Owner s Man ual. For 5110 and 5124 Series Portable Davit Cranes. Provided by:

Transcription

1 Provided y: Red this Own er s Mn u l thor ough ly e fore op er t ing the equip ment. Keep it with the equip ment t ll times. Re plce ments re vil le from Thern, Inc., PO Box 347, Winon, MN 55987, IMPORTANT: Plese record product informtion on pge 2. This informtion is re quired when clling the fc to ry for service. Owner s Mn ul For 50 nd 524 Series Portle Dvit Crnes

2 pge 2 Owner's Mnul for Thern 50 nd 524 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., 572 Industril Prk Rod, Winon, Minnesot 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 970 sttes tht it is the employer s re spon si il i ty 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 own er's re spon - si il i ty to o tin copies of these regultions nd to determine the suit il i ty of the equip ment to its intended use. This Owner s Mnul, nd wrning lels ttched to the equip ment, re to serve s guidelines for hzrd-free instlltion, op er tion, nd mintennce. They should not e understood to prepre you for every pos si le sitution. The informtion contined in this mnul is pplicle only to the Thern 50 nd 524 Series Portle Dvit Crnes. Do not use this mnul s source of in for - m tion for ny other equip ment. The following symols re used for emphsis throughout this mn u l: Filure to follow WARNING! instructions my result in equipment dm ge, property dmge, nd/or serious personl injury. Filure to follow CAUTION! instructions my result in equipment dmge, prop er ty dmge, nd/or minor personl injury. Importnt! Filure to follow importnt! instructions my result in poor per for mnce of the equipment.

3 Owner's Mnul for Thern 50 nd 524 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. Disconnect electric power efore servicing the equipment. Keep ll unnecessry personnel wy from 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. When operting the rtchet jck, void un-threding. Test the trvel limits of the rtchet jck efore ssemly to the crne nd efore loding, to verify it does not un-thred. Contct Thern if it does un-thred. 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. To do so could result in filure of the equipment. 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 use the crne nd winch 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 force the rtchet hndle pst trvel limits. This could sheer the trvel stop pin nd cuse dmge or injury.

4 pge 4 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes. 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 op er tion. 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... CONSULT APPLICABLE CODES AND REGULATIONS for specific rules on instlling the equipment...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...3 INSTALL THE CRANE on level surfce. An uneven surfce my cuse the oom to rotte in the direction the mst is lening...4 FASTEN THE BASE securely to the foundtion to withstnd pplicle overturning moments nd mounting olt rection. See Tle. FOR STANDARD PRODUCTS referred to in this mnul, use 5/8 - inch corse thred fsteners, grde 5 or etter. Torque for Grde 5 fsteners without luriction is 50 ft l. Mke sure mounting holes re secured to solid foundtion le to support the crne nd the lod under ll conditions with design fctors sed on ccepted engineering prctices. 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 PROFES- SIONAL TO OBTAIN PROPER STRUCTURE OR FOUNDATION SPECIFI- CATIONS FOR THE MOUNTING OF THERN PRODUCTS. Tle Crne Rections Pedestl Wll-Mount Bse Only Bse Only Crne Mst Suggested Axil Force Axil Force Sher Force Model Moment Bolt Size Per Bolt Per Bolt 50 37,87 in-l 5/8 inch,844 l,304 l,77 l ,236 in-l 5/8 inch 4,644 l 3,284 l 2,78 l Force in tension

