mast.......................................................................................... 20
3.3.1.1 Hardware Bag (P/N: 902853 or 5032501)............................................. 22
3.3.1.2 Drain Kit (P/N: 902982) ......................................................................... 24
3.3.1.3 Magnetic Warning Kit ............................................................................ 25
3.3.1.4 Hold Down Leash.................................................................................. 27
3.3.1.5 Mast Top Cover (P/N: 902989 or 5063501) .......................................... 27
3.3.1.6 Identification Plate (P/N: 902851) ......................................................... 28
3.3.1.7 Label Kit (English) ................................................................................. 28
3.3.2 Control System ............................................................................................. 29
3.3.3 Pneumatic System Options (Sold Separately).............................................. 31
3.3.4 Mounting Hardware Options (Sold Separately) ............................................ 32
3.3.4.1 Base Plate Options ............................................................................... 32
3.3.4.2 Support Bracket Options ....................................................................... 35
3.3.4.3 Shelf Bracket......................................................................................... 40
3.3.5 Payload Platform and Stub Adaptor Options (Sold Separately) ................... 40
3.3.6 Guy Line Options (Sold Separately) ............................................................. 43
3.3.7 Additional Accessory Options (Sold Separately) .......................................... 44
4 Technical Data.................................................................................................... 45
4.1 Specifications for all Pneumatic Masts with Remote Locking Systems .................. 45
4.2 Heavy Duty Locking Masts ..................................................................................... 46
4.3 Super Heavy Duty Locking Masts........................................................................... 48
4.4 Ultra Heavy Duty Locking Masts............................................................................. 50
4.5 Installation Specifications........................................................................................ 52
4.5.1 Mast Installation Specifications .................................................................... 53
4.5.2 Non-Rotating Base Plate Installation Specifications ..................................... 57
4.5.3 Rotating Base Plate Installation Specifications............................................. 59
4.5.4 Turning Handle Assembly Installation Specifications ................................... 60
4.5.5 Support Bracket Assembly Installation Specifications .................................. 61
4.5.6 Internal Mounting Kit Installation Specifications............................................ 65
4.5.7 Shelf Bracket Assembly Installation Specifications....................................... 68
4.5.8 Control Box Installation Specifications.......................................................... 70
5 Installation.......................................................................................................... 71
5.1 Pre-Installation Check............................................................................................. 71
5.2 Installation Equipment............................................................................................. 72
5.3 Installation Hardware .............................................................................................. 73
5.4 Lift the Mast System ............................................................................................... 78
5.5 Unpack the Mast System ........................................................................................ 78

