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
A11577B-0613
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.

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranes page 3
A11577B-0613
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.

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranespage 4
A11577B-0613
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

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranes page 5
A11577B-0613
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

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranespage 6
A11577B-0613
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
specified 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.
dREINSTALL 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 adjust-
ment 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
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
Figure 3 – Mounting Winch
Figure 2 – Sheave
CLEVIS PIN
CLEVIS END PINS

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranes page 7
A11577B-0613
2.1 General Theory of Operation
2.1.1 THE INTENDED USE of this machinery is to lift and lower loads of its
rated capacity or less. It is not for lifting people or things over people.
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 con-
tained 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 configurations 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 configurations do not typically exceed vibration levels of 2.5 m/s2.
CONTACT THE FACTORY FOR ANY ADDITIONAL INFORMATION.
Important!
• Limit non-uniform winding by
keeping tension on the wire rope.
• It is your responsibility to detect
and account for different fac-
tors affecting the condition and
performance of the equipment.

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranespage 8
A11577B-0613
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.
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 Perfor-
mance 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.
Figure 5 – Positioning
the Boom
center line
center line
correct
incorrect
Important!
• Start an inspection program as
soon as you put the crane into use.
• Appoint a qualified person to be
responsible for regularly inspecting
the equipment.
• Keep written records of in-
spection. This allows comparison
with comments from previous in-
spections so you can see changes
in condition or performance.

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranes page 9
A11577B-0613
2.3 Attaching the Load
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.
2.3.1 CLEAR OBJECTS from the path of the load so you can move it freely and
observe it at all times during the operation.
2.3.2 MAKE SURE THE WIRE ROPE is not twisted. A twisted wire rope could
cause the load to spin when it is raised off the ground.
2.3.3 ATTACH THE LOAD using a nylon sling, or other approved lifting device.
Follow the recommendations of the sling manufacturer.
a SEAT THE SLING in the saddle of the hook with the hook latch completely
closed. See Figure 6.
b CENTER THE LOAD on the hook so it will remain balanced and not tip or
rotate to one side.
2.4 Moving the Load
2.4.1 MOVE THE LOAD slowly and smoothly, only a small distance at first.
Make sure the load is balanced and securely attached before continuing.
2.4.2 OPERATE THE WINCH to raise or lower the load. Refer to the instructions
in the Winch Owner’s Manual.
2.4.3 OBSERVE THE WIRE ROPE as it winds onto the drum. If it becomes
loose, uneven, or overlapped, stop the operation and rewind the wire rope
before continuing. Continued operation with overlapped or uneven wire
rope can damage the wire rope and shorten its life.
2.4.4 ADJUST THE BOOM ANGLE, if necessary, to keep the sheave centered
over the load. Do not make adjustments while the crane is heavily loaded.
2.4.5 ROTATE THE BOOM to move the load side-to-side.
a ROTATE THE BOOM slowly and smoothly to avoid swinging the load or
causing shock loads. Do not jam the boom against other objects.
b USE THE HANDLE to rotate the boom. Do not push or pull the load or
the wire rope to rotate the boom.
Figure 6 – Attaching Load
latch closed
tight against
hook
sling seated in
saddle of hook
Important!
• Obey a stop signal from anyone.
• Maintain tension on the wire
rope to keep it tightly and evenly
wound on the drum.
• If the crane and load are not vis-
ible during the entire operation,
get help from another person.
• Appoint a supervisor if more
than one person is involved in
the operation. This will reduce
confusion and increase safety.
• When lifting a load, use a tag line
to keep the load from swinging or
twisting, while keeping yourself
away from the load.