5 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes pge 5.2 Assemling the Crne Importnt! Inspect the crne during s sem ly ccording to the Instructions for Periodic Inspection. This will give you record of the con di tion 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 dm ged. Do not overtighten fsteners, this my strip threds or cuse dmge to other prts. Figure Cotter Pins end rms ck When instlling the rtchet jck, support the end of the oom so the oom does not fll nd the rtchet jck does not swing up cusing dmge or injury. When instlling the oom extension, hold the oom extension securely so it does not slide ruptly in or out of the oom cusing dmge or injury..2. STUDY PARTS DRAWINGS to understnd how the crne is ssemled. See pges LUBRICATE PINS nd other components prior to ssemly. See Section 3.3 Luricting the Crne..2.3 INSTALL THE BASE nd then ssemle the crne in the following order. c d e f g h INSTALL THE MAST in the se. Move the mst side to side to mke sure the ottom of the mst properly sets on the pin in the ottom of the se. FASTEN THE BOOM to the mst using the clevis pin nd lynch pin provided. Mke sure the oom is positioned correctly, with the crrying hndles locted on the sme side s the hndles on the mst. INSTALL THE RATCHET JACK y fstening one end of the rtchet jck to the ers on the oom with the clevis nd lynch pin provided. Crefully pivot the oom up until the other end of the rtchet jck ligns with the ers on the mst, nd secure the rtchet jck to the mst using the clevis pin nd lynch pin provided. ADJUST THE BOOM with the rtchet jck so the oom is slightly ove the lowest oom ngle. See Figures 4 nd 4. Do not lower oom elow the lowest point, or the oom could fll nd my result in the lod escping. SLIDE THE BOOM EXTENSION into the oom, nd secure in plce with the clevis pin nd lynch pin provided. Mke sure the oom extension is positioned correctly with the oom ers positioned up. See ssemly drwings. 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 ove the sheve t the end of the oom. Secure in plce with the hir cotter pin provided. INSTALL THE HANDLE on the lower end of the oom, using the clevis pin nd lynch pin provided..2.4 FASTEN THE WINCH to the mounting plte on the oom using the 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 extension..2.5 INSTALL THE WINCH HANDLE on hnd winches, or connect electric current on power winches. Refer to instructions in the Winch Owner s Mnul..2.6 INSTALL THE WIRE ROPE. Use wire rope ssemlies in the length specified on pge 23. 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 instructions in the Winch Owner s Mnul..2.7 MAKE SURE ALL LYNCH PINS ARE PROPERLY INSTALLED, nd cotter pins properly ent to secure them in plce. See Figure.

6 pge 6 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes 2. 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 per for mnce of the equipment. 2.. THE FORCE REQUIRED to lift the lod must not exceed the lod rting of the crne. Consider the totl force required to lift the lod, not the weight of the lod 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 PERFORMANCE RATINGS of the equipment re ffected y the position of the oom, the mount of wire rope you use nd whether you use single or two prt line. Two-prt line not ville on the 50 Series. See the Performnce Chrcteristics Tles on pge 23. c LOAD RATING represents the mximum force tht cn e plced on new equipment. Lod rtings re ssigned vlues for specific oom positions, wire rope lengths, nd rigging configurtions (single or two prt line). Crne lod rtings decrese s you extend the oom, nd increse with twoprt line. Two-prt line not ville on 50 Series. See the Performnce Chrcteristics Tles pge 23. LIFT vries with the position of the oom, the length of the wire rope, nd the rigging configurtion (single or two prt line). Two-prt line not ville on the 50 Series. REACH vries with the position of the oom 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 lifting 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. CONTACT THE FACTORY FOR MORE INFORMATION.

