Thern ENSIGN 500, 5PA5G, 5PA5 Ensign Series, 5PA5S316, 5PA5M1 Owner's Manual

Read this Own er’s Man u al
thor ough ly be fore op er at ing
the equip ment. Keep it with
the equip ment at all times.
Re place ments are avail able
from Thern, Inc.,
5712 Industrial Park Road,
Winona, MN 55987,
507-454-2996.
www.thern.com

IMPORTANT: Please record
product information on
page 2. This information is
re quired when calling the
fac to ry for service.

ORIGINAL TEXT

A11577B-0613

Owner’s Man ual

For
5PA5 Ensign Series
Portable Davit Cranes

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranespage 2

Two-Year Limited Warranty

Please record the following:

Date Purchased:

Crane Model No.:

Crane Serial No.:

If sold with a winch:

Winch Model No.:

Winch Serial No.:

This information is required when
calling the factory for service.

Thern, Inc. warrants its products against defects in material or workmanship for two years from the date of purchase
by the original using buyer, or if this date cannot be established, the date the product was sold by Thern, Inc. to the
dealer. To make a claim under this warranty, contact the factory for an RGA number. The product must be returned,
prepaid, directly to Thern, Inc., 5712 Industrial Park Road, Winona, Minnesota 55987. The following information
must accompany the product: the RGA number, the date of purchase, the description of the claimed defect, and a com­plete explanation of the circumstances involved. If the product is found to be defective, it will be repaired or replaced
free of charge, and Thern, Inc. will reimburse the shipping cost within the contiguous USA.

This warranty does not cover any damage due to accident, misuse, abuse, or negligence. Any alteration, repair or
modifi cation of the product outside the Thern, Inc. factory shall void this warranty. This warranty does not cover any
costs for removal of our product, downtime, or any other incidental or consequential costs or damages resulting from
the claimed defects. This warranty does not cover brake discs, wire rope or other wear components, as their life is
subject to use conditions which vary between applications.

FACTORY AUTHORIZED REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS WARRANTY IS THE
EXCLUSIVE REMEDY TO THE CONSUMER. THERN, INC. SHALL NOT BE LIABLE FOR ANY INCIDEN­TAL OR CONSEQUENTIAL DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY ON
THIS PRODUCT. EXCEPT TO THE EXTENT PROHIBITED BY APPLICABLE LAW, ANY IMPLIED WAR­RANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ON THIS PRODUCT IS
LIMITED IN DURATION TO THE DURATION OF THIS WARRANTY.

Some states do not allow the exclusion or limitation of incidental or consequential damages, or allow limitations on
how long an implied warranty lasts, so the above limitation or exclusion may not apply to you. This warranty gives
you specifi c legal rights, and you may also have other rights which vary from state to state.

Note: Thern, Inc. reserves the right to change the design or discontinue the production of any product without
prior notice.

About This Manual

The Occupational Safety and Health Act of 1970 states that it is the employer’s
re spon si bil i ty to provide a workplace free of hazard. To this end, all equipment
should be installed, operated, and maintained in compliance with applicable trade,
industrial, federal, state, and local regulations. It is the equipment own er's re spon ­si bil i ty to ob tain copies of these regulations and to determine the suit abil i ty of the
equip ment to its intended use.

This Owner’s Manual, and warning labels attached to the equip ment, are to serve
as guidelines for hazard-free installation, op er a tion, and maintenance. They
should not be understood to prepare you for every pos si ble situation.

The information contained in this manual is applicable only to the Thern 5PA5
Ensign Series Portable Davit Cranes. Do not use this manual as a source of
in for ma tion for any other equip ment.

The following symbols are used for emphasis throughout this man u al:

Failure to follow ‘WARNING!’ instructions may result in equipment dam age,
property damage, and/or serious personal injury.

Failure to follow ‘CAUTION!’ instructions may result in equipment damage,
prop er ty damage, and/or minor personal injury.

Important!

Failure to follow ‘important!’ instructions may result in poor per for mance of
the equipment.

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Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranes page 3

Suggestions for Safe Operation

DO the following:

Read and comply with the guidelines set forth in this Owner’s Manual. Keep
this manual, and all labels attached to the crane, readable and with the equip­ment at all times. Contact Thern, Inc. for replacements.

Check lubrication before use.

Install the wire rope securely to the winch drum.