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5.6 Mast Installation External Mount............................................................................. 81
5.6.1 External Mount Quick Summary ................................................................... 82
5.6.2 External Mount Detailed Instructions ............................................................ 83
5.6.2.1 Select a Suitable Mounting Location..................................................... 83
5.6.2.2 Install the Shelf Bracket (Optional)........................................................ 84
5.6.2.3 Attach the Base Plate to the Mast......................................................... 85
5.6.2.4 Position the Mast................................................................................... 86
5.6.2.5 Install the External Support Bracket...................................................... 86
5.6.2.6 Secure the Base Plate to the Mounting Surface ................................... 93
5.6.2.7 Install the Turning Handles (Rotatable Mast Systems Only)................. 94
5.7 Mast Installation: Internal Mount ............................................................................. 95
5.7.1 Internal Mount: Quick Summary ................................................................... 96
5.7.2 Internal Mount Detailed Instructions ............................................................. 97
5.7.2.1 Select a Suitable Mounting Location..................................................... 97
5.7.2.2 Begin Installation of the Internal Mounting Kit....................................... 98
5.7.2.3 Lower Mast through the Internal Mounting Kit .................................... 102
5.7.2.4 Attach the Base Plate to the Mast....................................................... 102
5.7.2.5 Position the Mast................................................................................. 103
5.7.2.6 Secure the Base Plate to the Mounting Surface ................................. 103
5.7.2.7 Complete Installation of the Internal Mounting Kit............................... 104
5.8 Install the Control and Pneumatic Systems .......................................................... 108
5.8.1 Control and Pneumatic Systems Installation Quick Summary.................... 108
5.8.2 Control and Pneumatic Systems Installation Detailed Instructions............. 109
5.8.2.1 Install the Drain and Relief Fittings ..................................................... 109
5.8.2.2 Install the Air Supply ........................................................................... 111
5.8.2.3 Install the Control Box ......................................................................... 112
5.8.2.4 Connect the Air Supply to the Control Box.......................................... 113
5.8.2.5 Connect the Control Box to the Mast .................................................. 114
5.8.2.6 Exhaust the Control Box (Optional)..................................................... 115
5.8.2.7 Connect the HHRC to the Control Box (Optional Installation)............. 116
5.8.2.8 Connect Customer Power to the Control Box ..................................... 118
5.9 Install the Drain Kit................................................................................................ 119
5.10 Install the Magnetic Warning Kit ......................................................................... 121
5.11 Additional Accessory Installation ........................................................................ 125
5.12 Test the Installation............................................................................................. 125
5.13 Install Payload..................................................................................................... 126
6 Operation.......................................................................................................... 127
6.1 Pre-Operation Check ............................................................................................ 127
6.2 Operation Equipment ............................................................................................ 128
6.3 Mast System Operation ........................................................................................ 128
6.3.1 Prepare the System .................................................................................... 129
6.3.2 Extend the Mast.......................................................................................... 129
6.3.2.1 Partial Extension Applications............................................................. 130
6.3.2.2 Mast Extension Procedures ................................................................ 132
6.3.3 Lower the Mast ........................................................................................... 135
7 Transportation.................................................................................................. 137
7.1 General Transportation ......................................................................................... 137
7.2 Shipping ................................................................................................................ 138
8 Maintenance and Adjustments....................................................................... 139

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PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM
OPERATING INSTRUCTIONS
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8.1 Pre-Maintenance Check ....................................................................................... 139
8.2 Maintenance Equipment ....................................................................................... 140
8.3 Replacement Parts ............................................................................................... 141
8.4 Periodic Maintenance ........................................................................................... 141
8.4.1 Mast Cleaning and Lubrication ................................................................... 142
8.4.2 Weatherizing ............................................................................................... 144
8.5 Special Procedure: Reed Switch Adjustment ....................................................... 145
8.6 Long-Term Storage............................................................................................... 145
8.7 System Disposal ................................................................................................... 145
9 Troubleshooting............................................................................................... 147
10 References...................................................................................................... 149
10.1 Extended Glossary of Terms .............................................................................. 149
10.1.1 General Terms and Abbreviations ............................................................ 149
10.1.2 Mounting Position Terms .......................................................................... 151
10.2 Drawings ............................................................................................................. 151
10.3 System Wiring Diagram ...................................................................................... 151
10.4 Mast Wind Load Capacity ................................................................................... 153
10.4.1 Catalog Model 7-30 HDL .......................................................................... 154
10.4.2 Catalog Model 7-42 HDL .......................................................................... 155
10.4.3 Catalog Model 10-60 HDL ........................................................................ 156
10.4.4 Catalog Model 9-50 SHDL ........................................................................ 157
10.4.5 Catalog Model 10.3-60 SHDL ................................................................... 158
10.4.6 Catalog Model 8-39 UHDL........................................................................ 159
10.4.7 Catalog Model 11.3-59 UHDL................................................................... 160
10.4.8 Catalog Model 3-20M UHDL..................................................................... 161
10.4.9 Catalog Model 14.3-80 UHDL................................................................... 162
11 Document History.......................................................................................... 163

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PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM
OPERATING INSTRUCTIONS
TP-5580101-A
FEBRUARY 2022
1 Safety Summary
This section describes safety instructions for the Pneumatic Mast with Remote Locking System
that personnel must understand and apply throughout all product activities such as
transportation, handling, installation, operation, 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 or equipment damage. 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.