7 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes pge Prepring for Opertion Importnt! Strt n inspection progrm s soon s you put the crne into use. Appoint qulified person to e responsile for regulrly in spect ing the equipment. Keep written records of inspec tion. This llows comprison with com ments from previous inspec tions so you cn see chnges in condition or per for mnce. When operting the rtchet jck, void un-threding. Test the trvel limits of the rtchet jck efore ssemly to the crne nd efore loding, to verify it does not un-thred. Contct Thern if it does un-thred. Do not force the rtchet hndle pst trvel limits. This could sheer the trvel stop pin nd cuse dmge or injury. When djusting oom length, set the oom ngle just ove the lowest ngle nd hold the oom extension securely so it does not slide ruptly in or out of the oom cusing dmge or injury. See Figures 4 nd 4. When djusting the oom ngle, rise the rottion hndle with one hnd nd operte the rtchet jck with the other to void jmming the hndles nd cusing dmge or injury. Figure 2 Positioning the Boom center line 2.2. CONSIDER THE OPERATION. Do not egin until you re sure you cn perform the entire opertion without hzrd 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. correct center line KNOW YOUR LOAD nd mke sure you do not exceed the lod rting of the crne or ny other equipment in the system 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 2. ADJUST BOOM LENGTH y moving the oom extension in or out. The lod rting decreses s you increse oom length. See the Performnce Chrcteristics Tles pge 23. ADJUST BOOM ANGLE y operting the rtchet jck to rise or lower the oom. The lift height elow se level decreses s you rise the oom. See the Performnce Chrcteristics Tles pge 23. incorrect CONFIGURE THE CRANE for single prt or two-prt line opertion. Lod rtings my increse with two-prt line, lift height elow se level will decrese with two prt line. Two prt line not ville on 50 Series. See the Performnce Chrcteristics Tles pge 23. Study prts drwings on pges 8-22.

8 pge 8 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes 2.3 Attching the Lod Figure 3 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 CLEAR OBJECTS from the pth of the lod so you cn move it freely nd oserve it t ll times during the opertion 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 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 3. 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 op er tion, get help from nother person. Appoint supervisor if more thn one person is involved in the opertion. This will reduce con fu sion nd increse sfety. When lifting lod, use tg line to keep the lod from swing ing or twisting, while keeping yourself wy from the lod. When operting the rtchet jck, void un-threding. Test the trvel limits of the rtchet jck efore ssemly to the crne nd efore loding, to verify it does not un-thred. Contct Thern if it does un-thred. Do not force the rtchet hndle pst trvel limits. This could sheer the trvel stop pin nd cuse dmge or injury MOVE THE LOAD slowly nd smoothly, only smll distnce t first. Mke sure the lod is lnced nd securely ttched efore continuing OPERATE THE WINCH to rise or lower the lod. Refer to the instructions in the Winch Owner s Mnul 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 OPERATE THE RATCHET JACK if necessry, to djust the ngle of the oom to keep the sheve centered over the lod 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. USE THE HANDLE to rotte the oom. Do not push or pull the lod or the wire rope to rotte the oom.

9 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes pge 9 Figure 4 Lowest Boom Angle degrees Figure 4 Lowest Boom Angle degrees 3. Clening the Crne Importnt! Increse the frequency of min tennce 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.. 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 corro sion. WIPE OFF excessive mounts of oil to void the ccumultion of dirt REMOVE UNNECESSARY OBJECTS from the re surrounding the crne.

10 pge 0 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes 3.2 Disssemling the Crne When removing the oom extension, hold the oom extension securely so it does not slide ruptly in or out of the oom cusing dmge or injury. When removing the rtchet jck, support the end of the oom so the oom does not fll nd the rtchet jck does not swing up cusing dmge or injury REMOVE ANY ATTACHED LOAD from the wire rope REMOVE THE WIRE ROPE c REMOVE THE ROPE KEEPER CLEVIS PIN locted t the end of the oom. UNWIND THE ROPE from the winch drum nd relese the nchor. REPLACE THE ROPE KEEPER CLEVIS PIN REMOVE THE WINCH HANDLE on hnd winches, or disconnect electric current on power winches. Refer to instructions in the Winch Owner s Mnul REMOVE THE WINCH from the mounting plte. SECURE THE WINCH to prevent it from flling off when the fsteners re loosened. LOOSEN AND REMOVE the fsteners REMOVE THE ROTATION HANDLE from the ck of the oom. (NOTE: Remove the rottion hndle first efore the rtchet jck to void it swinging up if the oom should fll when the rtchet jck is relesed) REMOVE THE LYNCH PIN nd clevis pin nd remove the hndle. REPLACE THE CLEVIS PIN nd lynch pin REMOVE THE BOOM EXTENSION. c ADJUST THE BOOM ANGLE using the rtchet jck, so the oom is just slightly ove horizontl. SECURE THE BOOM EXTENSION then remove the lynch pin nd clevis pin securing the oom extension to the oom. CAREFULLY PULL THE BOOM EXTENSION out of the oom, then reinstll the clevis pin nd lynch pin in the oom REMOVE THE RATCHET JACK. c SECURE THE BOOM to prevent it from flling when the rtchet jck is relesed. DISCONNECT THE RATCHET JACK t the mst ers (ottom) y removing the lynch pin nd clevis pin nd slowly lower the oom until it is resting ginst the mst. Be creful tht the rtchet jck does not swing up nd cuse injury. REMOVE THE PINS AT THE BOOM (top) to disconnect the rtchet jck from the crne. Hold onto the rtchet jck to prevent it from flling wy.

