Table of Contents

1 Introduction……………………………………………………………...3
2 Technical performance ……………………………………………....…4
2.1 Table of hoisting feature……………………………………………....4
2.2 Hoisting feature curve…………………………………………………5
2.3 Table of technical performance………………………………………..5
2.4 Power supply equipment feature………………………………………6
2.5 Relation between hoisting speed and jib length,
Max. hoisting load, control gear………….……………………....……6
3 Construction description in brief……………………………………......6
3.1 Steel construction………..………………………………………..……6
3.2 Operating mechanism……...……………………………….…………13
3.3 Electric control and operation system………………………………...19
4. Installation and disassembly…….………………………………...........21
4.1 Preparations for pre-installation……………………………….......…..22
4.2 Requirements and considerations…...……………………………....…23
4.3 Installation procedure….…………………………………………........23
4.4 Installation procedure of standard section of fixed tower………......…30
4.5 Adjusting method of safety devices………….…………………...........32
4.6 Test working of the crane……………………..………………....…......34
4.7 Dis assembly of the crane…..…..……….....……………………….......35
5 Usage of the crane……………....…….…………………………….........35
5.1 General requirement…...……………………………………………....35
5.2 Climbing operation………………………………………………….…36
5.3 Considerations for pre-operation…………………………………...…36
5.4 Operation of the crane………………………………………............…37
6 Maintenance and repairing………..……………………………....…......38
6.1 Maintenance of the mechanical equipment…………………..…..……38
6.2 Maintenance of the hydraulic climbing system……………………….39
6.3 Maintenance of the steel construction…………………………………40
6.4 Maintenance of the electric system……………………………........…40
6.5 Repairing………………………………………………………………41

Page No. 1
7 Attached mode…………………………………………………….........…41
7.1 Sketch of ACE TC5040 in attached mode…………………………..….42
7.2 Technical parameter………………………………………………….....42
7.3 Attached mode of model ACE TC5040……………………….......….....48
7.4 Operating instruction…………………………….…..………….....…...50
7.5 Attached size……………………………………………………............51
7.6 Measurement and tensioning…………………………..……………....52
7.7 Strength of concrete foundation………………………….……...……..52
8 Performance of associated facilities……………………………...........…52
8.1 Slewing Ergo meter…………………………………….….…...………52
8.2 Hoisting mechanism reducer…………………………….…….....……53
8.3 Slewing mechanism reducer…………………………………………...54
8.4 Drawing mechanism reducer………………………......…….…….…..54
8.5 Motor………………………………………….………………………..54
8.6 Slewing bearing……………..…………….…….……………….....…..55
8.7 Multi-functional travel limiter…...…….....…….………………………56
8.8 Ganged console in Cabin………..………………..………...…………..57
9 Drawing Paper and lists………….....……………………………….........59
9.1 Foundation……...…………………………...……………………….…60
9.2 Lubrication list………………….………………………………..….....61
9.3 Prime components weight List…………..……………………………..62
9.4 Bearing List………………………………………….………..………..63
9.5 Wire rope list………………………………………………..……….....63
9.6 Electric equipment Installation……………………………………..….64
9.7 Circuit diagram……………………...…….....…………………...…....65
9.8 Electric Power Diagram………........……………………………….....66
9.9 Electric Schematic diagram....................................................................67
9.10 Electric Penal Box................................................................................68
9.11 Electric Connection Diagram................................................................69
9.12 Electric Joystick.....................................................................................70
9.13 Counter weight drawing………..……………………...…………......71
9.14 Tools and spare parts along with tower crane………..........………..…72
9.15 Maintenance Schedule ……………............…………............…….....73
10 Warranty …...............................................................................................74

Page No. 2
1 Introduction
ACE TC5040 self-raising tower crane is designed based on summarizing the domestic
experience of the same type of self-raising tower crane, and absorbing the latest achievements
of science and technology abroad. It is a new generation self-raising tower crane.
This crane has the horizontal jib, trolley-jib, top slewing and hydraulic climbing system. The
Max. range of the hoisting jib is 50m, the Max. payload capacity is 6t, the rated hoisting
moment is 630 KN•m (63t•m).
This crane holds a streamline form, which is artistic and perfect.
This crane is used in multi-work task, and the suitable working range is wide. It can be
installed in different modes, such as, fixed, attached and traveling mode.
The hoisting mechanism applies eddy-current motor. It has a wide speed adjustable range,
stable operation and high reliability, and can achieve low speed in heavy load, high speed in
light load. Max. hoist speed is 80m/min and Min. speed is 4.5m/min. The slewing mechanism
applies the moment motor of converter to adjust the speed and DC brake. It has larger
overload capacity and the advantage of starting up at heavy load. These ensure that the crane
can start up and brake more stably and the operation is safer and more reliable.
By using the added standard section and hydraulic climbing system to raise the crane, the
hoisting height of the crane rises with the building height rises, the hoisting performance
keeps quite well at various heights
The Cabin of the crane is streamline form, it is installed at the top of the crane, field of vision
is broad, and the operation is safe, comfortable and convenient. The Cabin can control
various mechanisms of the crane by advanced ganged console.
The safety and protection device of the crane is also complete and reliable, including hoisting
moment limiter, Slewing Ergo meter, slewing limiter, radius- variation limiter, height limiter,
rope-break and shaft-break protection device of the jib trolley, wire Cables twisting protection
device and brakes of the slewing, radius-variation and so on. And there are also platforms,
rails and other safety devices on it. All these ensure the crane runs safely and reliably.
ACE TC5040 self-raising tower crane is designed with advanced parameters, reliable
performance, nice appearance reasonable construction and high quality. It has advanced
automatic control system. It can perfectly meet the construction requirements of the high
buildings and industrial buildings.

Page No. 3
2 Technical performance
2.1 Table of hoisting feature

2.5 ~
Length R ange R (m) 14.16 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
of
Jib (m ) Hois t a=4 6.00
5.22 4.56 4.04 3.62 3.27 2.97
50 Ability
Q(t) a=2 2.72 2.50 2.31 2.15 2.00 1.87 1.75 1.64 1.54 1.46 1.37 1.30
3.00

Range R (m) 2.5 ~ 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44

15.88
Hois t a=4 6.00 5.95 5.20 4.62 4.14 3.74 3.41 3.13
44 Ability 2.88 2.67 2.48 2.31 2.16 2.03 1.91 1.80
Q(t) a=2
3.00

Range R (m ) 2.5 ~ 18 20 22 24 26 28 30 32 34 36 38
16.66
Hois t a=4 6.00 5.50 4.88 4.38 3.96 3.61 3.31 3.05
38 Ability
Q(t) a=2 2.83 2.63 2.46 2.30
3.00

2.2 Hoisting feature curve

Four Fall 14.16 15.88 16.66

Q(t)

6.00

5.50

5.00

4.50 50m J ib
4.00 44m Jib
Tw o Fall
3.50
38m Jib
3.00

2.50
2.30t
2.00
1.80t
1.50
1.30t
1.00
2 10 15 20 25 30 35 40 45 50 R(m )

Page No. 4
 2.3 Table of technical performance
Hoisting height No. of rope falls fixed With Attachment
(Mtrs) α=2 40 140
α=4 40 70
Rated hoisting Moment 720
(KN.m)
Max. payload capacity (t) 6
Radius (m) Max 50
Min 2.5
Hoisting Mechanism

