Owner s Manual For 5122 Series Portable Davit Cranes ORIGINAL TEXT

Red this Owner s Mnul thoroughly efore operting the equipment. Keep it with the equipment t ll times. Replcements re ville from Thern, Inc., PO Box 347, Winon, MN 55987, 507-454-2996. www.thern.com IMPORTANT: Plese record product informtion on pge 2. This informtion is required when clling the fctory for service. ORIGINAL TEXT Owner s Mnul For 5122 Series Portle Dvit Crnes

pge 2 Owner's Mnul for Thern 5122 Series Portle Dvit Crnes Two-Yer Limited Wrrnty Plese record the following: Dte Purchsed: Crne Model No.: Crne Seril No.: If sold with winch: Winch Model No.: Winch Seril No.: This informtion is required when clling the fctory for service. Thern, Inc. wrrnts its products ginst defects in mteril or workmnship for two yers from the dte of purchse y the originl using uyer, or if this dte cnnot e estlished, the dte the product ws sold y Thern, Inc. to the deler. To mke clim under this wrrnty, contct the fctory for n RGA numer. The product must e returned, prepid, directly to Thern, Inc., 5712 Industril Prk Rod, Winon, Minnesot 55987. The following informtion must ccompny the product: the RGA numer, the dte of purchse, the description of the climed defect, nd complete explntion of the circumstnces involved. If the product is found to e defective, it will e repired or replced free of chrge, nd Thern, Inc. will reimurse the shipping cost within the contiguous USA. This wrrnty does not cover ny dmge due to ccident, misuse, use, or negligence. Any ltertion, repir or modifiction of the product outside the Thern, Inc. fctory shll void this wrrnty. This wrrnty does not cover ny costs for removl of our product, downtime, or ny other incidentl or consequentil costs or dmges resulting from the climed defects. This wrrnty does not cover rke discs, wire rope or other wer components, s their life is suject to use conditions which vry etween pplictions. 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 sttes do not llow the exclusion or limittion of incidentl or consequentil dmges, or llow limittions on how long n implied wrrnty lsts, so the ove limittion or exclusion my not pply to you. This wrrnty gives you specific legl rights, nd you my lso hve other rights which vry from stte to stte. Note: Thern, Inc. reserves the right to chnge the design or discontinue the production of ny product without prior notice. Aout This Mnul The Occuptionl Sfety nd Helth Act of 1970 sttes tht it is the employer s responsiility to provide workplce free of hzrd. To this end, ll equipment should e instlled, operted, nd mintined in complince with pplicle trde, industril, federl, stte, nd locl regultions. It is the equipment owner's responsiility to otin copies of these regultions nd to determine the suitility of the equipment to its intended use. This Owner s Mnul, nd wrning lels ttched to the equipment, re to serve s guidelines for hzrd-free instlltion, opertion, nd mintennce. They should not e understood to prepre you for every possile sitution. The informtion contined in this mnul is pplicle only to the Thern 5122 Series Portle Dvit Crnes. Do not use this mnul s source of informtion for ny other equipment. The following symols re used for emphsis throughout this mnul: Filure to follow WARNING! instructions my result in equipment dmge, property dmge, nd/or serious personl injury. Filure to follow CAUTION! instructions my result in equipment dmge, property dmge, nd/or minor personl injury. Importnt! Filure to follow importnt! instructions my result in poor performnce of the equipment.

Owner's Mnul for Thern 5122 Series Portle Dvit Crnes pge 3 Suggestions for Sfe Opertion DO the following: Red nd comply with the guidelines set forth in this Owner s Mnul. Keep this mnul, nd ll lels ttched to the crne, redle nd with the equipment t ll times. Contct Thern, Inc. for replcements. Check luriction efore use. Instll the wire rope securely to the winch drum. Keep t lest 4 wrps of wire rope wound on the drum t ll times, to serve s nchor wrps. With less thn 4 wrps on the drum the wire rope could come loose, cusing the lod to escpe. Keep hnds wy from sheves, gers, wire rope, nd other moving prts of the equipment. Disconnect the power efore servicing the equipment. Keep ll unnecessry personnel wy from the crne while in opertion. Keep out of the pth of the lod, nd out of the pth of roken wire rope tht might snp ck nd cuse injury.

pge 4 Owner's Mnul for Thern 5122 Series Portle Dvit Crnes Suggestions for Sfe Opertion (Cont) DO NOT do the following: Do not lift people, or things over people. Do not wlk or work under lod or in the line of force of ny lod. Do not exceed the lod rting of the crne or ny other component in the system. Do not use more thn one crne to move lod tht exceeds the lod rting of single crne. A shift in lod weight could overlod the equipment. Do not use dmged or mlfunctioning equipment. To do so could result in filure of the equipment. Do not modify the equipment in ny wy. To do so could cuse equipment filure. Do not wrp the wire rope round the lod. This dmges the wire rope nd could cuse the lod to escpe. Use sling or other pproved lifting device. Do not operte the crne with gurds removed or improperly instlled. Do not divert your ttention from the opertion. Sty lert to the possiility of ccidents, nd try to prevent them from hppening. Do not jerk or swing the lod. Avoid shock lods y strting nd stopping the lod smoothly. Shock lods overlod the equipment nd my cuse dmge. Do not remove the winch or other components from the crne, nd do not use these components for ny use other thn for their originl intended function. Do not use the crne to drg or pull lods. This will crete side pulls which could dmge the equipment or cuse the lod to tip. Do not leve suspended lod unttended. Plce the lod on the ground if it must e left unttended. Do not djust the winch rke with the lod suspended. Do not operte or pply lods without ll pins securely in plce. Do not djust oom ngle while the crne is loded.