Keep at least 4 wraps of wire rope wound on the drum at all times, to serve as
anchor wraps. With less than 4 wraps on the drum the wire rope could come
loose, causing the load to escape.

Keep hands away from sheaves, gears, wire rope, and other moving parts.

Disconnect electric power before servicing the equipment.

Keep all unnecessary personnel away from crane while in operation.

Keep out of the path of the load, and out of the path of a broken wire rope
that might snap back and cause injury.

DO NOT do the following:

Do not lift people, or things over people. Do not walk or work under a load or
in the line of force of any load.

Do not exceed the load rating of the crane or any other component in the sys­tem. To do so could result in failure of the equipment.

Do not use more than one crane to move a load that exceeds the load rating of
a single crane. A shift in load weight could overload the equipment.

Do not use damaged or malfunctioning equipment. To do so could result in
failure of the equipment.

Do not modify the equipment in any way. To do so could cause equipment failure.

Do not wrap the wire rope around the load. This damages the wire rope and
could cause the load to escape. Use a sling or other approved lifting device.

Do not operate the crane with guards removed or improperly installed.

Do not divert your attention from the operation. Stay alert to the possibility of
accidents, and try to prevent them from happening.

Do not jerk or swing the load. Avoid shock loads by starting and stopping the
load smoothly. Shock loads overload the equipment and may cause damage.

Do not use the crane and winch components for any use other than for their
original intended function.

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Do not use the crane to drag or pull loads. This will create side pulls, which
could damage the equipment or cause the load to tip.

Do not leave a suspended load unattended. Place the load on the ground if it
must be left unattended.

Do not adjust the winch brake with the load suspended.

Do not operate the crane without all pins securely in place.

Do not adjust the sheave position or boom angle while the crane is loaded.

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranespage 4

1.1 Installing the Crane

Important!

• A qualifi ed professional should
inspect or design the founda­tion to insure that it will provide
adequate support.

• Locate the crane so it will be vis­ible during the entire op er a tion.

Do not install the crane in an area defi ned as hazardous by the National Electric
Code, unless installation in such an area has been thoroughly approved.

Do not install the crane near corrosive chemicals, fl ammable materials, ex­plosives, or other elements that may damage the crane or injure the operator.
Adequately protect the crane and the operator from such elements.

Position the crane so the operator can stand clear of the load, and out of the
path of a broken wire rope that could snap back and cause injury.

Attach the crane to a rigid and level foundation that will support the crane
and its load under all load conditions, including shock loading.

1.1.1 CONSULT APPLICABLE CODES AND REGULATIONS for specifi c

rules on installing the equipment.

1.1.2 LOCATE THE CRANE in an area clear of traffi c and obstacles that could

interfere with operation. Make sure the crane is accessible for maintenance
and operation.

1.1.3 INSTALL THE CRANE on a level surface. An uneven surface may cause

the boom to rotate in the direction the mast is leaning.

1.1.4 FASTEN THE BASE securely to the foundation to withstand applicable

overturning moments and mounting bolt reaction. See Table 1.

a MAKE SURE mounting holes are secured to a solid foundation able to sup-

port the crane and the load under all conditions with design factors based on
accepted engineering practices.

b FOR STANDARD PRODUCTS referred to in this manual, use 1/2 - inch

coarse thread fasteners, grade 5 or better. Recommended torque for Grade 5
bolts without lubrication is 75 ft lb. Refer to manufacturer’s instructions for
other fastener types with specifi c torque or installation instructions.

c NON-STANDARD PRODUCTS that vary from the original design may

have different fastening requirements. Contact a structural engineer or Thern,
Inc. for this information.

TO COMPLY WITH LOCAL CODES, CONTACT A QUALIFIED PROFES­SIONAL TO OBTAIN PROPER STRUCTURE OR FOUNDATION SPECIFI­CATIONS FOR THE MOUNTING OF THERN PRODUCTS.

Table 1 – Crane Reactions

Pedestal Wall-Mount
Base Only Base Only

Crane Mast Suggested Axial Force2 Axial Force2 Shear Force
Model Moment1 Bolt Size Per Bolt Per Bolt Per Bolt

5PA5 9410 in-lb 1/2 inch 880 lb 680 lb 540 lb

1

Mast moment includes the weight of the crane and winch.