No. of rope falls α=2 α=4

Speed(Mtrs./min) 9 39 80 4.5 19.5 40

Hoisting load (Ton) 3 3 1.5 6 6 3

Power (kW) 5.4 24 24 5.4 24 24

Slewing mechanism Speed (rpm) 0.6
Power (KW) 3.7KW
Drawing mechanism Speed (m/min) 40 20
Power (KW) 3.3 2.2
Climbing mechanism Speed (m/min) 0.55-0.7
Working pressure (M Pa) 20
Power (kW) 5.5
Weight of counter (kg) 50m:12500
44m:11250
38m:10000
Total power (KW) 31.0 (excluding the power for climbing mechanism)
Working temperature (°C ) -20 ~ 40

2.4 Power supply equipment feature

2.4.1 Power supply capacity: ≥35 KW
2.4.2 Power supply voltage : 440V±5%;
2.4.3 Power supply frequency: 50HZ.

Page No. 5
2.5 Relation between Hoisting speed and jib length, Max hoisting load with diff. Mode
@
2 4
S pe
Ji ed
b
le Max hoist(t) Speed(m/min) Max hoist (t) Speed(m/min)
ng
M

th
od

50m 50m
e

Slow 3.0 9 6.0 4.5

Middle 3.0 39 6.0 19.5
Quick 1.5 80 3 40

3 Construction description in brief

The crane is composed of steel structure, mechanical driver, hydraulic climbing mechanism,
electric control and safety protection device. We can describe all these as follows according
to their different functions:
3.1 Steel construction
The steel structure includes base section, standard section of fixed tower, Hoisting jib,
Counter jib, Slew Mast, Climbing frame, Wall Anchor Frame, Tower Head and Cabin.
3.1.1 Out Rigger
Out rigger is an I shaped welded structural section, Consists of main chord ,plates & adopters.
The Length of outrigger section is 1300mm. The structure of outrigger section is shown in
fig. 3.

Fig. 3 Out Rigger Section

Page No. 6
 3.1.2 Standard Mast Section
The Fixed tower crane consists of a quantity of standard sections. The numbers of standard
sections are determined by the height of crane. Standard section consists of main chord,
horizontal brace and tilting brace, which are welded to a spatial trussing. The length of each
standard section is 2.8m, the section size is 1.6×1.6m, the lower parts of fixed tower has 3
standard sections, which has three sleeves on the end, and two sleeves on the main chord of the
fixed tower. The sections have very good exchangeability due to assurance of technological
manufacturing. Changing the number of the standard section of fixed tower, the fixed tower can
reach its required height. Every standard section has platforms and ladders on.

Note: This figure shows the standard section of fixed tower; there are
three sleeves on the main chord of the lower mast section.
Fig. 3-3 Standard section

Page No. 7
3.1.3 Climbing Frame (Fig. 3-4)
Climbing frame consists of Telescopic cage platform, rail, pulley group, claw and hydraulic
climbing mechanism.The Telescopic cage is integral type, which is covered on the fixed
tower, its upper part is connected with the Lower Bracket by pins, its height is 7102mm, and
the section size is 2098×2098 from center to center.
By the action of the climbing oil cylinder, there are 16 rollers at the inside of the climbing
frame, which are supported outside of the main chord of fixed tower and act as guide and
support. The rollers can move up or down. The pins support is welded at the middle of the
horizontal beam at upper part of Telescopic cage and hinged with the single lug of the oil
cylinder, so that it supports the climbing load of the oil cylinder. There are two claws on the
Telescopic cage. The load of climbing can be transferred through the claws, when the oil
pump takes back its piston rod. There are two leading beams for standard section on the
Telescopic cage and four leading rollers also. The leading rollers are preset on the connection
sleeve of the standard section which will be led in, when the leading rollers roll along the
leading beam, the standard section can be pushed to right position smoothly. In order to the
safety of installation of climbing mechanism, there are platforms and rails around the
climbing frame.

Fig. 3-4 Climbing frame

3.1.4 Wall Anchor Frame (Fig. 3-5)

Wall Anchor Frame consists of four brace rods and two half- rectangle frames; it can fix the
crane to the column of building for attachment. During operation, the two half- rectangle
frames are connected with each other by bolts and covered the standard section, utilizing 4
adjusting bolts and 8 pressure blocks to press the standard section tightly. The length of the
brace rod can be adjusted. The distance between the center of crane and the building is 3.5m
in the special case, if it is more than 3.5m, then the four brace rods should be redesigned
according to the actual condition.

Page No. 8
 Fig. 3-5 Wall Anchor Frame

3.1.5 Slew Mast (Fig. 3-6)

The Slew Mast is a rectangular spatial trussing welded of angle irons and steel tubes. Its
bottom is connected with the Upper Bracket The top of the Slew Mast is connected with the
Tower Head of crane by pins. The Cabin is installed at the lateral side, a platform is set up to
ensure the safety and protection.

Fig. 3-6 Slew Mast

Page No. 9
 3.1.6 Upper Bracket (Fig. 3-7)
Upper Bracket is a box type structure which is welded by steel plate, its upper part is
connected with the Slew Mast by 8 bolts (M30x400), and the lower part of it is connected
with the inner cycle of the slewing bearing by 36 bolts (M24). A multi-function travel limiter
is installed on the other side of the structure.

Fig. 3-7 Upper Bracket

3.1.7 Lower Bracket (Fig. 3-8 )

The Lower Bracket is also a box welded by the plate as same as the Upper Bracket, the upper
part of the Lower Bracket is connected with the outer gear ring of the slewing bearing by 36
bolts(M24), the lower part of the Lower Bracket is connected with standard section by 8 bolts
(M30), and is connected with climbing frame by 4 pins ( Ø40).

Fig. 3-8 Lower Bracket

3.1.8 Tower Head (Fig.3-9)
Tower Head is a triangular spatial trussing. The front and rear chord is welded as a square
tube by two angle bars, the brace of which is made of the seamless tube. Its bottom is
connected with the Slew Mast. The front and rear side of which are installed with pulling
plates that hinged to tie bar of the jib and the counter jib respectively. The upper part of the
Tower Head has a platform, people can install and disassemble the crane and thread the
hoisting wire on it.

Page No. 10
 Fig. 3-9 Tower Head
3.1.9 Cabin (Fig. 3-10)
The Cabin is made of steel plate, and it locates on the right side of Slew Mast. The Cabin is
commodious and bright, and the field of vision is broad, the front window can be opened and
the door is opened to the rear side for air ventilation. There is a Fixed chair in Cabin. The
console is located both sides of the chair, there are lights on the ceiling of the Cabin, of
course, various power sockets are also ready for inspection and repair at night and for air
conditioning.

Fig 3-10 Cabin

Page No. 11
3.1.10 Counter jib (Fig. 3-11)

Fig 3-11 Counter Jib

The counter jib is a plane trussing composed of I-bar and angle bar, it can be divided into two
separable portions, which connected by high-tensile steel pins. The hoisting mechanism and
rope arrangement device is located at the rear of the jib; and the counter blocks are located at
the end of it. It has platform and rail for installation and maintenance. The root of the jib is
connected with the Slew Mast by two pins; another end is connected with the Tower Head by
two tie bars.
3.1.11 Hoisting jib (Fig. 3-12)
The hoisting jib is non-uniform section and isosceles triangle type, the upper and lower chord
is a square tube welded by two angle bars, the tilted brace and horizontal brace are made of
seamless tube. Both the upper and the outside surface of the lower chord are kept horizontal
and vertical, thus, the lower chord can also be used as a rail for jib trolley.
The hoisting jib can be divided into nine separable portions, which is connected each other by
pins, so it is quite convenient to dis-assembly the hoisting jib. In order to improve the
hoisting performance and to reduce the dead weight of hoisting jib, we apply the design, such
as double hoisting points and non-uniform section spatial trussing. The drawing mechanism is
placed on the first portion of the hoisting jib. Two hoisting holes is set respectively on 2nd
and 5th portion of hoisting jib, through these two holes, the hoisting jib is connected with the
Tower Head.
During assembling the hoisting jib, it is necessary to strictly follow the order mark on each
section, do not change the order or assemble at random.

