Thern ENSIGN 500 User manual

Read this Owner’s Manual
thoroughly before operating
the equipment. Keep it with
the equipment at all times.
Replacements are available
from Thern, Inc.,
5712 Industrial Park Road,
Winona, MN 55987,
507-454-2996.
www.thern.com
Owner’s Manual
For
5PA5 Ensign Series
Portable Davit Cranes
IMPORTANT: Please record
product information on
page 2. This information is
required when calling the
factory for service.
ORIGINAL TEXT
A11577B-0613

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranespage 2
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Two-Year Limited Warranty
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 com-
plete 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
modification 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 INCIDEN-
TAL OR CONSEQUENTIAL DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY ON
THIS PRODUCT. EXCEPT TO THE EXTENT PROHIBITED BY APPLICABLE LAW, ANY IMPLIED WAR-
RANTY 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 specific 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
responsibility 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 owner's respon-
sibility to obtain copies of these regulations and to determine the suitability of the
equipment to its intended use.
This Owner’s Manual, and warning labels attached to the equipment, are to serve
as guidelines for hazard-free installation, operation, and maintenance. They
should not be understood to prepare you for every possible 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
information for any other equipment.
The following symbols are used for emphasis throughout this manual:
Failure to follow ‘WARNING!’ instructions may result in equipment damage,
property damage, and/or serious personal injury.
Failure to follow ‘CAUTION!’ instructions may result in equipment damage,
property damage, and/or minor personal injury.
Important!
Failure to follow ‘important!’ instructions may result in poor performance of
the equipment.
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.

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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 equip-
ment 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 sys-
tem. 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.
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.

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Important!
• A qualified professional should
inspect or design the founda-
tion to insure that it will provide
adequate support.
• Locate the crane so it will be vis-
ible during the entire operation.
1.1 Installing the Crane
Do not install the crane in an area defined 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, flammable materials, ex-
plosives, 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 specific
rules on installing the equipment.
1.1.2 LOCATE THE CRANE in an area clear of traffic 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.
aMAKE 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.
bFOR 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 specific torque or installation instructions.
cNON-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 PROFES-
SIONAL TO OBTAIN PROPER STRUCTURE OR FOUNDATION SPECIFI-
CATIONS FOR THE MOUNTING OF THERN PRODUCTS.
Pedestal Wall-Mount
Base Only Base Only
Crane Mast Suggested Axial Force2Axial Force2Shear Force
Model Moment1Bolt Size Per Bolt Per Bolt Per Bolt
5PA5 9410 in-lb 1/2 inch 880 lb 680 lb 540 lb
1Mast moment includes the weight of the crane and winch.
2Force in tension
Table 1 – Crane Reactions

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BOOM
MAST
WINCH MOUNTING PLATE
ROTATION HANDLE
SHEAVE ASSEMBLY
COMPONENTS IN SHIPPING CARTON
FLANGE BEARING
Important!
• Inspect the crane during assembly
according to the Instructions for
Periodic Inspection. This will
give you a record of the condition
of the crane with which to com-
pare 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 damaged.
• Do not overtighten fasteners, this
may strip threads or cause dam-
age to other parts.
1.2 Assembling the Crane
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.
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.
e
FASTEN THE BOOM to the mast using the clevis pin and clevis end pins
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.
Figure 1 – Crane Packaging