2

Force in tension

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Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranes page 5

BOOM

MAST

WINCH MOUNTING PLATE

ROTATION HANDLE

SHEAVE ASSEMBLY

COMPONENTS IN SHIPPING CARTON

FLANGE BEARING

1.2 Assembling the Crane

Important!

• Inspect the crane during as sem bly
according to the Instructions for
Periodic Inspection. This will
give you a record of the con di tion
of the crane with which to com­pare future inspections.

• Save all boxes and crates that the
crane was shipped in, use them
again if you need to repackage
the crane.

• Contact the factory immediately if
any parts are missing or dam aged.

• Do not overtighten fasteners, this
may strip threads or cause dam­age to other parts.

When installing the mast, ensure the mast is fully and properly seated on the
pin in the bottom of the base.

When installing the boom, hold the boom securely so it does not move abruptly
causing damage or injury.

1.2.1 STUDY PARTS DRAWINGS to understand how the crane is assembled. See

pages 18-19.

1.2.2 LUBRICATE PINS and other components prior to assembly. See Section 3.2

- Lubricating the Crane

1.2.3 INSTALL THE BASE. See Section 1.1 for additional information and crane

overturning moments and mounting bolt reaction forces.

1.2.4 ASSEMBLE THE CRANE in the following order.

a FASTEN THE WINCH to the mounting bracket using the fasteners provided.

Position the winch so the wire rope cable is oriented as shown in Figure 3.

b INSTALL THE MAST in the base. Move the mast side-to-side to make sure

the bottom of the mast properly seats on the pin in the bottom of the base.

The crane will not be stable unless properly seated. See Figure 4.

c INSTALL THE HANDLE onto the mast using the longer clevis pin and

clevis end pins provided. There are three positions for the winch. Locate the
clevis pin and handle for the desired winch position.

Figure 1 – Crane Packaging

d INSTALL THE WINCH onto the mast. Rotate into position and secure with

provided clevis pin and clevis end pins as shown in Figure 4. Make sure the
winch is positioned correctly, with the mast/boom brace plate located on
the opposite side as the winch.

FASTEN THE BOOM to the mast using the clevis pin and clevis end pins

e

provided. Make sure the boom is positioned correctly as shown in Figure 4.

f INSTALL THE SHEAVE ASSEMBLY on the boom in the desired position

for the required hook reach. Secure in place using the clevis pin and clevis
end pins provided. See Figure 4.

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Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranespage 6

MAST

BEARING
ASSEMBLY

BASE

FLANGE
BEARING

MAST / BOOM
BRACE PLATE

WINCH &

HANDLE

SHEAVE
ASSEMBLY

BOOM

BOOM BRACE
ASSEMBLY

ADJUSTMENT
KNOB

MOUNTING
BRACKET

SUPPLIED
HARDWARE

WINCH

WIRE ROPE
DIRECTION

WIRE ROPE

ROPE
KEEPER
PIN

CLEVIS PIN

CLEVIS END PINS

Figure 2 – Sheave

Figure 3 – Mounting Winch

1.2.4 INSTALL THE WINCH HANDLE on hand winches, or connect electric cur-

rent on power winches. Refer to instructions in the Winch Owner’s Manual.

1.2.5 INSTALL THE WIRE ROPE. Use wire rope assemblies in the length

specifi ed on page 22.

a REMOVE ROPE KEEPER PINS at each sheave to allow rope to be

installed.

b PASS THE WIRE ROPE over the sheave at the end of the boom.

c PASS THE WIRE ROPE over the sheave at the mast.

d REINSTALL ROPE KEEPER PINS to prevent the rope from escaping the

sheave rope groove. Make sure the wire rope does not make contact with the
pins. See Figure 2.

e ANCHOR THE WIRE ROPE to the winch drum and wind 4 wraps of wire

rope onto the drum to act as anchor wraps. Refer to the instructions in the
Winch Owner’s Manual.

1.2.6 RAISE THE BOOM into position and secure in place with the boom brace

assembly as shown in Figure 4. Make sure the tip of the boom brace adjust­ment screw is correctly positioned with the mast/boom brace plate.

1.2.7 MAKE SURE ALL CLEVIS PINS ARE PROPERLY INSTALLED with all

clevis end pins in place to prevent components from shifting during use.

1.2.8

ADJUST BOOM ANGLE for the desired reach by turning the boom brace
adjustment knob. Do not make adjustments while crane is loaded. See Figure 4.