Owner's Mnul for Thern 5122 Series Portle Dvit Crnes pge 5 1.1 Instlling the Crne Importnt! A qulified professionl should inspect or design the foundtion to insure tht it will provide dequte support. Locte the crne so it will e visile during the entire opertion. Do not instll the crne in n re defined s hzrdous y the Ntionl Electric Code, unless instlltion in such n re hs een thoroughly pproved. Do not instll the crne ner corrosive chemicls, flmmle mterils, explosives, or other elements tht my dmge the crne or injure the opertor. Adequtely protect the crne nd the opertor from such elements. Position the crne so the opertor cn stnd cler of the lod, nd out of the pth of roken wire rope tht could snp ck nd cuse injury. Attch the crne to rigid nd level foundtion tht will support the crne nd its lod under ll lod conditions, including shock loding. 1.1.1 CONSULT APPLICABLE CODES AND REGULATIONS for specific rules on instlling the equipment. 1.1.2 LOCATE THE CRANE in n re cler of trffic nd ostcles tht could interfere with opertion. Mke sure the crne is ccessile for mintennce nd opertion. 1.1.3 INSTALL THE CRANE on level surfce. An unlevel surfce my cuse the oom to rotte in the direction the mst is lening. 1.1.4 FASTEN THE BASE securely to the foundtion to withstnd pplicle overturning moments nd mounting olt rection. See Tle 1. FOR STANDARD PRODUCTS referred to in this mnul, use 1/2 inch corse thred fsteners, grde 5 or etter. Torque for grde 5 fsteners without luriction is 75 ft ls. Refer to mnufcturer's instructions for other fstener types with specific torque or instlltion instructions. NON-STANDARD PRODUCTS tht vry from the originl design my hve different fstening requirements. Contct structurl engineer or Thern, Inc. for this informtion. TO COMPLY WITH LOCAL CODES, CONTACT A QUALIFIED PROFESSIONAL TO OBTAIN PROPER STRUCTURE OR FOUNDATION SPECIFICATIONS FOR THE MOUNTING OF THERN PRODUCTS.

Tle 1 - Crne Rections 2 Pedestl Bse Wll Mount Bse pge 6 Owner's Mnul for Thern 5122 Series Portle Dvit Crnes Figure 1 Instlling the Crne se instlled upright se instlled flush Crne Model Mst Moment Suggested Bolt Size Axil Force per Bolt 1 Axil Force per Bolt 1 Sher Force per Bolt 5122 21,050 in-ls 2,379 N-m 1/2 inch (M12) 1,990 ls 8,853 N 1,390 ls 6,184 N 1,100 ls 4,894 N 1 Force in tension. 2 This informtion my chnge without prior notice. It is the responsiility of the instller nd/or end user to ensure the most current informtion is used. Figure 2 Assemling the Crne Mke sure the winch is positioned correctly with the winch drum fcing forwrd towrd the oom. See winch mnul for wire rope instlltion. Both clevis pins must e instlled through the oom

Owner's Mnul for Thern 5122 Series Portle Dvit Crnes pge 7 1.2 Assemling the Crne Importnt! Inspect the crne during ssemly ccording to the Instructions for Periodic Inspection. This will give you record of the condition of the crne with which to compre future inspections. Sve ll oxes nd crtes tht the crne ws shipped in, use them gin if you need to repckge the crne. Contct the fctory immeditely if ny prts re missing or dmged. Do not overtighten fsteners, this my strip threds or cuse dmge to other prts. Figure 3 Cotter Pins end rms ck 1.2.1 STUDY PARTS DRAWINGS to understnd how the crne is ssemled. See pges 16 through 18. 1.2.2 LUBRICATE PINS nd other components prior to ssemly. Refer to Section 3.2 Luricting the Crne. 1.2.3 INSTALL THE BASE nd insert the mst in the se nd ssemle the crne in the following order. FOR 522 SERIES BASES, the rollers should e instlled in the lowest point of the se llowing the mst to rotte freely in the se mount. FOR MODEL 514 secure the mst in plce using the fsteners provided. Mke sure the cpscrew psses through the mst to prevent the mst from rotting in the se. On 514 models the mst should not rotte in se, the se is designed to hve the lod centered etween se legs. Allowing the mst to rotte in the se my cuse the crne to tip. 1.2.4 FASTEN THE BOOM to the mst using the clevis pins provided. Do not rest the oom on top of the front clevis pin, this my cuse it to end under lod. Both clevis pins must e instlled through the oom. See Figure 2. Mke sure the oom is positioned correctly. 1.2.5 POSITION THE SHEAVE etween the ers on the oom extension, nd fsten in plce with the clevis pin nd cotter pin provided. INSTALL THE CLEVIS PIN in the holes locted y the sheve t the end of the oom. Secure in plce with the hir cotter pin provided. 1.2.6 FASTEN THE WINCH to the mounting plte on the oom using fsteners provided. On some models you will need to use the winch dpter plte nd fsteners provided to fsten the winch to the crne. Mke sure the winch is positioned correctly with the winch drum fcing forwrd towrd the oom. 1.2.7 INSTALL THE WINCH HANDLE ccording to instructions in the Winch Owner s Mnul. 1.2.8 INSTALL THE WIRE ROPE. Use wire rope ssemlies in the length specified on pge 19. PASS THE WIRE ROPE over the sheve t the end of the oom. ANCHOR THE WIRE ROPE to the winch drum nd wind 4 wrps of wire rope onto the drum to ct s nchor wrps. Refer to the instrictions in the Winch Owner's Mnul. 1.2.9 COMPLETE ASSEMBLY. MAKE SURE ALL FASTENERS re tightened, nd cotter pins properly ent to secure them in plce, see Figure 3. LUBRICATE THE ENTIRE CRANE. See Section 3.2 Luricting the Crne.