11 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes pge d RECONNECT the clevis pins to the oom nd mst with the pproprite lynch pins DISCONNECT THE BOOM from the mst. c SECURE THE BOOM to prevent it from flling wy when the pins re removed. REMOVE THE LYNCH PIN AND CLEVIS PIN nd crefully remove the oom. REPLACE the clevis pin nd lynch pin in the mst REMOVE THE MAST FROM THE BASE, y lifting it out of the se. TO REASSEMBLE THE CRANE, SEE ASSEMBLING THE CRANE, SEC- TION Luricting the Crne Importnt! Mke sure luricnt hs temper ture 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 LUBRICATE ALL PINS efore instlltion nd t lest every 3 months. Use grese rush to pply light film of NLGI #2 grese to ll pins LUBRICATE THE MAST BEARING efore instlltion nd t lest every 3 months. Use grese rush to pply film of NLGI #2 grese to oth inside nd outside surfces LUBRICATE THE PIN BUSHING locted on the ottom of the mst efore instlltion nd t lest every 3 months. Use grese rush to pply film of NLGI #2 grese to the ushing LUBRICATE THE RATCHET JACK efore instlltion nd t lest every 3 months. Use grese gun to pply n NLGI #2 grese to the grese fittings on the rtchet jck until excess grese cn e seen LUBRICATE THE WINCH. Refer to the Winch Owner s Mnul for instructions LUBRICATE THE WIRE ROPE nd other equipment y following the mnufcturers recommendtions.

12 pge 2 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes 3.4 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 in spect ing the equipment. Keep written records of inspec tion. This llows comprison with com ments from previous inspec tions so you cn see chnges in condition or per for mnce. 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 CONSULT APPLICABLE CODES AND REGULATIONS for specific rules on inspecting the crne nd other equipment REFER TO THE WINCH OWNER S MANUAL for informtion regrding winch inspection 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 nd Figure 5. Check the wire rope for reduction of rope dimeter from loss of core support, or wer of outside wires. See Figure 7. 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. Mke sure the entire crne is properly luricted. Mke sure ll fsteners re tight nd secure. Mke sure mounting fsteners re tightened securely. Check the rtchet jck for signs of lekge or dmge, nd mke sure it opertes smoothly to rise nd lower the oom. 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. 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 the hndle, 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.

13 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes pge 3 Tle 2 Inspection Checklist checked oxes indicte dmge or prolem in need of repir dmges prolems generl fi nish wethered, fl king, 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 5 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 7 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 6 hook ltch fils to close when relesed replce if twist is 0 degrees or more twist = replce if throt width is 5% lrger thn nominl throt width = replce if thickness is 0% less thn nominl thickness = lels nd pltes dirty, illegile, otherwise dmged loosely ttched or missing comments: uthorized signture: dte