Figure 4 – Crane Assembly

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Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranes page 7

2.1 General Theory of Operation

2.1.1 THE INTENDED USE of this machinery is to lift and lower loads of its

Important!

rated capacity or less. It is not for lifting people or things over people.

• Limit non-uniform winding by
keeping tension on the wire rope.

• It is your responsibility to detect
and account for different fac­tors affecting the condition and
per for mance of the equipment.

2.1.2 THE FORCE REQUIRED to lift the load must not exceed the load rating of

the crane. Consider the total force required to lift the load, not the weight of
the load.

2.1.3 THIS EQUIPMENT CAN develop forces that will exceed the load rating.

It is the responsibility of the equipment user to limit the size of the load.
Inspect the equipment regularly for damage according to the instructions
contained in this manual.

2.1.4 PERFORMANCE RATINGS of the equipment are affected by the position

of the boom (hook reach). Crane load ratings decrease as you extend the
reach. See the Performance Characteristics Tables on page 20.

a LOAD RATING represents the maximum force that can be placed on new

equipment. See the Performance Characteristics Tables on page 20

b LIFT varies with the position of the boom and sheave and length of the wire

rope.

c REACH varies with the position of the boom and sheave.

2.1.5 DUTY RATINGS refer to the type of use the equipment is subject to. Con-

sider the following when determining duty rating.

a ENVIRONMENT: harsh environments include hot, cold, dirty, wet, corro-

sive, or explosive surroundings. Protect the equipment from harsh envi-

ronments when possible.

b MAINTENANCE: poor maintenance, meaning poor cleaning, lubrication,

or inspection, leads to poor operation and possible damage of the equipment.

Minimize poor maintenance by carefully following the instructions con­tained in this manual.

c LOADING: severe loading includes shock loading and lifting loads that

exceed the load rating of the equipment. Avoid shock loads, and do not

exceed the load rating of the equipment.

d FREQUENCY OF OPERATION: frequent or lengthy operations increase wear

and shorten the life span of gears, bearings, sheaves, and other components.

Increase maintenance of the equipment if used in frequent operations.

2.1.6 AIRBORNE NOISE EMISSIONS vary depending on load and the type of

winch being used. Standard confi gurations do not typically exceed a sound
pressure level of 80dB(A) at workstations.

2.1.7

VIBRATION LEVELS vary depending on load and type of winch being used.
Standard confi gurations do not typically exceed vibration levels of 2.5 m/s2.

CONTACT THE FACTORY FOR ANY ADDITIONAL INFORMATION.

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Important!

• Start an inspection program as
soon as you put the crane into use.

• Appoint a qualifi ed person to be
responsible for regularly in spect ing
the equipment.

• Keep written records of in­ spec tion. This allows comparison
with com ments from previous in­ spec tions so you can see changes
in condition or per for mance.

Figure 5 – Positioning

the Boom

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranespage 8

2.2 Preparing for Operation

2.2.1 CONSIDER THE OPERATION. Do not begin until you are sure you can

perform the entire operation without hazard.

2.2.2 INSPECT ALL COMPONENTS of the system.

a INSPECT THE CRANE and other equipment according to the Instructions

for Frequent Inspection.

b INSPECT THE WINCH according to the instructions in the Winch Owner’s

Manual.

c OPERATORS must be in good health, alert, thoroughly trained in operat-

ing the equipment, and properly clothed (hard hat, safety shoes and safety
glasses, no loose clothing, etc).

d THE LOAD must be clear of other objects and free to move. Make sure the

load will not tip, spin, roll away, or in any way move uncontrollably.

2.2.3 KNOW YOUR LOAD and make sure you do not exceed the load rating of

the crane or any other equipment in the system.

center line

center line

2.2.4 POSITION THE BOOM so the load hook is centered over the load. Avoid

side pulls which could damage the crane or cause the load to tip. See
Figure 5.

a ADJUST SHEAVE POSITION by moving the sheave assembly up or down

the boom. Do not make adjustments while the crane is loaded. The load rat-

ing decreases as you increase sheave distance from mast. See the Perfor­mance Characteristics Tables page 20.

b ADJUST BOOM ANGLE by rotating the boom adjustment brace knob to

raise or lower the boom. Do not make adjustments while the crane is loaded.
The lift height below base level decreases as you raise the boom. See the

Performance Characteristics Tables page 20.

correct

incorrect

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