Page No. 12
 Fig. 3-12 Hoisting Jib

3.1.12 Jib trolley (Fig. 3-13)

The jib trolley is a steel structure, which brings the hook and lifted goods to move back and
forth along the hoisting jib. it has Four traveling wheels & four supporting wheels arranged
symmetrically on each side of the trolley. The lower chord is the traveling rail of the trolley.
There is a cage on any side of the trolley, which can send the repairer to any position of
hoisting jib for repairing and installation. There is also an adjusting wheel for tensioning the
wire rope in jib trolley.

Fig. 3-13 Jib trolley

3.2 Operating mechanism

The mechanical driver of the crane consists of hoisting mechanism, slewing mechanism,
drawing mechanism and hydraulic climbing mechanism and so on. Brief description goes as
follows:

Page No. 13
3.2.1 Hoisting mechanism (Fig. 3-14)

Fig. 3-14 Hoisting mechanism driver system

The hoisting mechanism is designed with different speed to suit different hoisting load and to
meet fully the requirements of construction. It consists of motor, speed reducer, rope drum
and multi-function travel limiter.
The ACE TC5040 tower crane applies 24/24/5.4KW motor to drive the reel by the speed
reducer. The speed can be adjusted by changing the frequency so that the rope drum gets
different speed, then the crane can get the performance of light load with high speed and
heavy load with lower speed. A multi-function travel limiter is fitted on the end of the rope
drum, when the weight of goods reaches the highest or lowest limit, the hoisting mechanism
will stop automatically and it is allowed to operate reversed.
3.2.2 Slewing mechanism (Fig. 3-15)
The slewing mechanism is located on both sides of Upper Bracket The motor with air cooling
fan is connected with the planet gear speed reducer to drive the small slewing gear, and then
to drive the Slew Mast, hoisting jib and counter jib, which are located at the upper part of
crane, to swivel right or left. The max swiveling speed is 0.6r/min. The speed-adjusting type
is of variable frequency, which ensures that the crane can start up or brake stably without
impacting. The slewing brake is normal close type. When the crane is out of working, the
slewing unit can move with the wind.

Page No. 14
 Fig. 3-15 Slew Drive motor

3.2.3 Luffer mechanism of trolley (Fig. 3-16)

The jib trolley uses 3/2.2KW motor to drive rope drum through planet gear speed reducer, the
trolley moves back and forth on the rail with speed of 40 & 20m/min. The Luffer mechanism
of the trolley is located at the first jib.

Fig. 3-16 Drawing Mechanism Driver system

Page No. 15
3.2.4 Hydraulic climbing mechanism (Fig. 3-17)
The hydraulic climbing mechanism is composed of hydraulic cylinder, oil pump, motor,
valve, oil tank and so on.

1. Air filter 2. Oil filter 3. Oil pump 4. Motor 5. Overflow valve 6. pressure gauge

7. Manual valve 8. One-way throttle valve 9. Double way control valve 10. Oil cylinder

Fig. 3-17 hydraulic system

The works of hydraulic climbing mechanism mainly depend on the hydraulic oil cylinder,
which fitted at inner side of the climbing frame, and the oil pump station and valves. When
adding the standard section, the hook hoist the standard section onto the leading beam, loosen
the connection bolts between the standard section and Lower Bracket, and start up the pump
station to actuate the hydraulic oil cylinder. Prop up upper structure, and make the claw in
loading condition. The piston rod is returned back. Repeat the same operation again, so the
whole work of installing a standard section can be completed after two same cycles.
3.2.4.1 The main technical parameters of the hydraulic pump station and hydraulic cylinder:
Max. working pressure 25MPa Dia. of oil cylinder 160mm Rated flow 11L/min
Rated working pressure20Mpa Dia. of piston rod 110mm Oil tank volume 90L
Rated climbing capacity 40t Oil cylinder stroke 1600mm Motor power 5.5Kw
Climbing speed 0.7m/min Pump station dead weight 200Kg
3.2.4.2 Installation and operation of the hydraulic system
First of all, open the air filter 1, pour oil into the oil tank till it reaches the upper limit, the oil
should be filtered by portable filter and reach the filtering class 10U. Then the motor of the
oil pump just can start up. (Caution: check the impeller of motor to ensure that the rotating
direction is same as the mark of the pump, or else the system cannot work.)
3.2.4.2.1 System piping connection
First of all, check the high-pressure rubber tube to see whether the end of the tube is clean or
not. Clean the orifices A and B of hydraulic station and oil cylinder, then connect the orifices
A, B of hydraulic station with the orifices A, B of oil cylinder respectively by high-pressure
rubber tube. The connection should A to A and B to B. Then connect the B type combination

Page No. 16
gasket and tighten the joint (Caution: the combination gasket should be concentric with the
shaft of pipe joint and no offset). It is absolutely not allowed to change the order of the rubber
tube, or else there would be dangers.
3.2.4.2.2 Exhausting of the system
a. Exhausting of hydraulic station: As the oil cylinder is in no loading, loosen the handle
of overflow valve 5, and then loosen the orifice A of high-pressure rubber tube joint,
set the handle of manual directional control valve 7 in rising position, start the motor.
The airflow is exhausted from orifice A until the voice of oil pump is normal without
abnormal noise and no air bulb in oil.
b. Exhausting of the oil cylinder: As the oil cylinder in no loading, loosen the handle of
overflow valve 5, set the handle of the manual changing valve 7 in low limit position,
and loosen the high-pressure rubber tube joint of the oil cylinder orifice B by
hexagonal wrench after piston rod returns back. Set the manual directional control
valve 7 in rising position, tighten the joint B again as the piston rod extends out to full
travel (Max. value), then loosen the rubber tube joint A, set the valve 7 in descending
position, tighten the joint A again as the piston rod returns back (The operator can do
above operations leaning against the corner of standard section). Repeat above
operations until no air bulb in the overflow oil is seen (it is necessary to exhaust the air
for normally using).
3.2.4.2.3 Operation of the system
Before operation, check the connection between oil cylinder and rack to see whether it is
normal and reliable, and check the related parts of crane to see whether they are all meet the
relevant technical requirements. Then go on to following operation.
a. Loosen the high-pressure overflow valve 5, start the motor 4, set the handle of the
manual directional control valve 7 move to the rising position (marked position),
operate the handle of overflow valve 5 slowly, observe the piston rod of oil cylinder
extending out, tighten the overflow valve 5 with 1/4 to 1/2 cycle, now the pressure
gauge value is the normal working pressure of the system (the climbing pressure
should be adjusted to a little more than the Min. working pressure, but it is not allowed
to exceed the Max. working pressure in any case). After the oil cylinder has risen to the
limiter, set the manual directional control valve 7 in descending position (the
descending speed is set depending on one-way throttle), the oil cylinder is down (the
horizontal beam is down) to first portion of standard section. Readjust it, the piston rod
returns back to original position, set the manual directional control valve 7 to carry out
the second climbing operation, the operation steps is same as the first climbing (the
installation procedure is according to the tower crane operation manual). Repeat above
operation till the end of climbing operation.
b. The operation of descending
Start the motor 4, set the directional control valve to descending position. The
descending speed of oil cylinder depends on the one-way throttle valve. The
adjustment of one-way throttle valve should be carried out after the oil cylinder is
discharged to empty, and cannot be determined prior to operation; vibration will occur
during the process of going down if the flow is excessive, but the speed of descending