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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.
Read Operating Instructions! Read and observe the operating instructions. Non-observance of
the instructions, operation which is not in accordance with use as prescribed in the instructions,
wrong installation or incorrect handling can seriously affect the safety of operators and
machinery. Adhere to the safety instructions when carrying out any activity relating to the
Pneumatic Mast with Remote Locking System.

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OPERATING INSTRUCTIONS
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Trained Personnel Only! This product is intended for use by trained professionals only. It is not
intended for general use by the public or untrained personnel. Handling, installation, operation
and maintenance to be performed by trained and authorized personnel only. Only a properly
trained and qualified certified electrician should perform electric installations and service.
Erratic Mast Operation Impact Hazard! The mast should operate smoothly during extension
and retraction. If erratic mast motion is observed during extension or retraction that results in
impact loading between the tube and the tube collar (mechanical travel stop), cease use of the
mast and contact The Will-Burt Company service department. Repeated operation with impact
loading can damage tubes and lead to mast separation.
Over-current Protection! Over-current protection or power switching by the installer on mast
incoming power supply as specified in this document should be a type suitable to allow lock-out
tag-out procedures for power disconnect.
Safety Instruction - Explosion! For outdoor use only. Do not use in explosive areas or areas
that have been classified as hazardous as defined in Article 500 of the National Electric Code or
equivalent national standards. Do not use in the presence of flammable gases or liquids such as
paint, gasoline or solvents. Do not use in areas of limited ventilation or where high ambient
temperatures are present.
Safety Equipment (PPE)! Proper personal protective equipment (PPE) like hard hats, gloves,
and safety shoes shall be properly worn while working on mast or near the deployment area of
mast. In addition, eye protection shall be worn during maintenance procedures. Follow national
PPE guidelines in your area of operation.
Pinch Point Hazard! Keep clear of all moving parts like mast collars nesting. Be sure to stay
clear of system during operation. Moving parts can crush and cut resulting in serious injury. The
mast shall be mounted out of reach of the operator during operation.
Crush Hazard - Mast Failure! Do not stand directly beneath mast or its payload. Be certain the
payload is properly installed and secured.
Entanglement Hazard! Tangled cables can cause equipment damage. Ensure payload cables,
Nycoil®, trip lines, guy lines or other cables are not tangled and are free to pay out as mast is
deployed. Cables that get tangled or snagged on mast or other objects can cause mast tubes to
lurch upward suddenly when the cable is freed. This can cause damage to mast and lead to mast
separation if repeatedly allowed to continue.

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Health and Safety Hazard while Cleaning! Solvent used to clean parts is potentially
dangerous. Avoid inhalation of fumes and prolonged contact to skin.
Fire Hazard Solvent! Cleaning solvent, used for maintenance, is flammable and can be
explosive. Do not smoke near solvent. Use cleaning solvent in a well-ventilated area. Keep
cleaning solvent away from ignition sources. Always store cleaning solvent in the proper marked
container and in a proper location.
Bright Light Radiation Hazard! For systems equipped with scene lighting or look-up lights, do
not look directly into lights when they are illuminated. Temporary impairment or permanent vision
damage could occur.
Personnel Freezing/Burn Hazard! If the system is equipped with lights, make sure the lights are
completely cool before attempting to clean the lens, replace bulbs or perform maintenance. Wear
gloves to protect from contact with exposed metal that may be at extremes of hot and cold
temperatures from sun or cold outdoor exposure.
Mast Extension Hazard - Obstruction! Extending mast into obstructions could result in death or
serious injury and could render mast inoperable and partially extended. Before applying power
and operating 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 mast. Locate the operator station such that the operator has
a clear view of the operating space of mast and payload prior to deployment to avoid contact with
overhead objects.
Manual Retraction! For powered masts, make sure all power sources have been disconnected
from the system prior to manually lowering mast to avoid unexpected start-up motion and/or
damage to mast.
Mast Lifting/Handling! Use extreme caution while lifting mast System and when mast System is
suspended to avoid injury and equipment damage. Be certain mast is properly secured using at
least two sling points at the center of gravity label. 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.
Remove Payload! For mast systems shipped with no payload (customer installed payloads),
remove payload before performing maintenance on mast system. The Will-Burt Company
installed devices can remain installed.