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranespage 10
A11577B-0613
3.1 Cleaning the Crane
Clean the crane to remove dirt and help prevent rust and corrosion.
3.1.1 CLEAN THE CRANE every six months or whenever it is dirty.
a WIPE ALL EQUIPMENT to remove dirt and grease.
b LEAVE A LIGHT FILM of oil on all surfaces to protect against rust and cor-
rosion.
c WIPE OFF excessive amounts of oil to avoid the accumulation of dirt.
3.1.2 REMOVE UNNECESSARY OBJECTS from the area surrounding the
crane.
3.2 Lubricating the Crane
Lubricate the crane properly to help protect it from wear and rust. Read the
following instructions carefully.
3.2.1 LUBRICATE ALL PINS before installation and at least every 3 months. Use
a grease brush to apply a light film of NLGI #2 grease to all pins.
3.2.2 LUBRICATE THE BASE PIN located at the bottom of the base before in-
stallation and at least every 3 months. Use a grease brush to apply a film of
NLGI #2 grease to the pin.
3.2.3 LUBRICATE THE MAST BEARING located on the bottom of the mast
before installation and at least every 3 months. Use a grease brush to apply a
film of NLGI #2 grease to the bearing.
3.2.4 LUBRICATE THE BOOM ADJUSTMENT SCREW before installation and
at least every 3 months. Apply a light film of anti-seize compound to the
screw threads. Wipe away any excess lubricant.
3.2.5 LUBRICATE THE WINCH. Refer to the Winch Owner’s Manual for in-
structions.
3.2.6 LUBRICATE THE WIRE ROPE and other equipment by following the
manufacturers recommendations.
Important!
• Make sure lubricant has a tem-
perature rating appropriate for
the ambient temperatures of the
operation.
Important!
Increase the frequency of mainte-
nance procedures if the crane is:
• Operated for long periods.
• Used to lift heavy loads.
• Operated in wet, dirty, hot, or
cold surroundings.

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranes page 11
A11577B-0613
3.3 Disassembling the Crane
When removing the boom brace assembly, carefully support the boom so that
it does not fall abruptly causing damage or injury.
3.3.1 STUDY PARTS DRAWINGS to understand how the crane is assembled. See
pages 18-19.
3.3.2 REMOVE ANY ATTACHED LOAD from the wire rope.
3.3.3 LOWER THE BOOM by removing the boom brace assembly. Carefully
support the boom so that it does not fall abruptly causing damage or injury.
3.3.4 REMOVE THE WIRE ROPE.
a REMOVE ROPE KEEPER PINS located at each sheave near the ends of the
boom.
b UNWIND THE ROPE from the winch drum and release the anchor.
c REPLACE THE ROPE KEEPER PINS
3.3.5 REMOVE THE WINCH HANDLE on hand winches, or disconnect electric
current on power winches. Refer to instructions in the Winch Owner’s Man-
ual.
3.3.6 REMOVE THE SHEAVE ASSEMBLY from the boom. Replace the attach-
ment clevis pin back in the sheave assembly to prevent loss.
3.3.7 DISCONNECT THE BOOM from the mast.
a SECURE THE BOOM to prevent it from falling when the clevis pin is re-
moved.
b REMOVE THE CLEVIS PIN and carefully remove the boom.
c REPLACE the clevis pin to prevent loss.
3.3.8 REMOVE THE WINCH and mounting bracket from the mast. Replace the
clevis pin to prevent loss.
3.3.9 REMOVE THE ROTATION HANDLE from the mast. Replace the clevis
pin to prevent loss.
3.3.10 REMOVE THE MAST FROM THE BASE by lifting it straight out of the
base.
TO REASSEMBLE, SEE SECTION 1.2 – ASSEMBLING THE CRANE.