Page No. 17
 will be much lower if the flow is less, so the throttle valve must be adjusted to a
suitable position.
The method of adjusting: stop the motor or set the directional control handle in the
middle position, loosen the locking nut a little, then loosen the pointed end bolt with
1/6 cycle (at most the 1/6 cycle for each time). Tighten the locking nut and observe the
speed. If it is not suitable, re-loosen the pointed end bolt with 1/6 cycle and repeat the
above operation until it suits well. Caution: Do not adjust the throttle valve when the
oil cylinder is loaded, or else serious accident will occur.
3.2.4.2.4 The operation rhythm of oil cylinder during the climbing operation
Piston rod extends out----returns a short distance----returns fully. The oil cylinder repeats the
operations to complete the installation and the disassembly of a standard section (the
installation procedure is given in the tower crane operation manual). With such an operation, the
crane can be climbed up to required height.
The operation of descending (i.e. disassemble of the crane):
Piston rod extends out ----returns back ----extends out ----returns back ----repeats again until
the disassemble of the crane is completed.
3.2.4.3 Maintenance of hydraulic system and the considerations
This hydraulic system is extra-high pressure or a high-pressure hydraulic mechanism. From oil
filling to adjusting, the whole process should be completed strictly following the regulations of
the tower crane operation manual.
3.2.4.3.1 Adjustment of the high-pressure overflow valve 7
a. Before applying, loosen the nut of handle of the high overflow valve, make the manual
directional control valve 7 in “rising” position, then tighten the nut gradually until the
oil cylinder is ready to work, then tighten the nut 1/4 to 1/2 cycle again to make the oil
cylinder work normally.
b. In any case, the adjusted pressure should not exceed the rated working pressure.
3.2.4.3.2 Adjustment of the one-way throttle valve (not mentioned)
3.2.4.3.3 Oil for hydraulic system
a. In south, the anti-wear hydraulic oil, which has the character of resistance to wear and
air bulb, should be used. In north, composed spindle oil should be used.
b. Oil filling of the hydraulic system
The oil tank should be filled up fully when it’s used first time. After starting up, the
piston rod extends out from cylinder, and then the piston rod returns back, then
supplying oil into the oil tank till it reaches the upper limit.
c. This hydraulic system belongs to the extra-high pressure or high-pressure system. We
should use the portable filter to filter the oil for 4-6 hours. As the cleaning index of the
oil should reach to 7-8 class, unless the system is not allowed to start up.
d. When this system has worked for 2400 hours, all oil should be changed, and when it
has worked for 200 hours, some clean oil should be added in.
3.2.4.3.4 The heat radiation condition of this system is not very good, so when the crane is
out of working, please shut it off in time to avoid that its temperature rises too high and its

Page No. 18
normal operation is affected.
During hydraulic climbing, the hydraulic power is transferred in such a way: turn on the
power, push the button of pneumatic switch “ON”, meanwhile the control handle stands in
middle position. The motor drives the plunger pump rotating, the oil flowed from the
hydraulic oil pump through the middle position of the directional control valve to the oil
return line of filter, now the system is in a state of unloading. Pull the handle upward to top
position, the pressure gauge displays the climbing pressure (Caution: the pressure of the
gauge should be set no more than 25 Mpa), the oil cylinder starts to rise. Pull the handle
downward to lower position; the pressure gauge displays the descending pressure (this
pressure is set by balance valve), now the piston rod returns back.
3.3 Electric control and operation system
The control and operation system of this crane uses advanced ganged console, which is
located in the front of the Cabin, console can be divided into right and left parts, each one has
a control handle. The left handle can control two movements concurrent: radius variation and
slewing operation, the right handle can control hoisting operation. There are also indication
lights and buttons on the console. The Cabin is convenient and comfortable for operation.
Through the control handles (ganged switch) of the console, control various contactors, relays
and speed-adjusting controller to change the working state of the motors, to attain forward
and reversed motions, and to shift speeds and brake.
Main instructions are sent out from the console to control the operation of the individual
mechanisms of the crane.
3.3.1 Hoisting mechanism
The hoisting mechanism is driven by 24/24/5.4KW motor. The converter mechanism is
controlled to adjust the speed and shift of high, middle, low speed by the handle of console.
The hydraulic push-bar brake carries out the braking. If the hoisting load reaches the 50% of
the rated load, even if the control handle engages high-speed gear, the crane still operates at
middle speed automatically.
3.3.2 Slewing mechanism
The slewing mechanism is driven by motor with cooling fan, and performs to slew clockwise
or anti-clockwise with the handle of the console. The mechanism has speed adjusting
methods, that is, variable frequency . Right or left slewing control handle has four positions
respectively, the frequency of motor stator can be adjusted from 0 to 50Hz, and the input
voltage of current circuit is DC 20V. The time interval of the speed shifting is 1.6 to 2.0s.
When the handle returns back to zero position from the third gear suddenly, the stator will
break the currents immediately, under the influence of the frequency conversion of tring
resistance and arrester, the slewing mechanism carries out damping speed reducing till stop.
3.3.3 Drawing mechanism
The drawing mechanism is driven by the 3.3/2.2KW moment motor with cooling fan. It
applies variable frequency and adjustable speed, and controls the jib trolley moving inward,
outward or stop with the handle of console.

Page No. 19
3.3.4 Safety device
3.3.4.1 Protection of zero position
When the ganged console stops operation, the handle will return back to zero position
automatically.
3.3.4.2 Electric protection of main circuit
The protections is as follows: main power supply short protection, the motors of various
devises short, overload, over current protection, and the hoisting system has phase break,
phase absent and the current between three phases unbalance reaching to 15% protection.
3.3.4.3 Protection of earthing
Various electric parts, control box and the ganged console are all earthed well.
3.3.4.4 Protection of circuit breaker
The circuit of control loop, lighting, signal light and ventilator are all installed with breaker
as the short protection.
3.3.4.5 Electric whistle
Before starting up the crane, the electric whistle sounds to inform all people at site. The
electric whistle is fitted at control box and controlled by the button on console.
3.3.4.6 Audial and visible warning
When the hoisting moment or the hoisting load exceeds 80% of rated value, the warning
system will switch on a flash buzzer to warn the driver, when the hoisting load or moment
reaches to 110% of the rated value, the red indication light will ignite to ask the driver to stop
this dangerous operation.
3.3.4.7 Anti-collision light
In order to avoid the impact between the crane and other objects, a red anti-collision light is
respectively installed on the top of the crane and the front end of the hoisting jib to indicate
the height level. Caution that when the crane stops work at night, the anti-collision light
should be switched on.
3.3.4.8 Power supply indicating light
A power supply indicating light is on the ganged console. This light should be ignited to
indicate the power supply in normal condition, the voltage should be 380V±5%, and the
frequency should be 50Hz, and then the crane allows working normally.
3.3.4.9 Limiter of height, traveling and slewing
The limitation of height, traveling and slewing are carried out by the multi-function travel
limiter to record the cycle numbers of rotation of the reel or the angles of slewing, when
slewing to set position, the memory cam makes the micro-switch action and the crane stop.
3.3.4.10 Moment limiter (Fig. 3-18)
In order to ensure the hoisting moment of the crane doesn’t exceed the rated value, this crane
has the reliable mechanical moment limiter. When the hoisting load exceeds the 80% of the