14 pge 4 Owner's Mnul for Thern 50 nd 524 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 in spec tion. Whenever you hve, or think you my hve, overloded or shock loded the crne. Figure 5 Broken Wires wire strnd Figure 6 Lod Hook Inspection twist one ly Wire rope ssemly must e replced if more thn 6 wires re ro ken in one ly, or if more thn 3 wires re roken in one strnd in one ly Instructions for Periodic Inspection VISUALLY INSPECT the crne nd ll other equipment. 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 nd 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. Check the rtchet jck for signs of lekge or dmge, nd mke sure it opertes smoothly to rise nd lower the oom. Mke sure ll lels nd pltes re redle, firmly ttched, free of dmge nd clen. Replcements re ville from the fctory. REMOVE THE WIRE ROPE entirely from the crne. 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 5. 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 6. 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. throt opening thickness The wire rope ssemly must e replced if the throt opening is 5% wider thn nominl, if the thick ness is 0% less thn nominl, or if the hook is twisted 0 or more. c d e f 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 7. REMOVE THE WINCH nd inspect it y following the instructions in the Winch Owner s Mnul. DISASSEMBLE THE CRANE y removing the rtchet jck, the oom, nd the winch. Inspect ech component 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.

15 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes pge 5 Figure 7 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 dimeter minimum dimeter /4 in 5/64 in (.2344 in) 5/6 in 9/64 in (.2969 in) g h i FASTEN THE CRANE BASE securely to the foundtion. 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. 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 the hndle, 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. Tle 3 Trouleshooting Chrt Completely correct ll prolems efore continuing. Use the Trouleshooting Chrt to help determine the cuse of certin prolems. See Tle 3. 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 fl nge 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.

16 pge 6 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes 3.5 Repiring the Crne Importnt! It is your responsiility to deter mine when to replce prts. When considering whether to continue using prt or to replce it, re mem er tht re plc ing it is the est wy to void further equipment dm ge. Appoint qulified person to e responsile for ll repirs to the equipment GET FACTORY AUTHORIZATION for ll repirs. Unuthorized repirs will void the wrrnty, nd my led to dmge or filure of the crne REPLACE DAMAGED OR POORLY OPERATING PARTS with Thern repir prts 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 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 Tle 4 Crne Weight Chrt Model 50 Prt Numers Component Weight Assemly/Disssemly Weight (with pins) Component Stndrd / Glvnized / Stinless LB KG LB KG Mst C3857RED / C3857GAL / C Boom D2558RED / D2558GAL / D Boom Ext C3858RED / C3858GAL / C Jck C340 / C34 / C Hndle B356RED / B356GAL / B TOTAL Model 524 Prt Numers Component Weight Assemly/Disssemly Weight (with pins) Component Stndrd / Glvnized / Stinless LB KG LB KG Mst C3385RED / C3385GAL / C Boom D2049RED / D2049GAL / D Boom Ext C3386RED / C3386GAL / C Jck C340 / C34 / C Hndle B356RED / B356GAL / B TOTAL Winches Configurtion Prt Numers LB KG M M432PB-K 26.8 M2 4WM2-K M3 M432PBSS-K E2 4WP2-K E K E4DC 4777DC-K

17 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes pge 7 4. Trnsporting the Crne Importnt! Keep record of wht you ship, nd when you send it. 4.. PARTIALLY DISASSEMBLE THE CRANE into components tht cn e trnsported PACK THE CRANE for trnsport, using the originl pckging mterils, if pproprite PACK THE WINCH for trnsport, using the originl pckging mterils, if pproprite. Plese see the winch owner s mnul for instructions REASSEMBLE THE CRANE t its new loction following the instructions under Section.2 Assemling the Crne INSPECT THE CRANE ccording to the Instructions for Frequent Inspection efore instlling it for opertion. See Section Instructions for Frequent Inspection. 4.2 Storing the Crne 4.2. PARTIALLY DISASSEMBLE THE CRANE nd store ll prts in cool clen plce wy from corrosive chemicls nd moisture SEAL THE CRANE in plstic with desiccnt to help protect it from rust, corrosion, nd other dmge SEAL THE WINCH in plstic with desiccnt to help protect it from rust, corrosion, nd other dmge. Plese see the winch owner s mnul for instructions REASSEMBLE THE CRANE t its new loction following the instructions under Assemling the Crne INSPECT THE CRANE ccording to Section Instructions for Periodic Inspection efore instlling it for opertion.