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranespage 12
A11577B-0613
3.4 Inspecting the Equipment
Do not use damaged or malfunctioning equipment. Place an “OUT OF ORDER”
sign on the crane. Do not use the crane until the sign is removed by a qualified
maintenance person who has completely corrected the problem.
Inspect the crane to detect signs of damage or poor operation before they
become hazardous. See Table 2 - Inspection Checklist.
3.4.1 CONSULT APPLICABLE CODES AND REGULATIONS for specific rules
on inspecting the crane and other equipment.
3.4.2 REFER TO THE WINCH OWNER’S MANUAL for information regarding
winch inspection.
3.4.3 Instructions for Frequent Inspection
a VISUALLY INSPECT the entire crane and all other equipment involved in
the operation.
• Check all equipment for cracks, dents, bending, rust, wear, corrosion and
other damage.
• Make sure the wire rope is installed correctly and anchored securely.
• Make sure the entire crane is properly lubricated.
• Make sure all fasteners are tight and secure.
• Make sure mounting fasteners are tightened securely.
• Make sure the foundation is in good condition, and capable of supporting
the crane and its load under all load conditions.
b TEST CRANE PERFORMANCE by operating the crane with a load not
exceeding the load rating.
• Listen for unusual noises, and look for signs of damage as you operate the
crane.
• Make sure the wire rope winds evenly and tightly onto the drum. If it is
loose or uneven, rewind it before continuing.
• Make sure the load moves smoothly, without hesitation or strain.
• On hand operated models, make sure the winch handle rotates freely in
both directions.
• On power operated models, make sure the winch responds to the control
device. It must rotate as shown on the control labels, and it must turn off
when you release the control.
• Make sure the boom rotates freely when you push the handle, and re-
mains stationary when you release it.
• Check the winch brake. Raise the load, then lower it and stop it a few feet
off the ground. If the load continues to coast or creep under normal oper-
ating conditions, the brake may be worn and in need of repair or replace-
ment. Contact the factory.
Completely correct all problems before continuing. Use the Troubleshooting
Chart to help determine the cause of certain problems. See Table 3.
Perform frequent inspections:
• Before each operation.
• Every 3 hours during operation.
• Whenever you notice signs of
damage or poor operation.
Frequent Wire Rope Inspection:
• Use ASME B30.7 as a guideline
for rope inspection, replacement
and maintenance.
• Check the wire rope, end connec-
tions and end fittings for corrosion,
kinking, bending, crushing, bird-
caging or other signs of damage.
• Check the number, distribution
and type of visible broken wires.
See paragraph 3.4.4 b and Figure 7.
• Check the wire rope for reduc-
tion of rope diameter from loss of
core support, or wear of outside
wires. See Figure 9.
• Take extra care when inspecting
sections of rapid deterioration
such as sections in contact with
saddles, sheaves, repetitive pickup
points, crossover points and end
connections.
Important!
• Start an inspection program as
soon as you put the crane into use.
• Appoint a qualified person to be
responsible for regularly inspecting
the equipment.
• Keep written records of inspec-
tion. This allows comparison with
comments from previous inspec-
tions so you can see changes in
condition or performance.

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranes page 13
A11577B-0613
Table 2 – Inspection Checklist
damages problems
general finish weathered, flaking, otherwise damaged equipment not properly lubricated
parts cracked, bent, rusted, worn, otherwise damaged unusual noises, other signs of malfunction
foundation loose, unstable, otherwise damaged not level - boom swerves
fasteners stripped threads, bent, worn, otherwise damaged loose, not tightened to the proper torque
boom assembly holes worn, distorted, or otherwise damaged does not rotate freely
winch assembly gears, bearings, and other parts worn, otherwise damaged winch jerks or hesitates under load
brake corroded, cracked, worn, otherwise damaged brake does not operate properly
sheaves holes worn, distorted, or otherwise damaged does not rotate freely
wire rope bent, crushed, otherwise damaged wire rope loosely or unevenly wound
broken wires, see Figure 7
replace if more than 6 wires in one lay, number per strand =
or 3 wires in one strand in one lay, are broken number per lay =
diameter reduced, see Figure 9
replace if diameter is excessively worn diameter =
end connections corroded, rusted, worn, otherwise damaged not securely attached
load hook twisted, bent, worn, otherwise damaged, see Figure 8 hook latch fails to close when released
replace if twist is 10 degrees or more twist =
replace if throat width is 15% larger than nominal throat width =
replace if thickness is 10% less than nominal thickness =
labels and plates dirty, illegible, otherwise damaged loosely attached or missing
comments:
authorized signature: date
checked boxes indicate damage or problem in need of repair