Page No. 20
 rated value, the axial deformation of the main chord (the chord of the Tower Head)
transforms to lateral deformation through the moment limiter, then touches the limit switch
and switches on the buzzer with audible warning. When the hoisting moment reaches to
110% of the rated value, the circuit that control the hook upward and the trolley outward will
cut off, so the hook can only go down and the trolley can move inside only.
3.3.4.11 Slewing Ergo meter (Fig. 3-19)
The limitation of the hoisting load is attained through the metal elastic chip of the Slewing
Ergo meter. When the hoisting load reaches 50% of the rated value, the pull deformation of
the elastic chip reaches its load value and impacts the limit switch and cuts off the power of
control of the high speed hoisting. Then the hoisting mechanism cannot operate at high speed.
When reaching 110% of the rated hoisting load, the red indication light ignites, cuts off the
power of control of the hoisting mechanism, so the hook can only go down. When hoisting
load reaches 80% of the rated value, the buzzer warns with audio and visible signal.
Fig. 3-18 Moment Limiter Fig. 3-19 Slewing Ergo meter

The parameter of the protection parts

Name of parts Parameter Name of parts Parameter

Hoisting motor circuit breaker QM1 60A
Slewing energy consumption brake 10A Control transformer circuit breaker 10A
circuit breaker QF1 QF3
Signal light circuit breaker QF2 10A Control box power supply breaker 10A
QF5
Slewing motor circuit breaker QM3 15A Second control circuit cutout QF6 10A
Radius variation motor circuit 15A Slewing 2 4 VII power supply 10A
breaker QM4 breaker QF7

4. Installation and Disassembly

The most suitable machinery for the installation of ACE TC5040 self-raising tower crane is
the truck crane, because it is nimble and flexible. A truck crane with hoisting capacity of 25
ton can complete the installation work. During installation, the wind power should not exceed
13 m/sec.

Page No. 21
4.1 Preparations for Pre-installation
4.1.1 To know the conditions of site layout and the characters of the soil, clean off the
obstacles.
4.1.2 According to the layout of the building, the location of crane foundation shall be
determined opposite to the building (Fig. 4-1). Then the construction work can perform
according to the technical requirements of the concrete foundation drawing.

Fig. 4-1 Installation site layout drawing

4.1.3 Equip the hoisting machinery. Need a truck crane, which hoisting capacity is 25 ton,
and its hoisting height should not lower than 25m.
4.1.4 Prepare the auxiliary hoisting equipment, sleeper, tapered wooden pieces, and wires,
ropes, etc for work.
4.1.5 Complete the concrete foundation in advance; the installation work will be done in 5-6
days.
4.1.6 The power supply should be provided reasonably, safety and convenient, and it should
not be far from the site.
4.2 Requirements and considerations
4.2.1 The installation and disassembly of the crane should be done according to the required
sequences and requirements strictly.
4.2.2 During the installation, the staff should put on the safety cap and belt.
4.2.3 Before installing the connection pins should be spread with grease. The cotter pins that
connect pins holes should be opened after installed, and the clip plates should be fixed well,
and the connection bolts should be tightened.
4.2.4 For mounting of this crane always use standard parts manufacture by ACE.
4.2.5 The electric control system should be installed according to the circuit drawings strictly,
and not allowed to modify willfully.

Page No. 22
4.3 Installation Procedure
4.3.1 Installation of the base section: Base section consists of placed type and fixed base section.

Fig. 4-2 Installation of the outrigger Fig. 4-3 Installation of the lower standard section

4.3.1.1 Installation of the fixed base section (Fig4-2)

4.3.1.2 Installation of the burying base section
4.3.2 Installation of the lower standard section
4.3.2.1 Hoist three lower standard sections (Fig. 4-3) on the base section and connect them
each other with 12 high-tensile bolts (M30). The pre-tightening moment is 140kg.m
(caution: All crown plate (yoke resting plates) welded on mast should be in same side.
4.3.2.2 Fix the rest two lower standard sections in turn (Fig. 4-4), and connect them each
other with 12 high-tensile bolts (M30). The pre-tightening moment is 180kg.m
4.3.2.3 After installing and fixing the bolts, inspect the installed frame by theodolite or with
normal line method to ensure that the verticalness between the vertical plane formed by the
flange of the four main chords and the supporting plane formed by the four chords of the
lower sections is 1/1000. Now the installation height of burying base section is 8825m, and
the installation height of fixed base section is 8750mm.

Page No. 23
4.3.3 Hoisting climbing frame (Fig. 4-5)

Fig. 4-4 Installation of the lower standard section Fig. 4-5 Hoisting the climbing frame
4.3.3.1 Hoist the climbing frame covered on the lower fixed tower (Caution: the mounting
bracket of climbing cylinder should be mounted crown plate side. and put it down slowly,
until the upper surface of climbing frame is about 600mm higher than the lower fixed tower.
4.3.3.2 Install the platform of climbing frame from upper parts to lower parts. Then hoist the
hydraulic oil pump on the platform, connect oil piping and check the operation of the pump
station.
4.3.4 On the ground, connect the Tower Head with the first portion of tie bar of counter jib
by pins, and ensure that the moment limiter fitted on the Tower Head and the Cabin should
be located in the same side of the crane, then connect by 4 pins(φ50), install the cotter pin
and open its tail fully.

Page No. 24
 Fig. 4-6 Hoisting of slewing unit
4.3.5 Hoisting the slewing unit (Fig. 4-6)
4.3.5.1 The slewing unit including Lower Bracket, slewing bearing, Upper Bracket, Slew
Mast, Cabin, Tower Head and so on. These should be pre-assembled on ground.
4.3.5.2 Hoist the assembled slewing unit, connect the Lower Bracket and the climbing frame
by 4 pins (φ40) and connect the Lower Bracket and lower fixed tower by 8 bolts (M30), put 4
cotter pin (φ5) on the pins, and open the tail of the cotter pin fully.
4.3.5.3 In some special case, the slewing unit can be hoisted separately according to the
actual condition.

Page No. 25
4.3.6 Hoisting the counter jib
4.3.6.1 Pre-assemble the portions of the counter jib on the ground, connect them by high-
tensile pins and lock tightly, and then install the platform and rail of counter jib.
4.3.6.2 Assemble the tie bar of the counter jib (Fig. 4-7). Each tie bar has three portions, the
end of lower two portions connects with the tail of the counter jib, and the end of top portion
can be inserted the pin hole of the pulled plate of the Tower Head (pre-assemble on the
ground), the other parts can be placed on the counter jib, fastened by ropes, and be ready for
hoisting.

62
40

62
40

6968
62
40
120

150

155
9735 1200

Fig. 4-7 Tie bar of counter jib

4.3.6.3 Hoist the counter jib (Fig. 4-8). The joint of the jib root is inserted in the connection
lug plate of the Slew Mast, install the pins and open the tail of cotter pin. Then rise up the tail
of the jib, link the three-portion tie bar together to form a whole and insert the pins, open the
cotter pin.
4.3.6.4 Put down the tail of the counter jib slowly. The tie bar is pulled to straight gradually
due to the tension force, till the counter jib nearly reaches the horizontal position.
4.3.6.5 Hoist a counter block weight 2.500t, and put it on the location of weight balance (near
to the tie bar).