pge 8 Owner's Mnul for Thern 5122 Series Portle Dvit Crnes 2.1 Generl Theory of Opertion Importnt! Limit nonuniform winding y keeping tension on the wire rope. It is your responsiility to detect nd ccount for different fctors ffecting the condition nd performnce of the equipment. 2.1.1 THE INTENDED USE of this mchinery is to lift nd lower lods of its rted cpcity or less. It is not for lifting people or things over people. 2.1.2 THE PULL REQUIRED to move the lod must not exceed the lod rting of the crne. Consider the totl force required to move the lod, not the weight of the lod. 2.1.3 THIS EQUIPMENT CAN develop forces tht will exceed the lod rting. It is the responsiility of the equipment user to limit the size of the lod. Inspect the equipment regulrly for dmge ccording to the instructions contined in this mnul. 2.1.4 PERFORMANCE RATINGS of the equipment re ffected y the position of the oom, nd the mount of wire rope you use. See the Performnce Chrcteristics Tles on pge 19. c LOAD RATING represents the mximum pull tht cn e plced on new equipment. Lod rtings re ssigned vlues for specific oom positions nd wire rope lengths. LIFT vries with the position of the oom nd the length of the wire rope. REACH vries with the position of the oom. 2.1.5 DUTY RATINGS refer to the type of use the equipment is suject to. Consider the following when determining duty rting. c d ENVIRONMENT: hrsh environments include hot, cold, dirty, wet, corrosive, or explosive surroundings. Protect the equipment from hrsh environments when possile. MAINTENANCE: poor mintennce, mening poor clening, luriction, or inspection, leds to poor opertion nd possile dmge of the equipment. Minimize poor mintennce y crefully following the instructions contined in this mnul. LOADING: severe loding includes shock loding nd moving lods tht exceed the lod rting of the equipment. Avoid shock lods, nd do not exceed the lod rting of the equipment. FREQUENCY OF OPERATION: frequent or lengthy opertions increse wer nd shorten the life spn of gers, erings, sheves, nd other components. Increse mintennce of the equipment if used in frequent opertions. 2.1.6 AIRBORNE NOISE EMISSIONS vry depending on lod nd the type of winch eing used. Stndrd configurtions do not typiclly exceed sound pressure level of 80dB(A) t worksttions.. 2.1.7 VIBRATION LEVELS vry depending on lod nd type of winch eing used. Stndrd configurtions do not typiclly exceed virtion levels of 2.5 m/s 2. CONTACT THE FACTORY FOR MORE INFORMATION.

Owner's Mnul for Thern 5122 Series Portle Dvit Crnes pge 9 2.2 Prepring for Opertion Importnt! When determining whether the lod will exceed the lod rting, consider the totl force required to move the lod. 2.2.1 CONSIDER THE OPERATION. Do not egin until you re sure you cn perform the entire opertion without hzrd. 2.2.2 INSPECT ALL COMPONENTS of the system. INSPECT THE CRANE nd other equipment ccording to the Instructions for Frequent Inspection. c d INSPECT THE WINCH ccording to the instructions in the Winch Owner s Mnul. OPERATORS must e in good helth, lert, thoroughly trined in operting the equipment, nd properly clothed (hrd ht, sfety shoes nd sfety glsses, no loose clothing). THE LOAD must e cler of other ojects nd free to move. Mke sure the lod will not tip, spin, roll wy, or in ny wy move uncontrollly. 2.2.3 KNOW YOUR LOAD nd mke sure you do not exceed the lod rting of the crne or ny other equipment in the system. 2.2.4 POSITION THE BOOM so the lod hook is centered over the lod. Avoid side pulls which could dmge the crne or cuse the lod to tip. See Figure 4. 2.2.5 ADJUST THE BOOM ANGLE y repositioning the clevis pin on the mst. Do not reposition the oom while the crne is under lod. See pge 19 to view different oom positions, A nd B. Figure 4 Positioning the Boom center line center line correct incorrect