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranespage 14
A11577B-0613
Perform periodic inspections:
• Every 6 months.
• Whenever you return the crane to
service from storage.
• Whenever you notice damage
or poor operation in a frequent
inspection.
• Whenever you have, or think you
may have, overloaded or shock
loaded the crane.
3.4.4 Instructions for Periodic Inspection
a VISUALLY INSPECT the crane and all other equipment.
• Check the finish for wear, flaking, or other damage.
• Check all equipment for cracks, dents, bending, rust, wear, corrosion and
other damage. If the equipment was overloaded, or if you notice cracks
and other signs of overloading and damage, promptly remove equipment
from use and have it repaired or replaced. DO NOT CONTINUE TO
USE DAMAGED OR OVERLOADED EQUIPMENT OR WIRE
ROPE.
• Check all fasteners for stripped threads, wear, bending, and other damage.
• Make sure the entire crane is properly lubricated.
• Make sure all labels and plates are readable, firmly attached, free of dam-
age and clean. Replacements are available from the factory.
b INSPECT THE WIRE ROPE according to the wire rope manufacturer's rec-
ommendations, or follow accepted industry standards for wire rope inspection.
• Always wear protective clothing when handling wire rope.
• Check the entire length of wire rope for bent wires, crushed areas, broken
or cut wires, corrosion, and other damage. Carefully inspect areas that
pass over sheaves or through roller guides.
• Note the location and concentration of broken wires. Replace wire rope if
more than 6 wires are broken in one lay, or more than 3 wires are broken
in one strand in one lay. See Figure 7.
• Make sure the load hook or other device is securely attached to the wire
rope, and the wire rope where it is attached is not frayed, corroded, bro-
ken, or otherwise damaged.
• Measure the throat opening, thickness, and twist of the hook. Replace the
hook if it shows signs of damage. See Figure 8.
• Make sure hook latch opens without binding and closes when released.
• Check the anchor holes in the drum and the surrounding area for signs of
wear or distortion.
c PLACE enough weight to keep the wire rope straight and tightly drawn.
• Measure the diameter of the wire rope, especially in areas where wear
is noticeable. Replace the wire rope if the diameter measures below the
minimum diameter at any point. See Figure 9.
d REMOVE THE WINCH and inspect it by following the instructions in the
Winch Owner’s Manual.
e DISASSEMBLE THE CRANE.
• Inspect each component for damage.
f REMOVE THE CRANE BASE from the foundation.
• Check fasteners for stripped threads, wear, bending, and other damage.
• Check the foundation for cracks, corrosion, and other damage.
twist
throat
opening
thickness
Figure 8 – Load Hook
Inspection
The wire rope assembly must be
replaced if the throat opening is
15% wider than nominal, if the
thickness is 10% less than nomi-
nal, or if the hook is twisted 10°
or more.
wire
strand
one
lay
Figure 7 – Broken Wires
Wire rope assembly must be re-
placed if more than 6 wires are
broken in one lay, or if more than
3 wires are broken in one strand
in one lay.

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranes page 15
A11577B-0613
g FASTEN THE CRANE BASE securely to the foundation.
h REASSEMBLE THE CRANE.
i TEST CRANE PERFORMANCE by operating the crane with a load not
exceeding the load rating.
• Listen for unusual noises, and look for signs of damage as you operate the
crane.
• Make sure the wire rope winds evenly and tightly onto the drum. If it is
loose or uneven, rewind it before continuing.
• Make sure the load moves smoothly, without hesitation or strain.
• On hand operated models, make sure the winch handle rotates freely in
both directions.
• On power operated models, make sure the winch responds to the control
device. It must rotate as shown on the control labels, and it must turn off
when you release the control.
• Make sure the boom rotates freely when you push the handle, and re-
mains stationary when you release it.
• Check the brake. Raise the load, then lower it and stop it a few feet off
the ground. If the load continues to coast or creep under normal operating
conditions, the brake may be worn and in need of repair or replacement.
Contact the factory.
Completely correct all problems before continuing. Use the Troubleshooting
Chart to help determine the cause of certain problems. See Table 3.
diameter
correct incorrect
Figure 9 – Rope Diameter
The wire rope assembly must
be replaced if the diameter mea-
sures less than the minimum
diameter at any point.
wire rope
diameter minimum diameter
3/16 in 11/64 in (.1719 in)
1/4 in 15/64 in (.2344 in)
5/16 in 19/64 in (.2969 in)
Table 3 – Troubleshooting Chart
problem cause correction
overheating • operated too long without rest. .. . .. . .. . .. . .. . allow to cool
• load too heavy .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . lighten load
• poor lubrication.. . .. . .. . .. . .. . .. . .. . .. . .. . .. . inspect and lubricate as necessary
• bearing seized up .. . .. . .. . .. . .. . .. . .. . .. . .. . inspect and replace as necessary
boom bounces up and down • load too heavy .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . lighten load
• mounting bolts loose .. . .. . .. . .. . .. . .. . .. . .. . tighten mounting bolts to proper torque
• sheave worn or damaged. . .. . .. . .. . .. . .. . .. . inspect and replace as necessary
• foundation loose or unlevel .. . .. . .. . .. . .. . .. . inspect and repair as necessary
• winch gears worn or damaged .. . .. . .. . .. . .. . inspect and repair as necessary
boom does not rotate • rotation points contaminated or worn .. . .. . .. . inspect and repair as necessary
• flange bearing broken or locked. . .. . .. . .. . .. . inspect and replace as necessary
boom rotates on its own • foundation loose or unlevel .. . .. . .. . .. . .. . .. . inspect and repair as necessary
• mast bent, distorted, or leaning.. . .. . .. . .. . .. . inspect and repair as necessary
unusual noises
high pitched squeak • poor lubrication.. . .. . .. . .. . .. . .. . .. . .. . .. . .. . lubricate entire crane properly
grinding noise • contaminated lubricant at rotation points .. . .. . clean and lubricate rotation points
rattling noise • loose bolts, set screws or other fasteners. . .. . tighten all bolts and other fasteners
Refer to the Winch Owner’s Manual for possible problems with the winch and brake.