Page No. 26
 Fig. 4-8 Hoisting of counter jib
4.3.7 Hoists the hoisting jib
4.3.7.1 Assemble the portions of the hoisting jib according to its order, install the jib trolley
on it, reeving the wire ropes of the jib trolley (Fig. 4-9), and fasten the jib trolley on the
fourth portion of hoisting jib.

Fig. 4-9 Reeving the drawing wire rope

Page No. 27
 Fig. 4-10 Installation of the jib

4.3.7.2 Connect the tie bar of hoisting jib (Fig. 4-11), and fasten the tie bar on the upper
chord of hoisting jib.
4.3.7.3 Hoist the hoisting jib horizontally (Fig. 4-10). The joint of the jib root is inserted in
the connection lug plate of the Slew Mast, install the pins and open the tail of cotter pin. Then
hoist the hoisting jib and make the jib head rise up to about 3°, and be ready for installing of
the tie bar.
4.3.7.4 Thread the hoisting wire ropes onto the pulley which is located at the end of tie bar of
hoisting jib (five multiple ratio). Start up the hoisting mechanism slowly, hold up the tie bar,
connect the tie bar with the pulled plate of the Tower Head by pins, and loosen the wire ropes
of the hoisting mechanism. The tie bar of the hoisting jib extends straight gradually due to the
tensile force. The hoisting jib drops its rising position to nearly horizontal; then we may
remove the wire ropes. Fig. 4-12

Page No. 28
 Fig. 4-11 Tie Bar and Hoisting Jib

Fig. 4-10 Installation illustration of the hoisting Jib tie bar

Page No. 29
 4.3.8 Hoisting the counter block
Hoist appropriate quantity of counter blocks according to the length of the acting jib:
Length of jib Qty. Total weight of counter block
(m) (kg)

50 6 12500
44 5 11250
38 4 10000

4.3.9 Reeving the hoisting wire rope (Fig. 4-13)

Hoisting wire rope is led out from the hoisting mechanism, through the rope arrangement
device, it goes to the pulley of the Tower Head, passes the Slewing Ergometer, then goes to
jib trolley and hook, finally gets fixed on the end of hoisting jib (The rope reeving should be
done after mounting of all counter weights.

Fig. 4-13
4.3.10 After the crane is installed, it needs test working. Inspect to see whether all wire ropes
are in normal. If the wire rope of any parts of the crane has worn, it should be removed.
Before putting the crane in to operation,ensure proper working of all function/
operations.
4.4 Installation procedure of standard section of fixed tower (Fig. 4-14)
4.4.1 Hoist a standard section of fixed tower, start up the slewing mechanism, swivel the
hoisting jib to the direction which the standard section of fixed tower will be led in.

Page No. 30
operating condition I operating condition II operating condition III operating condition IV

Fig. 4-14 Climbing operation illustration

4.4.2 Insert 4 leading rollers in the leading and connecting sleeve hole located on the lower
part of the standard section which is waiting for being led in. Let the jib trolley hoist a
standard section and move to the place where the radius is about 15.35m(jib length 50m) ,
23.05m(jib length44m),25.8m(jib length38m), so as to keep the center of gravity of climbing
unit almost at the center of the oil cylinder. Adjust the clearance (0~2.5mm) between the
rollers of the climbing frame and standard section, and leave the slewing mechanism in
braking state.
4.4.3 Inspect carefully to see whether the connections of various mechanical parts are correct
or not, inspect the electric and hydraulic system, and inspect to see whether the pin of
climbing beam has been put into the pin hole of the Crown Plate of standard Mast. If every
thing is all right, then prepare to perform the climbing operation.
4.4.4 Remove the connection bolts between Lower Bracket and lower fixed tower, start up
the oil pump, control the handle, make the oil cylinder jack up the above tower and make the
claw of climbing frame support onto the climbing plate of the fixed tower.
4.4.5 Control the handle, and make the piston rod return bark. At this time, the horizontal
beam has been raised into the topper climbing supporting plate. And it climbs again, awaiting
the piston rod extends out fully again, the standard section of the fixed tower can be led in.
4.4.6 The led standard section should align with the lower fixed tower, control the handle,
and let this led standard section down slowly. After the two units have been abutted, draw out
the leading roller, connect the led standard section with the lower fixed tower by bolts, and
tighten the bolts. Thus the climbing operation of a standard section of fixed tower has
completed.

Page No. 31
4.4.7 Following the below described methods we can easily complete the fixed tower rising
operation.
4.4.8 Before hoisting a standard section of fixed tower, it is necessary to tighten a bolt at least
on each main chord between the fixed tower and the Lower Bracket. After hoisting a standard
section and putting onto the leading beam, the jib trolley moves to required balance position,
we can remove these bolts to perform the climbing operation.
4.4.9 During the climbing operation, the wind should be less than grade 4.
4.4.10 After having completed all climbing operation, low down the climbing frame to the
bottom of fixed tower and fix it for lower center of gravity and reduction of the projected
wind area to the crane.
4.5 The adjusting method of safety devices
4.5.1 Adjustment of the hoisting height limiter
Start up the hoisting mechanism, make the up edge of the hook lateral plate to the lower edge
of the jib trolley with a distance of 1.5m, connect the electric wires of the limiter, tighten the
stop motion screws of the limiter input shaft and the main shaft of the reel, adjust the height
limiter. Then start up the hoisting mechanism again to low down the hook about 10m. When
the hook is hoisted again rapidly to 1.5m, the height limiter acts to cuts off the hoisting power
supply, so as to the hook can only go down. Repeat the action several times, checking
whether the height limiter is normal or not. Repeat till it complies with the requirements.
After raising the crane to the required working height, put the hook down to the ground, make
the lower limiter switch turn off, raise the hook again and put it down again. When the hook
is down to the ground, the hook system should be cut off automatically, if it doesn’t comply
with the requirements, we should adjust it again till it turns out to be satisfying. When the
height of the crane has changed, the limiter should be readjusted too.
4.5.2 Adjustment of the slewing limiter
Make the jib trolley (hook no load) move to the root of hoisting jib, ensuring that the power
supply Cables is not twisted. Push the micro switches one by one, confirming that the micro
switches controlling of the right and left is correct. Slew it to right with 540°, loosen the
screw and regulate the adjusting cam, through which the micro-switch acts immediately.
Tighten the nuts, and use the same method to adjust the left slewing limiters.
Repeat the action several times till it complies with the requirements.
4.5.3 Adjustment of radius limiter
Start up the drawing mechanism to draw the jib trolley to the place where the radius from
hook to the slewing center is 2.5m and 50m, connect the Cables of limiter, loosen the stop
screws of the input shaft of the limiter and the spindle of the reel, and adjust the radius
limiter. Then start up the drawing mechanism again to draw the jib trolley inward or outward.
As the radius reaches 2.5m or 50m, the switch of the radius limiter will actuate to limit the
radius and cut off the power supply of the motor of slewing mechanism. Now the jib trolley
can only move inward (not outward) or only move outward (not inward). Repeat above
operations several times till the test meet the requirements.