pge 10 Owner's Mnul for Thern 5122 Series Portle Dvit Crnes 2.3 Attching the Lod Figure 5 Attching Lod ltch closed tight ginst hook Do not wrp the wire rope round the lod. This dmges the wire rope nd could cuse the lod to escpe. Use sling or other pproved lifting device. 2.3.1 CLEAR OBJECTS from the pth of the lod so you cn move it freely nd oserve it t ll times during the opertion. 2.3.2 MAKE SURE THE WIRE ROPE is not twisted. A twisted wire rope could cuse the lod to spin when it is rised off the ground. sling seted in sddle of hook 2.3.3 ATTACH THE LOAD using nylon sling, or other pproved lifting device. Follow the recommendtions of the sling mnufcturer. SEAT THE SLING in the sddle of the hook with the hook ltch completely closed. See Figure 5. CENTER THE LOAD on the hook so it will remin lnced nd not tip or rotte to one side. 2.4 Moving the Lod Importnt! Oey stop signl from nyone. Mintin tension on the wire rope to keep it tightly nd evenly wound on the drum. If the crne nd lod re not visile during the entire opertion, get help from nother person. Appoint supervisor if more thn one person is involved in the opertion. This will reduce confusion nd increse sfety. When lifting lod, use tg line to keep the lod from swinging or twisting, while keeping yourself wy from the lod. 2.4.1 MOVE THE LOAD slowly nd smoothly, only smll distnce t first. Mke sure the lod is lnced nd securely ttched efore continuing. 2.4.2 OPERATE THE WINCH to rise or lower the lod. Refer to the instructions in the Winch Owner s Mnul. 2.4.3 OBSERVE THE WIRE ROPE s it winds onto the drum. If it ecomes loose, uneven, or overlpped, stop the opertion nd rewind the wire rope efore continuing. Continued opertion with overlpped or uneven wire rope cn dmge the wire rope nd shorten its life. 2.4.4 ROTATE THE BOOM to move the lod side-to-side. ROTATE THE BOOM slowly nd smoothly to void swinging the lod or cusing shock lods. Do not jm the oom ginst other ojects. PUSH AGAINST THE BOOM t the midpoint etween the mst nd the end of the oom. Do not push or pull the lod, wire rope, or ny other prt of the crne other thn the oom.

Owner's Mnul for Thern 5122 Series Portle Dvit Crnes pge 11 3.1 Clening the Crne Importnt! Increse the frequency of mintennce procedures if the crne is: Operted for long periods. Used to lift hevy lods. Operted in wet, dirty, hot, or cold surroundings. Clen the crne to remove dirt nd help prevent rust nd corrosion. 3.1.1 CLEAN THE CRANE every six months or whenever it is dirty. c WIPE ALL EQUIPMENT to remove dirt nd grese. LEAVE A LIGHT FILM of oil on ll surfces to protect ginst rust nd corrosion. WIPE OFF excessive mounts of oil to void the ccumultion of dirt. 3.1.2 REMOVE UNNECESSARY OBJECTS from the re surrounding the crne. 3.2 Luricting the Crne Importnt! Mke sure luricnt hs temperture rting pproprite for the mient tempertures of the opertion. Luricte the crne properly to help protect it from wer nd rust. Red the following instructions crefully. 3.2.1 LUBRICATE THE ROLLER ASSEMBLY on the 522 se t lest every 3 months. Use grese rush to pply light film of NLGI #2 grese to the rollers nd cpscrew. 3.2.2 LUBRICATE THE WHEELS on the 514 se t lest every 3 months. Use grese rush to pply light film of NLGI #2 grese to the roller erings on the rer cster wheels. Apply 2 to 3 drops of 150 grde ger oil to the shfts on ll wheels. Rotte the wheels to llow oil to penetrte, nd wipe off excess oil to void ccumultion of dirt. 3.2.3 LUBRICATE ALL PINS t lest every 3 months. Use grese rush to pply light film of NLGI #2 grese to ll pins. 3.2.4 LUBRICATE THE WINCH. Refer to the Winch Owner s Mnul for instructions. 3.2.5 LUBRICATE THE WIRE ROPE nd other equipment y following the mnufcturer's recommendtions.