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranespage 16
A11577B-0613
3.5 Repairing the Crane
3.5.1 GET FACTORY AUTHORIZATION for all repairs. Unauthorized repairs
will void the warranty, and may lead to damage or failure of the crane.
3.5.2 REPLACE DAMAGED OR POORLY OPERATING PARTS with Thern
repair parts.
3.5.3 REFINISH AREAS where the paint is worn or flaking. A good finish helps
to protect against corrosion and weather damage.
a REMOVE THE FINISH from damaged areas, down to the bare metal.
b CLEAN THE AREA thoroughly.
c REPAINT with a high quality primer and finishing coat.
3.5.4 TO ORDER REPAIR PARTS, contact your local dealer. Include the follow-
ing information when ordering:
• model number
• serial number (or code number)
• part number
• date purchased, and from whom
• description of what happened, or what is wrong
• your name and return address
Important!
• It is your responsibility to de-
termine when to replace parts.
When considering whether to
continue using a part or to replace
it, remember that replacing it
is the best way to avoid further
equipment damage.
• Appoint a qualified person to be
responsible for all repairs to the
equipment.

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranes page 17
A11577B-0613
4.1 Transporting the Crane
4.1.1 PARTIALLY DISASSEMBLE THE CRANE into components that can be
transported. Figure 10 shows a configuration with the mast and boom se-
cured together.
4.1.2 PACK THE CRANE for transport, using the original packaging materials, if
appropriate.
4.1.3 PACK THE WINCH for transport, using the original packaging materials, if
appropriate. Please see the winch owner’s manual for instructions.
4.1.4 REASSEMBLE THE CRANE at its new location following the instructions
under Section 1.2 Assembling the Crane.
4.1.5 INSPECT THE CRANE according to the Instructions for Frequent Inspec-
tion before installing it for operation. See Section 3.4.3 Instructions for Fre-
quent Inspection.
4.2 Storing the Crane
4.2.1 PARTIALLY DISASSEMBLE THE CRANE and store all parts in a cool
clean place away from corrosive chemicals and moisture.
4.2.2 SEAL THE CRANE in plastic with a desiccant to help protect it from rust,
corrosion, and other damage.
4.2.3 SEAL THE WINCH in plastic with a desiccant to help protect it from rust,
corrosion, and other damage. Please see the winch owner’s manual for in-
structions.
4.2.4 REASSEMBLE THE CRANE at its new location according to Section 1.2
Assembling the Crane.
4.2.5 INSPECT THE CRANE according to Section 3.4.4 Instructions for Periodic
Inspection before installing it for operation.
Important!
• Keep a record of what you ship,
and when you send it.
CONFIGURATION
WITH MAST AND
BOOM SECURED.
ASSEMBLY WEIGHT
IS 58 LBS (26.3 kg).
Figure 10 – Packing the
Crane
Assembly Weight
Model 5PA5 LB KG
Mast Assembly 21 9.5
Boom Assembly 29 13.1
Boom Brace Assembly 3 1.4
Sheave Assembly 5 2.3
Handle 2 0.9
TOTAL 60 27.2
Winch (including bracket) LB KG
M1 (M4022PB-K) 19 8.6
M3 (M4042PBSS-K) 26 11.8
M2 (4WM2V-K) 42 19.0
E3 (4WP2-K) 84 38.1
Table 4 – Component Weight Chart