18 pge 8 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes 50 Series 50GAL Series 50SS Series 50 Series Portle Dvit Crnes Red Fusiond Glvnized Finish Stinless Steel item description prt numer qty. prt numer qty. prt numer qty. MAST C3857RED C3857GAL C BOOM D2558RED D2558GAL D BOOM EXTENSION C3858RED C3858GAL C COTTER PIN.25 X.250 A4305 A4305 A CLEVIS PIN.750 X.765 A4438 A4438 A COTTER PIN.88/.250 X.042 DIA A6452 A6452 A CLEVIS PIN.250 X.734 A6905 A6905 A SHEAVE ASSEMBLY B2462 B2462 B CLEVIS PIN.500 X A8082 A8082 A LYNCH PIN A A A CLEVIS PIN.750 X A7257 A7257 A CLEVIS PIN.906 X A A A CLEVIS PIN.625 X A7260 A7260 A RATCHET JACK C340 C34 C34 5 HANDLE B356RED B356GAL B WARNING LABEL A96 A96 A96 7 IMPORTANT INSERT PIN LABEL A288 8 A288 8 A LOAD RATING LABEL A8083 A8083 A THERN LOGO A6889 A6889 A NAMEPLATE SST A976 A976 A976 for winch nd fsteners see pge

19 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes pge Series 524GAL Series 524SS Series 524 Series Portle Dvit Crnes Red Fusiond Glvnized Finish Stinless Steel item description prt numer qty. prt numer qty. prt numer qty. MAST C3385RED C3385GAL C BOOM D2049RED D2049GAL D BOOM EXTENSION C3386RED C3386GAL C COTTER PIN.25 X.250 A4305 A4305 A CLEVIS PIN.750 X.765 A4438 A4438 A COTTER PIN.88/.250 X.042 DIA A6452 A6452 A CLEVIS PIN.250 X.734 A663 A663 A663 8 SHEAVE ASSEMBLY B2462 B2462 B CLEVIS PIN.750 X A7257 A7257 A LYNCH PIN A A A CLEVIS PIN.250 X A7258 A7258 A CLEVIS PIN.906 X A A A CLEVIS PIN.625 X A7260 A7260 A RATCHET JACK C340 C34 C34 5 HANDLE B356RED B356GAL B WARNING LABEL A96 A96 A96 7 IMPORTANT INSERT PIN LABEL A288 8 A288 8 A LOAD RATING LABEL A726 A726 A726 9 THERN LOGO A6889 A6889 A NAMEPLATE SST A976 A976 A976 for winch nd fsteners see pge

20 pge 20 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes 50M Series 50M2 Series 50M3 Series 50E2 Series 50 nd 524 Series Winch 524M Series 524M2 Series 524M3 Series 524E2 Series item description prt numer qty. prt numer qty. prt numer qty. prt numer qty. WINCH M432PB-K 4WM2-K M432PBSS-K 4WP2-K 2 CAPSCREW HEXHD A A A A HEX NUT A A A A M nd 50M3 Series 50M2 Series 50E2 Series 524M nd 524M3 Series 524M2 Series 524E2 Series 524 Series Two Prt Line Option Model 524TPL item description prt numer qty. Clevis Pin A Cotter Pin A Swivel 5/6 Chin Size A Sntch Block with Hook A Ltch Kit A