pge 12 Owner's Mnul for Thern 5122 Series Portle Dvit Crnes 3.3 Inspecting the Equipment Importnt! Strt n inspection progrm s soon s you put the crne into use. Appoint qulified person to e responsile for regulrly inspecting the equipment. Keep written records of inspection. This llows comprison with comments from previous inspections so you cn see chnges in condition or performnce. Do not use dmged or mlfunctioning equipment. Plce n OUT OF ORDER sign on the crne. Do not use the crne until the sign is removed y qulified mintennce person who hs completely corrected the prolem. Inspect the crne to detect signs of dmge or poor opertion efore they ecome hzrdous. See Tle 2 - Inspection Checklist. 3.3.1 CONSULT APPLICABLE CODES AND REGULATIONS for specific rules on inspecting the crne nd other equipment. 3.3.2 REFER TO THE WINCH OWNER S MANUAL for informtion regrding winch inspection. 3.3.3 Instructions for Frequent Inspection Perform frequent inspections: Before ech opertion. Every 3 hours during opertion. Whenever you notice signs of dmge or poor opertion. Frequent Wire Rope Inspection: Use ASME B30.7 s guideline for rope inspection, replcement nd mintennce. Check the wire rope, end connections nd end fittings for corrosion, kinking, ending, crushing, irdcging or other signs of dmge. Check the numer, distriution nd type of visile roken wires. See prgrph 3.3.4 nd Figure 6. Check the wire rope for reduction of rope dimeter from loss of core support, or wer of outside wires. See Figure 8. Tke extr cre when inspecting sections of rpid deteriortion such s sections in contct with sddles, sheves, repetitive pickup points, crossover points nd end connections. VISUALLY INSPECT the entire crne nd ll other equipment involved in the opertion. Check ll equipment for crcks, dents, ending, rust, wer, corrosion nd other dmge. Mke sure the wire rope is instlled correctly nd nchored securely to the drum. Mke sure the entire crne is properly luricted. Mke sure ll fsteners re tight nd secure. Mke sure mounting fsteners re tightened securely. Mke sure the foundtion is in good condition, nd cple of supporting the crne nd its lod under ll lod conditions. TEST CRANE PERFORMANCE y operting the crne with lod not exceeding the lod rting. Listen for unusul noises, nd look for signs of dmge s you operte the crne. Mke sure the wire rope winds evenly nd tightly onto the drum. If it is loose or uneven, rewind it efore continuing. Mke sure the lod moves smoothly, without hesittion or strin, nd tht the winch hndle rottes freely in oth directions. On hnd operted models, mke sure the winch hndle rottes freely in oth directions. On power operted models, mke sure the winch responds to the control device. It must rotte s shown on the control lels nd it must turn off when you relese the control. Mke sure the oom rottes freely when you push it, nd remins sttionry when you relese it. Check the rke. Rise the lod, then lower it nd stop it few feet off the ground. If the lod continues to cost or creep under norml operting conditions, the rke my e worn nd in need of repir or replcement. Contct the fctory. Completely correct ll prolems efore continuing. Use the Trouleshooting Chrt to help determine the cuse of certin prolems. See Tle 3.

Owner's Mnul for Thern 5122 Series Portle Dvit Crnes pge 13 Tle 2 Inspection Checklist checked oxes indicte dmge or prolem in need of repir dmges prolems generl finish wethered, flking, otherwise dmged equipment not properly luricted prts crcked, ent, rusted, worn, otherwise dmged unusul noises, other signs of mlfunction foundtion loose, unstle, otherwise dmged not level - oom swerves fsteners stripped threds, ent, worn, otherwise dmged loose, not tightened to the proper torque oom ssemly holes worn, distorted, or otherwise dmged does not rotte freely winch ssemly gers, erings, nd other prts worn, otherwise dmged winch jerks or hesittes under lod rke corroded, crcked, worn, otherwise dmged rke does not operte properly sheves holes worn, distorted, or otherwise dmged does not rotte freely wire rope ent, crushed, otherwise dmged wire rope loosely or unevenly wound roken wires, see Figure 6 replce if more thn 6 wires in one ly, numer per strnd = or 3 wires in one strnd in one ly, re roken numer per ly = dimeter reduced, see Figure 8 replce if dimeter is excessively worn dimeter = end connections corroded, rusted, worn, otherwise dmged not securely ttched lod hook twisted, ent, worn, otherwise dmged, see Figure 7 hook ltch fils to close when relesed replce if twist is 10 degrees or more twist = replce if throt width is 15% lrger thn nominl throt width = replce if thickness is 10% less thn nominl thickness = lels nd pltes dirty, illegile, otherwise dmged loosely ttched or missing comments: uthorized signture: dte