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranespage 18
A11577B-0613
5PA5 Series Portable Davit Cranes
item description part number qty. material
1 BEARING ASSY 5PA5 B5834 1 SEE TABLE
2 WELDMENT MAST 5PA5 B5829 1 SEE TABLE
3 BRACKET SHEAVE 5PA5 C4826 1 SEE TABLE
4 WELDMENT BOOM 5PA5 C4831 1 SEE TABLE
5 HANDLE ROTATION 5PA5 B5825 1 SEE TABLE
6 BOOM BRACE ASSY 5PA5 B5827 1 SEE TABLE
7 WELDMENT WINCH MOUNT 5PA5 C4828 1 SEE TABLE
8 FLANGE BEARING B5811 1
9 SHEAVE ASSMBLY B2462 2
10 PIN HEADLESS .750 X 2.625 EFF LENGTH SST A11538 1
11 PIN HEADLESS .750 X 3.000 EFF LENGTH SST A11539 1
12 PIN HEADLESS .750 X 3.500 EFF LENGTH SST A11540 1
13 PIN HEADLESS .500 X 2.625 EFF LENGTH SST A11541 1
14 PIN HEADLESS .500 X 3.000 EFF LENGTH SST A11542 2
15 PIN HEADLESS .500 X 4.000 EFF LENGTH SST A11543 1
16 PIN QUICK RELEASE .188 X .800 SST SEE SPEC A11534 6
17 PIN QUICK RELEASE .188 X 3.000 SST SEE SPEC A11535 2
18 PLUG FINISH RND 2.250 X 10-14GA BLK A11560 1
19 LABEL NAMEPLATE CRANES CE A11529 1
20 LABEL NAMEPLATE THERN LOGO A6889 2
21 LABEL WARNING B5790 1
22 LABEL WARNING BEFORE LOADING B5791 2
23 LABEL LOAD RATING 5PA5 B5792 1
24 LABEL MODEL ENSIGN 500 B5839 2
5PA5 5PA5G 5PA5S 5PA5S316
Fusibond Galvanized Stainless Stainless316
item
1 B5834 B5834 B5834 B5834 SS316
2 B5829 RED B5829 GAL B5829 SS B5829 SS316
3 C4826 RED C4826 GAL C4826 SS C4826 SS316
4 C4831 RED C4831 GAL C4831 SS C4831 SS316
5 B5825 RED B5825 GAL B5825 SS B5825 SS316
6 B5827 RED B5827 GAL B5827 SS B5827 SS316
7 C4828 RED C4828 GAL C4828 SS C4828 SS316
Use component part numbers for material / finish that matches crane
model number.
Example: Crane model 5PA5Guses components with part numbers
XXXXXGAL.
21
18
6
22
23
2
1
5
8
7
15 16
14 16
12
16
19
14
16
17
11
9
20
24
4
1316
3
10 9
17
5PA5 Series 5PA5M1 5PA5M2 5PA5M3 5PA5E2
description part number part number part number part number
WINCH M4022PB-K 4WM2V-K M4042PBSS-K 4WP2-K