21 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes pge 2 50E4 50E4GAL 50E4SS 524E4 524E4GAL 524E4SS 50E4 nd 524E4 Series Winch Red Fusiond Glvnized Finish Stinless Steel item description prt numer qty. prt numer qty. prt numer qty. POWER WINCH 4777-K 4777-K 4777-K 2 MOUNTING PLATE ASSEMBLY C34 C34GAL C34 2 MOUNTING PLATE C3RED C3GAL C3RED 2 CAPSCREW HEXHD.375-6NC X.750 A A A c WASHER HELSPRLK.375 X.683 X.094 A A A d CAPSCREW HEXHD.32-8NC X A A A e HEX NUT NYLK.32-8NC A A A f FLAT WASHER SAE.32 X.688 X.065 A A A E4DC 50E4DCGAL 50E4DCSS 524E4DC 524E4DCGAL 524E4DCSS 50E4DC nd 524E4DC Series Winch Red Fusiond Glvnized Finish Stinless Steel item description prt numer qty. prt numer qty. prt numer qty. POWER WINCH 4777DC-K 4777DC-K 4777DC-K 2 MOUNTING PLATE ASSEMBLY C34 C34GAL C34 2 MOUNTING PLATE C3RED C3GAL C3RED 2 CAPSCREW HEXHD.375-6NC X.750 A A A c WASHER HELSPRLK.375 X.683 X.094 A A A d CAPSCREW HEXHD.32-8NC X A A A e HEX NUT NYLK.32-8NC A A A f FLAT WASHER SAE.32 X.688 X.065 A A A CONTROL BRACKET B326 B326 B326 4 CAPSCREW SOXHD NC X.000 A A A HEX NUT NYLK NC A A A FLAT WASHER A A A c 2d 2e 2f E4 Series 50E4DC Series C34 Mounting 524E4 Series 524E4DC Series Plte Assemly

22 pge 22 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes 2 Pedestl Bse 50 Series 50 50GAL 50SS item description prt numer qty prt numer qty prt numer qty BASE C3876 C3876 C FLANGE BEARING B2450 B2450 B2450 When ordering prts, e sure to specify whether the fi nish is red, glvnized or stinless. 50 nd 524 Series Pedestl Bse Pedestl Bse 524 Series GAL 524SS item description prt numer qty prt numer qty prt numer qty BASE C3399 C3399 C FLANGE BEARING B3565 B3565 B3565 When ordering prts, e sure to specify whether the fi nish is red, glvnized or stinless. 2 Wll Bse 50W Series 50W 50WGAL 50SSW item description prt numer qty prt numer qty prt numer qty BASE C3880 C3880 C FLANGE BEARING B2450 B2450 B2450 When ordering prts, e sure to specify whether the fi nish is red, glvnized or stinless. 50W nd 524W Series Wll Bse Wll Bse 524W Series 524W 524WGAL 524SSW item description prt numer qty prt numer qty prt numer qty BASE C3407 C3407 C FLANGE BEARING B3565 B3565 B3565 When ordering prts, e sure to specify whether the fi nish is red, glvnized or stinless. 2 Socket Bse 50F Series 50F 50FGAL 50SSF item description prt numer qty prt numer qty prt numer qty BASE C3878 C3878 C FLANGE BEARING B2450 B2450 B2450 When ordering prts, e sure to specify whether the fi nish is red, glvnized or stinless. 50W nd 524W Series Socket Bse Socket Bse 524F Series 524F 524FGAL 524SSF item description prt numer qty prt numer qty prt numer qty BASE C3402 C3402 C366 2 FLANGE BEARING B3565 B3565 B3565 When ordering prts, e sure to specify whether the fi nish is red, glvnized or stinless.