pge 14 Owner's Mnul for Thern 5122 Series Portle Dvit Crnes Perform periodic inspections: Every 6 months. Whenever you return the crne to service from storge. Whenever you notice dmge or poor opertion in frequent inspection. Whenever you hve, or think you my hve, overloded or shock loded the crne. Figure 6 Broken Wires wire strnd Figure 7 Lod Hook Inspection twist throt opening thickness one ly Wire rope ssemly must e replced if more thn 6 wires re roken in one ly, or if more thn 3 wires re roken in one strnd in one ly. The wire rope ssemly must e replced if the throt opening is 15% wider thn nominl, if the thickness is 10% less thn nominl, or if the hook is twisted 10 or more. 3.3.4 Instructions for Periodic Inspection. See Tle 2. c d e f g VISUALLY INSPECT the crne nd ll other equipment. Disssemly my e required in order to properly inspect individul components. Contct fctory for ssemly/disssemly instructions. Disssemly of the winch or crne efore contcting Thern, Inc voids ll wrrnties. Check the finish for wer, flking, or other dmge. Check ll equipment for crcks, dents, ending, rust, wer, corrosion nd other dmge. If the equipment ws overloded, or if you notice crcks or other signs of overloding nd dmge, promptly remove equipment from use nd hve it repired or replced. DO NOT CONTINUE TO USE DAMAGED OR OVERLOADED EQUIPMENT OR WIRE ROPE. Check ll fsteners for stripped threds, wer, ending, nd other dmge. Mke sure the entire crne is properly luricted. Mke sure the wheels on the 514 se rotte freely. Mke sure ll lels nd pltes re redle, firmly ttched, free of dmge nd clen. Replcements re ville from the fctory. INSPECT THE WIRE ROPE ccording to the wire rope mnufcturer's recommendtion, or follow ccepted industry stndrds for wire rope inspection. Alwys wer protective clothing when hndling wire rope. Check the entire length of wire rope for ent wires, crushed res, roken or cut wires, corrosion, nd other dmge. Crefully inspect res tht pss over sheves or through roller guides. Note the loction nd concentrtion of roken wires. Replce wire rope if more thn 6 wires re roken in one ly, or more thn 3 wires re roken in one strnd in one ly. See Figure 6. Mke sure the lod hook or other device is securely ttched to the wire rope, nd the wire rope where it is ttched is not fryed, corroded, roken, or otherwise dmged. Mesure the throt opening, thickness, nd twist of the hook. Replce the hook if it shows signs of dmge. See Figure 7. Mke sure hook ltch opens without inding nd closes when relesed. Check the nchor holes in the drum nd the surrounding re for signs of wer or distortion. PLACE enough weight to keep the wire rope stright nd tightly drwn. Mesure the dimeter of the wire rope, especilly in res where wer is noticele. Replce the wire rope if the dimeter mesures elow the minimum dimeter t ny point. See Figure 8. REMOVE THE WINCH nd inspect it y following the instructions in the Winch Owner s Mnul. DISASSEMBLE THE CRANE, nd inspect ech prt for dmge. REMOVE THE CRANE BASE from the foundtion. Check fsteners for stripped threds, wer, ending, nd other dmge. Check the foundtion for crcks, corrosion, nd other dmge. FASTEN THE CRANE BASE securely to the foundtion.

Owner's Mnul for Thern 5122 Series Portle Dvit Crnes pge 15 Figure 8 Rope Dimeter correct dimeter incorrect The wire rope ssemly must e replced if the dimeter mesures less thn the minimum dimeter t ny point. wire rope size minimum dimeter 1/8 in 7/64 in (.1094 in) 3/16 in 11/64 in (.1719 in) 1/4 in 15/64 in (.2344 in) h i REASSEMBLE THE CRANE. TEST CRANE PERFORMANCE y operting the crne with lod equl to the lod rting. Listen for unusul noises, nd look for signs of dmge s you operte the crne. Mke sure the wire rope winds evenly nd tightly onto the drum. If it is loose or uneven, rewind it efore continuing. Mke sure the lod moves smoothly, without hesittion or strin, nd tht the winch hndle rottes freely in oth directions. On hnd operted models, mke sure the winch hndle rottes freely in oth directions. On power operted models, mke sure the winch responds to the control device. It must rotte s shown on the control lels nd it must turn off when you relese the control. Mke sure the oom rottes freely when you push it, nd remins sttionry when you relese it. Check the rke. Rise the lod, then lower it nd stop it few feet off the ground. If the lod continues to cost or creep under norml operting conditions, the rke my e worn nd in need of repir or replcement. Contct the fctory. Completely correct ll prolems efore continuing. Use the Trouleshooting Chrt to help determine the cuse of certin prolems. See Tle 3. Tle 3 Trouleshooting Chrt Contct the fctory for detiled instructions if you re required to disssemle the crne or winch for ny reson. Disssemly of the crne or winch efore contcting Thern, Inc. voids ll wrrnties. prolem cuse correction overheting oom ounces up nd down oom does not rotte oom rottes on its own unusul noises high pitched squek grinding noise rttling noise operted too long without rest................ llow to cool lod too hevy.............................. lighten lod poor luriction...inspect nd luricte s necessry ering seized up........................... inspect nd replce s necessry lod too hevy.............................. lighten lod mounting olts loose........................ tighten mounting olts to proper torque sheve worn or dmged...inspect nd replce s necessry foundtion loose or unlevel.................. inspect nd repir s necessry winch gers worn or dmged............... inspect nd repir s necessry rottion points contminted or worn......... inspect nd repir s necessry flnge ering roken or locked...inspect nd replce s necessry foundtion loose or unlevel.................. inspect nd repir s necessry mst ent, distorted, or lening...inspect nd repir s necessry poor luriction...luricte entire crne properly contminted luricnt t rottion points...... clen nd luricte rottion points loose olts, set screws or other fsteners...tighten ll olts nd other fsteners Refer to the Winch Owner s Mnul for possile prolems with the winch nd rke.