Page No. 32
4.5.4 Adjustment of the Slewing Ergometer (Fig. 3-19), a=4
4.5.4.1 At radius R<25.88m radius, hoisting load Q=3000kg, the hook can go up and down
with high or low speed normally. It must be assured that the crane can hoist in any speed.
4.5.4.2 At radius R<25.88m radius, hoisting load Q=3300kg, regulate the adjusting screw of
the force measuring ring to engage high speed gear. At the moment the crane cannot hoist,
and it switches to low speed automatically.
4.5.4.3 At radius R<17.30m, hoisting load Q=4800kg, regulate the adjusting screw of the force
measuring ring, the buzzer will send out the signal.
4.5.4.4 At radius R<14.16m, hoisting load Q = 6600kg, regulate the adjusting screw of the
force measuring ring, limit the rising motion, allow the action of going down only. Now the
red warning light of the ganged console ignites for overload.
4.5.4.5 Repeat above items twice, till adjusting is all right.
4.5.5 Adjustment of the moment limiter (Fig. 3-18)
The adjustment of the moment limiter carries out with two different modes: hoisting load-
variable with radius fixed, or radius-variable with hoisting load fixed.
4.5.5.1 Hoisting load-variable with radius fixed
a. Radius change from R= 50m to R =19.42m, respectively hoisting load vary from
Q =1170kg to Q = 3780kg, regulate the adjusting screw of moment limiter; make the
buzzer send signal.
b. Radius change from R= 50m to R =19.42m, respectively hoisting load vary from
Q = 1300kg to Q = 4200kg, the moment limiter should not act.
c. Radius change from R= 50m to R =19.42m, respectively hoisting load vary from
Q = 1430kg to Q = 4620kg, regulate the adjusting screw of the moment limiter; limit
the hoisting action and only allow to go down. The jib trolley cannot move outward but
inward.
4.5.5.2 Radius-variable with hoisting load fixed
a. Hoisting load change from Q = 5400kg to Q = 1620kg, jib trolley moves out with
normal speed from the small radius, as the radius reaches R = 14.16m to R = 42.46m,
regulate the adjusting screw of the moment limiter; make the buzzer send signal.
b. Hoisting load change from Q = 6000kg to Q =1800kg, jib trolley moves out with
normal speed from the small radius, as the radius reaches R = 14.16m to R = 42.46m,
the moment limiter should not act.
c. Hoisting load Q =6600kg,Q = 1980kg, jib trolley moves out with normal speed from
the small radius, as the radius reaches R = 14.16m-R = 42.46m, regulate the adjusting
screw of the moment limiter; limit the hoisting action and only allow to go down. The
jib trolley cannot move outward but inward.
4.5.5.3 Repeat above items for three times, till the adjusting work is all right.
4.5.6 The adjustment of the multiple ratio
When the hoisting load is under 3t, we may use the 2, or 4 multiple ratio to work; but when

Page No. 33
the hoisting load is over 3t, it is necessary to use the 4 multiple ratio.
The purpose of the pulley multiple-ratio device is to change the multiple ratio of the wire
rope of hook, double the hoisting capacity of the hoisting mechanism and slow down the
speed half or 1/2.
The method of multiple ratio changing as follows: draw the jib trolley to the root of the jib,
put down the hook to the leading platform, loosen the wire ropes, divide the coupling links
between main and vice trolley, draw the vice trolley to the lug which is used to fix the vice
trolley on the hoisting jib, fix the vice trolley by pins, remove the connection pin between
vice and main hook, tighten the wire rope, let the vice hook just beneath the vice trolley, use
the pins to connect and fix the hook with the lug plate which is located at the lower part of the
vice trolley. Change the hole of the hook and draw the jib trolley, now the hook pulley has
changed its multiple ratio from 2 to 4.
If you still want to change the multiple ratio, remove the pins of main hook, tighten the wire
rope further, then hoist the holding plate of the upper pulley to contact the lower part of the
jib trolley. Now the hook pulley has changed its multiple ratio from 4 to2. Using the same
method but in reversed sequence, you can change the multiple ratio from 2 to 4.
4.6 Test working of the crane
After the crane has installed and adjusted, the testing operation should start.
4.6.1 No-load testing operation
Through the non-loading testing operation we can check if the operation of the various
mechanisms is normal, or if the various switches of limiters work reliably. The hoisting jib
slews to right and left twice respectively, we can also check whether each slewing action is
normal or not.
4.6.2 Testing operation under rated loading
Through the rated loading testing operation we know whether the operation of the various
mechanisms is normal or not; check the overloading protection device to make sure it’s
reliable. It is required that the crane operates normally at the radius of 50m and the hoisting
load 1.3t or at the radius of 2.5~14.16m and the hoisting load 6t.
4.6.2.1 Check the hoisting limiter: When the radius is less than 14.16m and hoist load is 6.6t,
the crane should send out audio and visible warning, and the circuit of the hoisting
mechanism should be cut off.
4.6.2.2 Check the hoisting moment limiter, as radius is less than 50m, hoisting load is 1.43t
and jib trolley moves out, and as the radius reaches 50m, the buzzer should alarm (buzz and
lights), the jib trolley will stop automatically, and the hook stop hoisting. Check the crane
regularly (it is necessary to check working of all limiter in 5~10 days, the longest
checking cycle should not exceed more than 15 days, in order to avoid over-moment
operation and accidents).
4.6.2.3 Hoist 6t, radius 14.16m, the hoisting jib slews right to left for three times.
4.6.2.4 Hoist 6t, jib trolley between radius 2.5m to 14.16m, and it goes back and forth one
time.
4.6.2.5 Hoist 6t, radius less than 7m, hoisting height of the hook is not higher than 5m, do the

Page No. 34
braking test for three times.
4.6.2.6 Hoist 1.3t, radius 50m, the hoisting jib slews to right to left for one time.
4.6.2.7 Hoist 1.3t, jib trolley between radius 2.5m to 50m, and it goes back and forth one
time.
4.6.2.8 Hoist 1.3t, perform the combined operation of slewing and hoisting movement for one
cycle, and the combined operation of radius variation and slewing movement for one cycle.
4.7 The disassembly of the crane
The method of disassembly is the same as installation, but in reversed sequence, which means
the parts that were installed first will be disassembled later. However we should be very
careful in the process of the disassembly, or else it may cause the casualties and the damage
of equipment.
4.7.1 After having disassembled a standard section of fixed tower, when the climbing frame
falls down, we should turn over the climb claws on both sides by hand so as to make the
climbing frame fall down to the next lower climbing plate smoothly.
4.7.2 When ever the hook block is in operation (hoists the standard section of fixed
tower and the other units), the connection bolts between the standard section and the
lower bracket must be fully torqued. We should be very conscientious in the operation
to avoid any unnecessary accidents.
5 Usage of the crane
5.1 General requirement
5.1.1 The crane must be fitted on concrete foundation that conforms to the requirements of
design drawings.
5.1.2 The ambient temperature for the crane normal operation is -20-40.
5.1.3 At the max. installation height of the crane, the wind speed must be below 10m/sec.
5.1.4 The distance of safe operation is not less than 0.6m.
5.1.5 After the crane has been installed completely, the vertical of crane axial line to the
support plane is 4/1000 in calm wind.
5.1.6 The earthing of crane must be secure, the earth resistances is not more than 4Ω.
5.1.7 If the crane is transferred from one site to another, it must be inspected through no load
test, static load test and dynamic load test, or else it cannot perform the hoisting operation.
5.1.8 Besides the lighting on the crane, the construction site must be provided with perfect
lighting at night work too.
5.1.9 The crane must be kept away from the high-tension transmission line. If the hoisting jib,
counter jib or hook interferes with the power line or lighting line, the safety precautions
should be taken as per Standard.
5.1.10 When several cranes work together, safety precautions of air interference should be
taken as per Standard.
5.1.11 The cranes should stop work in heavy snow, thundershower, storm and fog etc. If a
force 10 wind is forecasted, crane must be reinforced with thick ropes.
5.1.12 The crane’s operators should read this operation manual carefully and be trained to