23 Owner's Mnul for Thern 50 nd 524 Series Portle Dvit Crnes pge Series Performnce Chrcteristics 2 wire lod rting for 50M nd M3 lod rting for 50M2, E2, E4, nd E4DC lift elow rope wire rope position position 2 position 3 position 4 position position 2 position 3 position 4 fl oor level di. length (min mx) /4 in 20 ft 000 l 700 l 600 l 500 l 000 l 700 l 600 l 500 l 5 ft /4 in 28 ft 000 l 700 l 600 l 500 l 000 l 700 l 600 l 500 l 9 3 ft /4 in 36 ft 000 l 700 l 600 l 500 l 000 l 700 l 600 l 500 l 7 2 ft /4 in 45 ft 000 l 700 l 600 l 500 l 000 l 700 l 600 l 500 l ft /4 in 60 ft 000 l 700 l 600 l 500 l 000 l 700 l 600 l 500 l 4 45 ft /4 in 75 ft 000 l 700 l 600 l 500 l ft 524 Series Performnce Chrcteristics 2 wire lod rting for 524M nd M3 lod rting for 524M2, E2, E4, nd E4DC lift elow rope wire rope position position 2 position 3 position 4 position position 2 position 3 position 4 fl oor level di. length (min mx) /4 in 20 ft 2000 l 600 l 300 l 000 l 2000 l 600 l 300 l 000 l 0 4 ft /4 in 28 ft 800 l 600 l 300 l 000 l 700 l 600 l 300 l 000 l 8 2 ft /4 in 36 ft 600 l 600 l 300 l 000 l 600 l 600 l 300 l 000 l 6 20 ft /4 in 45 ft 600 l 600 l 300 l 000 l 500 l 500 l 300 l 000 l ft /4 in 60 ft 300 l 300 l 300 l 000 l 300 l 300 l 300 l 000 l ft /4 in 75 ft 200 l 200 l 200 l 000 l ft 5/6 in 20 ft 2000 l 600 l 300 l 000 l 2000 l 600 l 300 l 000 l 0 4 ft 5/6 in 28 ft 700 l 600 l 300 l 000 l 600 l 600 l 300 l 000 l 8 2 ft 5/6 in 36 ft 500 l 500 l 300 l 000 l 400 l 400 l 300 l 000 l 6 20 ft 5/6 in 45 ft 400 l 400 l 300 l 000 l 400 l 400 l 300 l 000 l ft 524 Series with 524TPL Two-Prt Line Kit Performnce Chrcteristics 2 wire lod rting for 524M nd M3 lod rting for 524M2, E2, E4, nd E4DC lift elow rope wire rope position position 2 position 3 position 4 position position 2 position 3 position 4 fl oor level di. length (min mx) /4 in 20 ft 2000 l 600 l 300 l 000 l 2000 l 600 l 300 l 000 l -3 ft /4 in 28 ft 2000 l 600 l 300 l 000 l 2000 l 600 l 300 l 000 l 5 ft /4 in 36 ft 2000 l 600 l 300 l 000 l 2000 l 600 l 300 l 000 l 5 9 ft /4 in 45 ft 2000 l 600 l 300 l 000 l 2000 l 600 l 300 l 000 l 9 3 ft /4 in 60 ft 2000 l 600 l 300 l 000 l 2000 l 600 l 300 l 000 l 7 20 ft /4 in 75 ft 2000 l 600 l 300 l 000 l ft 5/6 in 20 ft 2000 l 600 l 300 l 000 l 2000 l 600 l 300 l 000 l -3 ft 5/6 in 28 ft 2000 l 600 l 300 l 000 l 2000 l 600 l 300 l 000 l 5 ft 5/6 in 36 ft 2000 l 600 l 300 l 000 l 2000 l 600 l 300 l 000 l 5 9 ft 5/6 in 45 ft 2000 l 600 l 300 l 000 l 2000 l 600 l 300 l 000 l 9 3 ft B Lift elow fl oor level vries depending on oom position nd se confi gurtion. For longer lifts, plese contct fctory. 2 Performnce Chrcteristics re for stndrd products referred to in this mnul. Nonstndrd products my vry from the originl design. Contct Thern, Inc. for this informtion. A lift elow floor level

24 Thern, Incorported 572 Industril Prk Rod Winon, MN PHN FAX