pge 16 Owner's Mnul for Thern 5122 Series Portle Dvit Crnes 3.4 Repiring the Crne Importnt! It is your responsiility to determine when to replce prts. When considering whether to continue using prt or to replce it, rememer tht replcing it is the est wy to void further equipment dmge. Appoint qulified person to e responsile for ll repirs to the equipment. 3.4.1 GET FACTORY AUTHORIZATION for ll repirs. Unuthorized repirs will void the wrrnty, nd my led to dmge or filure of the crne. 3.4.2 REPLACE DAMAGED OR POORLY OPERATING PARTS with Thern repir prts. 3.4.3 REFINISH AREAS where the pint is worn or flking. A good finish helps to protect ginst corrosion nd wether dmge. c REMOVE THE FINISH from dmged res, down to the re metl. CLEAN THE AREA thoroughly. REPAINT with high qulity primer nd finishing cot. 3.4.4 TO ORDER REPAIR PARTS, contct your locl deler. Include the following informtion when ordering: model numer seril numer (or code numer) prt numer dte purchsed, nd from whom description of wht hppened, or wht is wrong your nme nd return ddress 4.1 Trnsporting the Crne Importnt! Keep record of wht you ship, nd when you send it. 4.1.1 REMOVE THE WIRE ROPE from the crne if necessry, y disconnecting it from the winch drum. 4.1.2 FOLD THE BOOM DOWN y removing the rer pin nd lowering the oom until it rests ginst the mst. Replce the pin to void loosing it. 4.1.3 PACK THE CRANE for trnsport, using the originl pckging mterils, if pproprite. 4.1.4 INSPECT THE CRANE ccording to Section 3.3.3 Instructions for Frequent Inspection efore instlling it for opertion.

Owner's Mnul for Thern 5122 Series Portle Dvit Crnes pge 17 4.2 Storing the Crne 4.2.1 REMOVE THE WIRE ROPE from the crne if necessry, y disconnecting it from the winch drum. 4.2.2 FOLD THE BOOM DOWN, or remove the oom from the mst. 4.2.3 STORE THE CRANE in cool clen plce wy from corrosive chemicls nd moisture. 4.2.4 SEAL THE CRANE in plstic with desiccnt to help protect it from rust, corrosion, nd other dmge. 4.2.5 INSPECT THE CRANE ccording to Section 3.3.4 Instructions for Periodic Inspection efore instlling it for opertion. Tle 4 Winch Weight Chrt Component Weight Crne Winch LB KG 5122M1 / 5122M1GAL / 5122M1SS M4022PB-K 15 6.8 5122M3 / 5122M3GAL / 5122M3SS M4042PBSS-K 23 10.4 Tle 4 Crne Weight Chrt Model 5122M1 / 5122M1GAL Prt Numers Component Weight Assemly/Disssemly Weight (with pins) Component Stndrd / Glvnized LB KG LB KG Mst B1483 / B1483GAL 25 11.3 - - Boom C4372 / C4372GAL 27 12.2 - - TOTAL 52 23.5 53 24.1 Model 5122M1SS Prt Numers Component Weight Assemly/Disssemly Weight (with pins) Component Stinless LB KG LB KG Mst B2467 26 11.8 - - Boom C4375 30 13.6 - - TOTAL 56 25.4 57 25.9 Model 5122M3 / 5122M3GAL Prt Numers Component Weight Assemly/Disssemly Weight (with pins) Component Stndrd / Glvnized LB KG LB KG Mst B1483 / B1483GAL 25 11.3 - - Boom C4372 / C4372GAL 27 12.3 - - Adpter Plte SB6013 4 1.8 - - TOTAL 56 25.4 57 25.9 Model 5122M3SS Prt Numers Component Weight Assemly/Disssemly Weight (with pins) Component Stinless LB KG LB KG Mst B2467 26 11.8 - - Boom C4375 30 13.6 - - Adpter Plte SB6013 4 1.8 - - TOTAL 60 27.2 61 27.7

pge 18 Owner's Mnul for Thern 5122 Series Portle Dvit Crnes 5122 Series 5122GAL Series 5122SS Series 5122 Series Portle Dvit Crnes Red Fusiond Glvnized Finish Stinless Steel item description prt numer qty. prt numer qty. prt numer qty. 1 MAST WELDMENT B1483RED 1 B1483GAL 1 B2467 1 2 CAPSCR HEXHD.375-16NCx1.250 SST A4180 2 A4180 2 A4180 3 3 NUT HEX NYLK.375-16NC SST A4325 2 A4325 2 A4325 3 4 BOOM WELDMENT C4372RED 1 C4372GAL 1 C4375 1 5 CLEVIS PIN A2840 2 A2840 2 A2840 2 6 PIN HAIR COTTER.500/.625x.148 DIA SST A2838 2 A2838 2 A2838 2 7 PIN CLEVIS.750x1.765 EFF LENGTH SST A4438 1 A4438 1 A4438 1 8 PIN COTTER.125x1.250 SST A4305 1 A4305 1 A4305 1 9 SHEAVE ASSEMBLY B2462 1 B2462 1 B2462 1 10 PIN CLEVIS.250x1.734 EFF LENGTH SST A6905 1 A6905 1 A6905 1 11 PIN HAIR COTTER.188/.250x.042 DIA SST A6452 1 A6452 1 A6452 1 12 LOAD RATING LABEL A7559 2 A7559 2 A7559 2 13 THERN LOGO A6889 1 A6889 1 A6889 1 14 NAMEPLATE SST A1976 1 A1976 1 A1976 1 15 WARNING LABEL A1961 1 A1961 1 A1961 1 4 6 5 1 10 11 2 3 9 8 7 12 13 14 15 for winch nd For winch fsteners see nd fsteners, pge 17 see pge 19.