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranes page 19
A11577B-0613
model material item 1 item 2
5BP5 STEEL B5821RED B6251RED
5BP5G STEEL B5821GAL B6251GAL
5BP5S SST, AISI 304 B5821SS B6251SS
5BP5S316 SST, AISI 316 B5821SS316 B6251SS316
model material item 1 item 2
5BF5 STEEL B5820RED B6251RED
5BF5G STEEL B5820GAL B6251GAL
5BF5S SST, AISI 304 B5820SS B6251SS
5BF5S316 SST, AISI 316 B5820SS316 B6251SS316
model material item 1 item 2
5BW5 STEEL B5819RED B6251RED
5BW5G STEEL B5819GAL B6251GAL
5BW5S SST, AISI 304 B5819SS B6251SS
5BW5S316 SST, AISI 316 B5819SS316 B6251SS316
Pedestal Base
5BP5 Series
item part no. description
1 B5821 WELDMENT BASE 5PA5
2 B6251 BASE COVER
3 B6252 LANYARD ASSEMBLY
Flush Base
5BF5 Series
item part no. description
1 B5820 WELDMENT BASE 5BF5
2 B6251 BASE COVER
3 B6253 LANYARD ASSEMBLY
Wall Base
5BW5 Series
item part no. description
1 B5819 WELDMENT BASE 5PA5
2 B6251 BASE COVER
3 B6253 LANYARD ASSEMBLY
1
2
3
1
2
3
1
2
3

Owner's Manual for Thern 5PA5 Ensign Series Portable Davit Cranespage 20
A11577B-0613
5PA5 Performance Ratings2
Boom Load Hook Hook
Position Rating Reach Height
(lb) (kg) (in) (mm) (in) (mm)
A-1 500 226 17 432 74 1880
A-2 400 181 22 559 79 2007
A-3 300 136 28 711 87 2210
A-4 250 113 36 914 96 2438
B-1 500 226 14 356 76 1930
B-2 400 181 17 432 83 2108
B-3 300 136 22 559 91 2311
B-4 250 113 28 711 101 2565
1Lift below floor level varies depending on boom position and base configuration. For longer lifts,
please contact factory.
2Performance Characteristics are for standard products referred to in this manual. Non-standard
products may vary from the original design. Contact Thern, Inc. for this information.
3Wire rope assemblies include a swivel hook and swaged ball fitting to work with quick
disconnect anchor on winches.
1
2
3
4
A
B
0
24 in
12 in
36 in
60 in
48 in
84 in
72 in
96 in
108 in
120 in
48 in24 in12 in 36 in
MAST C
L
hook reach
hook
height
lift below
floor level
114 in
2.5 in. DIA
64 mm
2896 mm
IMPORTANT:
It is the owner or operator's responsibility to
determine the suitability of the equipment to its
intended use. Study all applicable codes, manuals
and regulations. Be sure to read the Owner's
Manual supplied with the equipment before
operating it.
5PA5 Lift Below Floor 2
Lift Below1Wire Rope Wire Rope Winch Wire Rope
Floor Diameter Length Configurations Part Numbers3
Minimum (B4) Maximum (B1) M1 M2 M3 E2 7x19 Galvanized Aircraft Cable 7x19 304 Stainless Steel
(ft) (m) (ft) (m) (in) (mm) (ft) (m)
0 0 5 1.5 3/16 5 20 6.0 x - x - WA19-20NS WS19-20NS
8 2.4 13 3.9 3/16 5 28 8.5 x - x - WA19-28NS WS19-28NS
16 4.8 21 6.4 3/16 5 36 10.9 x - x - WA19-36NS WS19-36NS
25 7.6 30 9.1 3/16 5 45 13.7 x - x - WA19-45NS WS19-45NS
40 12.1 45 13.7 3/16 5 60 18.2 - - x - WA19-60NS WS19-60NS
55 16.7 60 18.2 3/16 5 75 22.8 - - x - WA19-75NS WS19-75NS
70 22.3 75 22.8 3/16 5 90 27.4 - - x - WA19-90NS WS19-90NS
0 0 5 1.5 1/4 6 20 6.0 - x x x WA25-20NS WS25-20NS
8 2.4 13 3.9 1/4 6 28 8.5 - x x x WA25-28NS WS25-28NS
16 4.8 21 6.4 1/4 6 36 10.9 - x x x WA25-36NS WS25-36NS
25 7.6 30 9.1 1/4 6 45 13.7 - x x x WA25-45NS WS25-45NS
40 12.1 45 13.7 1/4 6 60 18.2 - x x x WA25-60NS WS25-60NS