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Equipment Damage - Submerged! Do not submerge mast in liquid or operate the vehicle in a
fording situation that would result in a submerged mast.
Safety Instruction – Keep Clear! Keep personnel clear of the system during operation.
Safety Instruction - Potential Air Contaminants! If internally mounted in a vehicle, air from
mast and any accumulated water will discharge into the vehicle. Install appropriate drainage and
venting.
Fastener Vibration Hazard! Mast system and payload mounting hardware must include proper
means to resist vibration loosening such as thread-locking compound, locking hardware, or
equivalent. Use specified assembly torques appropriate for the fastener size.
Frozen Water Hazard! Water freezing inside mast or air fittings may render mast inoperable and
cause major equipment damage such as tube deformation. Ensure water is free to exit at the
base of mast. Open drain cock when mast is not in operation. The drain cock shall be installed at
the lowest position in the pneumatic system. If mounted internally in a vehicle or structure, direct
the draining water to a suitable location. Cover locking masts when not in use to limit water
ingress. Non-locking masts stored outdoors should be covered if possible. A cover is available
from The Will-Burt Company.
Safety Instruction - Guy Anchors! For masts using Guy Lines, verify the Guy Anchor point
strength is adequate to support the Guy Line forces.
Lubrication! Do not lubricate the exterior of mast moving tubes. The lubricant will attract dust
and other environmental contaminants into mast.
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 - Support Bracket! For masts using an upper support bracket, do not
over-tighten mast support bracket. Over-tightening may damage the Base Tube causing mast
tubes to stick.
Mast and Payload Access! The operator must provide safe means to access mast and payload
during installation, removal and maintenance.

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Tripping Hazard! Cables, trip lines, guy lines and guy anchors can be hard to see during and
after installation. Any equipment posing trip hazards should be clearly marked.
Lifting Hazard! Manually lifting over 55 lb. (25 kg) is prohibited. In the UK, all lifting equipment
must be thoroughly examined annually by a competent person according to the Lifting
Operations and Lift Equipment Regulations 1998. Equivalent regulations exist in other EU states.
Safety Instruction – Roof Access! If the mast will be mounted to a vehicle, the operator must
provide a safe means to access the roof of the vehicle during installation and maintenance.
Pressurized Device Hazard! Mast disassembly prior to depressurization may release
pressurized air jet. Completely lower the mast, depressurize and shut down power before
disassembly. Ensure an over-pressurization safety valve is installed in the system.
Safety Instruction – Remote Control! The equipment is subject to remote control and may be
operated at any time. Persons working on the equipment should take appropriate precautions to
ensure that any unexpected movement does not occur as this could lead to injury.
Safety Instruction – Lightning! Lightning protection is not part of this system. A proper means
of electrical grounding should be provided. Failure to observe this warning could result in death
or serious injury.
Crush Hazard – Hoist Failure! Use extreme caution while installing the base plate to the mast.
Be certain mast is properly secured during installation of base plate. Death or serious injury could
occur if hoist fails or mast slips suddenly.
Safety Instruction – Operation! At all times prior to mast operation, ensure:
• The mast area is free of personnel and mechanical obstruction
• Be certain mast is level, stable, and secure before and during installation, operation,
maintenance, and transportation. Operate on level ground only.
• Any transit tie-downs on the payload have been removed
• Before operating, the base section shall be within:
• 5° of vertical for Heavy Duty masts with extended heights ≤ 60 feet
• 3° for all Super Heavy Duty masts
• Ultra Heavy Duty masts: Before operating, the base tube for masts extended up to 60 feet
(18.2 m) shall be within:
• 5° of vertical for payloads 200 lb. (90.7 kg) or less
• 4° of vertical for payloads 200 lb. to 800 lb. (90.7 kg to 362.9 kg)
• 2° of vertical for payloads 800 lb. to 1,200 lb. (362.9 kg to 544.3 kg)
• Ultra Heavy Duty masts: Before operating, the base tube for masts extended 60 ft. to 80 ft.
(18.2 m to 24.4 m) shall be within:

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• 4° of vertical for payloads 600 lb. (272.2 kg) or less
• 1° of verticals for payloads 600 lb. to 1,200 lb. (272.2 kg to 544.3 kg)
All values assume a maximum of 12 inch (30.5 cm) payload offset. If offsetting any payload
greater than 600 lb. (272 kg), the payload offset direction must be in-line with the tube keys, and
not perpendicular to the keys.
Burst Hazard! Over-pressurizing mast will trip safety valve and could result in death or serious
injury. Do not exceed maximum operating pressure of 35 psi (241 kPa) for Heavy Duty, Super
Heavy Duty, and Ultra Heavy Duty masts. Keep personnel clear of safety valve exhaust direction.
Safety Instruction – Mast Access! The operator must provide safe means to access the top of
the mast during installation and removal of the payload.
Safety Instruction – Hose Installation! At all times while using pipe and hose during
installation, recognize that:
• Pipe and hose should be routed, mounted and restrained to protect from damage
• Do not use second hand piping for installation. Use piping adhering to regional standards.
• Do not bend air pipe and hose at a radius less than specified by the manufacturer
• Pipes should be marked to avoid hazards from incorrect connection
• The exhaust should be fitted with a silencer and be directed away from personnel
• When routing piping, install in such a way as to minimize torsion on the joints
• Mounting of air pipe and hose shall be done with tools and in such a way to prevent air pipe
and hose from easily disconnecting from the mast
Safety Instruction – Air Control Valve! Improper positioning and operation of air control valve
can result in moderate injury or equipment damage. Air control valve must be mounted in a
location where the operator has full view of the mast and mast operating space but does not
make contact with the mast during operation (except for yokes). Only use a Hold-To-Run type air
control valve or switch. The air control valve shall be normally open to atmosphere when the
mast is in transit or not in use.
Drain Valve Kit Installation! Failure to follow Drain Kit installation instructions could damage the
mast and render the mast inoperable. Read and understand the installation instructions before
installing the Drain Kit.
Equipment Damage – Band Clamp Fasteners! Do not overtighten the band clamp fasteners.
Overtightening may damage the base tube causing the mast tubes to stick.
Equipment Damage – Deviation! Deviation from standard operating conditions and procedures
could cause system failure.

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Safety Instruction - Motion on Power Interruption or Emergency Stop! When using a
normally open control valve as required for vehicle applications, if power is lost or turned off or
the emergency stop is activated while the mast is extended, the mast will begin releasing air
pressure and retracting at a controlled rate until power is restored or the mast fully retracts.
Safety Instruction – Insufficient Mast Lock! Ensure all mast sections are locked prior to
removing air from the mast. One unlocked section will result in all mast sections above it
retracting back into the nested position.
Safety Instruction – Lock Adjustment! Do not adjust the lock hardware. Doing so can cause
the mast lock to fail, resulting in mast retraction. Adjusting the lock hardware removes the
warranty.
Safety Instruction – Hold Down Leash! To partially deploy the mast, use the hold down leash
to tether the tubes to the mast payload platform. Do not use the hold down leash cable to secure
mast sections to the base tube during operation. This causes the mast to fully retract after air is
removed.
Safety Instruction - Guy Lines! For masts using guy lines, do not overtighten guy lines or
tension them unevenly.
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
• 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

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1.3 Symbols Used on Product Labels
The following symbols are displayed on the product. The symbol meanings are as follows:
This symbol indicates an electrocution hazard or hazardous voltage hazard.
There is voltage present inside mast and control box. Do not operate mast
near electrical lines or during electrical storms. 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, handling, installation, maintenance, operation and
decommissioning. 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. Water must be permitted to exit mast to avoid ice
damage to mast.
This symbol indicates a burst hazard. The mast contains air pressure. Never
install the mast without installing the overpressure safety valve. Never
operate the mast above the maximum rated pressure.
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
operating instructions before handling, installing, operating, or maintaining the
mast system.
This symbol indicates an electrical ground connection point.
This symbol is used to indicate the center of gravity (COG) of a fully nested
mast in a horizontal transport position.