Owner's Mnul for Thern 5122 Series Portle Dvit Crnes pge 19 5122 Series Winch 5122M1 5122M1SS 5122M3 5122M3SS item description prt numer qty. prt numer qty. prt numer qty. prt numer qty. 1 HAND WINCH M4022PB-K 1 M4022PB-K 1 M4042PBSS-K 1 M4042PBSS-K 1 2 CAPSCR HEXHD.375-16NCx1.250 SST A4180 2 A4180 2 A4180 3 A4180 3 3 NUT HEX NYLK.375-16NC SST A4325 2 A4325 2 A4325 5 A4325 3 4 ADAPTER PLATE SB6013 1 5 CAPSCR HEXHD.375-16NCx1.500 SST A3884 2 1 1 1 1 2 3 2 3 5 4 2 3 5122M1 5122M1SS 5122M3 5122M3SS 2 3 514 Wheel Bse item description prt numer qty. 1 BASE C1252 1 2 CAPSCR HEXHD.375-16NC X 2.500 ZNPL GR5 A3518 4 3 NUT HEX.375-16NC ZNPL GR5 A3231 4 4 WASHER HELSPRLK.375 X.683 X.094 ZNPL A2926 4 5 SOCKET BASE C1254 1 6 CAPSCR HEXHD.500-13NC X 4.500 ZNPL GR5 A3135 1 7 NUT HEX.500-13NC ZNPL GR2 A3227 1 8 WASHER HELSPRLK.500 X.873 X.125 ZNPL A2930 1 9 PIN CLEVIS.500 X 2.266 EFF LENGTH STL A2024 2 10 WASHER FLT SAE.500 X 1.062 X.095 ZNPL A2932 2 11 PIN COTTER.125 X 1.000 STL ZNPL A3179 2 12 WHEEL A2023 2 5 2 3 4 6 7 8 9 10 11 1 12 514 Wheel Bse

pge 20 Owner's Mnul for Thern 5122 Series Portle Dvit Crnes 522 Series Pedestl/Socket Bse 522 522GAL 522SS item description prt numer qty prt numer qty prt numer qty 1 BASE C1250 1 C1250 1 C2560 1 2 CAPSCREW HEXHD.500-13NC X 4.500 SST A4198 1 A4198 1 A4198 1 3 WASHER HELSPRLK.500 X.879 X.125 SST A3937 1 A3937 1 A3937 1 4 HEX NUT.500-13NC SST A4717 1 A4717 1 A4717 1 5 ROLLER A6791 2 A6791 2 A6791 2 6 FLANGE BEARING 2.890ID X 3.50OD X 2.25 522 B1914 1 B1914 1 B1914 1 522W Series Wll Bse 522W 522WGAL 522SSW item description prt numer qty prt numer qty prt numer qty 1 BASE C3082 1 C3082 1 C3116 1 2 CAPSCREW HEXHD.500-13NC X 4.500 SST A4198 1 A4198 1 A4198 1 3 WASHER HELSPRLK.500 X.879 X.125 SST A3937 1 A3937 1 A3937 1 4 HEX NUT.500-13NC SST A4717 1 A4717 1 A4717 1 5 ROLLER A6791 2 A6791 2 A6791 2 6 FLANGE BEARING 2.890ID X 3.50OD X 2.25 B1914 1 B1914 1 B1914 1 1 1 2 3 4 5 2 3 4 5 522 Series Pedestl/Socket Bse 522W Series Wll Bse

Owner's Mnul for Thern 5122 Series Portle Dvit Crnes pge 21 5122 Series Performnce Chrcteristics 2 5122 Series with M1 winch 5122 Series with M3 winch wire rope wire rope lod rting lod rting lod rting lod rting lift elow floor di. length position A position B position A position B level (min mx) 1 3/16 in 20 ft 500 l 500 l 500 l 500 l 9 10 ft 3/16 in 28 ft 500 l 500 l 500 l 500 l 17 18 ft 3/16 in 36 ft 500 l 500 l 500 l 500 l 25 26 ft 3/16 in 45 ft 500 l 500 l 500 l 500 l 34 35 ft 3/16 in 60 ft 500 l 500 l 49 50 ft 3/16 in 75 ft 500 l 500 l 64 65 ft 1 Lift elow floor level vries depending on oom position nd se configurtion. For longer lifts, plese contct fctory. 2 Performnce Chrcteristics re for stndrd products referred to in this mnul. Non-stndrd products my vry from the originl design. Contct Thern, Inc. for this informtion. B A lift elow floor level

pge 22 Owner's Mnul for Thern 5122 Series Portle Dvit Crnes NOTES:

Owner's Mnul for Thern 5122 Series Portle Dvit Crnes pge 23 NOTES:

Thern, Incorported 5712 Industril Prk Rod Winon, MN 55987 PHN 507-454-2996 FAX 507-454-5282 EMAIL: info@thern.com www.thern.com