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PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM
OPERATING INSTRUCTIONS
TP-5580101-A
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PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM
OPERATING INSTRUCTIONS
TP-5580101-A
FEBRUARY 2022
2 Specification Compliance
2.1 CE Declaration of Conformity
Refer to the Product page at www.willburt.com for the latest Declaration of Conformity.
The Pneumatic Mast with Remote Locking System conforms to CE standards when used with a
CE approved control system.

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PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM
OPERATING INSTRUCTIONS
TP-5580101-A
FEBRUARY 2022

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PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM
OPERATING INSTRUCTIONS
TP-5580101-A
FEBRUARY 2022
3 Introduction
Thank you for selecting The Will-Burt Company for your critical payload elevation needs. These
operating instructions describe the installation, operation, transportation, maintenance, storage,
and troubleshooting procedures for the Pneumatic Mast with Remote Locking System (Heavy
Duty, Super Heavy Duty, and Ultra Heavy Duty models). These procedures assume the use of
standard catalog mast systems with a clear anodized finish. Procedures and characteristics for
mast systems customized to meet customer-specific needs may vary. Review this document 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.
The Pneumatic Mast with Remote Locking System comprises of:
• Telescoping mast
• Control System
• Pneumatic System (Sold Separately)
• Mounting Hardware (Sold Separately)
• Additional Accessory Options (Sold Separately)
The Pneumatic Mast with Remote Locking System is available in the following models:
• Heavy Duty Locking Pneumatic Masts
• Super Heavy Duty Locking Pneumatic Masts
• Ultra Heavy Duty Locking Pneumatic Masts
This manual is not for:
• Non-Locking Pneumatic Masts
• Standard Duty Pneumatic Masts
• Pneumatic Masts without the Remote Locking System
Note: Model numbers listed 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.

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PNEUMATIC MAST WITH REMOTE LOCKING SYSTEM
OPERATING INSTRUCTIONS
TP-5580101-A
FEBRUARY 2022
3.1 Intended Use
The Pneumatic Mast with Remote Locking System is intended for use by professionals in the fire/
rescue/first responder/security/towing/cellular industries to provide elevated and directional
emergency scene lighting and surveillance or communication capabilities. It is not intended for
use by non-professionals. Do not use the mast to lift personnel. The Pneumatic Mast with
Remote Locking System is intended to be installed on fire/rescue/towing first responder vehicles
with the magnetic warning kit installed and operational.
The Pneumatic Mast with Remote Locking System is intended to be used only when the vehicle
is stationary and the vehicle parking brake is properly applied. Do not supply input supply voltage
or operate the mast system when the vehicle is in motion. The mast shall remain in the powered-
down, nested position during vehicle motion. Contact The Will-Burt Company with any questions
on the intended use or available training programs for installation and operation.
3.2 Definition of Terms and Abbreviations
Throughout this manual, the following terms are used.
General Terms:
• HD stands for Heavy Duty
•Mast refers to the telescoping Pneumatic Mast
•Mast System refers to the entire Pneumatic Mast system (telescoping mast, control system,
pneumatic system, mounting hardware, and additional accessories)
•Payload refers to the object or equipment being raised by the mast to an operational height
•RLS stands for Remote Locking System
•SHD stands for Super Heavy Duty
•UHD stands for Ultra Heavy Duty
See Section 10.1 for an Extended Glossary of Terms used within this manual. The Extended
Glossary of Terms includes:
• General Terms and Abbreviations (Section 10.1.1)
• Mounting Position terms (Section 10.1.2)