Page No. 35
have permit. Special men should be charged with specific responsibilities. Person not
concerned is not permitted entering into the Cabin and operate the crane. No one is permitted
to climb into the crane except the installation and maintenance personnel. Electric fault must
be treated by electric maintenance personnel.
5.1.13 When crane stops working, the hoisting jib can freely swiveled with wind.
5.1.14 The allowable load of the Cabin is 150kg. It is strictly prohibited to store lubricant, oil
cotton yarn, and the other flammable and explosive materials in the Cabin. Prevent fires when
using electric stove for warming.
5.1.15 The operation of crane must strictly conform to the requirements of this Operation
Manual.

5.2 Climbing operation

5.2.1 In the process of the climbing operation, special operators should be arranged to direct
and take care of the electric power, operate the hydraulic pressure system and tighten the
bolts. Persons not concerned are forbidden to climb onto the operation plane and start up the
pump and electric equipment.
5.2.2 In the process of the climbing operation, special operators are arranged to check
carefully. Release the vertical Cables in advance in order to have the excess length of the
Cables to climbing height. Prevent any scraping, clipping, and squeezing that damage the
Cables.
5.2.3 The climbing operation should be done in the daytime. If it is done at night, sufficient
lighting equipments must be provided.
5.2.4 The climbing operation should not be done, if weather as follows:
a. Wind the force exceeds the max wind force provided in this operation manual.
b. Rain, snow, fog.
c. Smog.
5.2.5 Before climbing operation, slewing units must be brake firmly to prohibit upper unit
slewing and other operation method which is not permitted. It is necessary to adjust the
position of the jib trolley to keep the balance of the climbing units, making the least
imbalance moment of forces.
5.2.6 During the climbing operation, if any fault is found, stop to check immediately. Ensured
that the cause of the trouble is found and the trouble has been removed before climbing
operation again.
5.2.7 The preparing and ending work must be made carefully before and after each climbing
operation, especially after the climbing operation. We should check whether the bolts are
tightened according to the regulations or the power of the hydraulic system is shut off.
5.2.8 After the climbing operation, swivel the slewing jib to different angles, check the
tightening condition of the bolts connected between the tower bodies (Tighten the bolts on the
chord which just beneath the counter jib).
5.3 Considerations for pre-operation
5.3.1 After switching on the main power supply, check the crane steel structure whether it is
electrified by test pencil. Ensure that the crane is safe before boarding the crane.
5.3.2 The various connection bolts should be tightened, and the main welding seams should

Page No. 36
 not have any cracks and any opening at weld.
5.3.3 Before switching on the main power supply in the Cabin, the branch control switch of
the control box should be turned on and hold. Check various operation switches to see
whether they are set in the zero position. After switching on the main power supply switch,
check the voltage and power supply. When everything accords with the requirements, the
operation may begin.
5.3.4 Check the volume of the hydraulic oil tank and the oil storage device of brake, they
should comply with the regulations, and no any leakage of oil is allowed.
5.3.5 Before operation, the driver of the crane should check following items confirming they
are OK, and then start to operate:
5.3.5.1. Operate a working cycle in no load condition.
5.3.5.2. Test to hoist a weight.
5.3.5.3. Verify and check the hoisting height, radius and slewing limiter and hoisting load and
moment limiter and other protection safety device.
5.3.6 The wire rope should be wound on the reel in good order. It is not allowed to operation
in following situations:
5.3.6.1. The wire rope is climbed in no order, and it is scraped and gnawed.
5.3.6.2. When multiple layers wire rope is wound, the wire ropes tangle up.
5.3.7 Prohibit putting the tools, parts and sundries on any part of the crane. Forbid to throw
any thing down from the crane
5.3.8 When the crane which has stopped operating over one month will be used, we should
lubricate, adjust, maintain and check the various parts of the crane.
5.3.9 Daily and period maintenance must be done according the requirements of this
operation manual.
5.3.10 Fill in the personal details table of the crane and various records during operation.
5.4 Operation of the crane
5.4.1 The operation of the crane should strictly follow the regulations in Tower Crane
Operational Manual.
5.4.2 The driver of the crane can never operate unless the order signal is given first. The
driver should ring the bell (whistle) to alarm the others before operation. He must concentrate
his mind on the operation.
5.4.3 The driver of the crane should operate according to the crane hoisting performance table
that shows the data of the hoisting load and radius. Overloading is prohibited.
5.4.4 The crane is not allowed to hoist or pull goods from a tilted direction, and not allowed
to be used for staking or other similar work.
5.4.5 During the operation of the crane, no one is allowed to stand on the platform and ladder.
The adjusting or maintenance work is forbidden, and transporting persons with the hooks of
the crane is also prohibited.
5.4.6 During the operation of the crane, persons not concerned are prohibited from entering
into the moving range of the jibs.
5.4.7 The adjusted data of various electric system protection device, hydraulic system,
various parts and safety device are prohibited from modifying or remove.

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 5.4.8 Before the slewing mechanism stops, it’s forbidden to operate the slewing brake.
5.4.9 For the mechanism with both forward and reversed motion, when it needs to perform
reversed motion, the reversed switch should not be turned on until the inertial force has
disappeared and the motor has stopped. Prohibit turning on the forward and reversed motion
switch suddenly.
5.4.10 For the operation of the mechanism that has quick and slow speed controls, we should
operate from the quick to slow, or from the slow to quick sequentially, operating with
jumping is forbidden, the interval of the changing of two different speed should last 2-4
seconds.
5.4.11 When hoisting goods slowly with the hoisting mechanism, in order to avoid burning of
the motor, the full loading operation time in every 10 minutes should not exceed 2 minutes
5.4.12 The load of the hanging repairing basket of the jib trolley is not allowed to exceed
100kg. It is also not allowed to carry any persons when hoisting goods.
5.4.13 Before the driver goes off work, he should hoist the hooks to the height which is 3m
higher than the highest hindrance.
5.4.14 Before the driver leaves the Cabin, he should make various controlling switches to the
zero position, relax the brake of the slewing mechanism, shut off the power supply of Cabin,
lock the Cabin door, and after he comes backs to the ground, cut off the main power supply
steel casing switch.
6 Maintenance and repairing
The crane should be checked, repaired and maintained frequently. The driving parts should
have enough lubricant. The vulnerable parts should be checked, repaired or changed
regularly. The various bolts, especially for the vibrated parts, such as the connection bolts of
the fixed tower, should be checked whether they are loose. If the bolt is found loosed, tighten
it in time.
6.1 Maintenance of mechanical equipments
6.1.1 The various parts, such as gear box, out clenching gear, should lubricate according to
the requirements of lubrication list. Before changing the oil, we should clean off the iron
filings and impurities in the tanks. When filling oil, we should make the oil clean and
plentiful.
6.1.2 Check to see whether the wire rope of various units have broken and loosed. If over 5%
of the wires ropes have broken or 5% of the nominal diameter are worn out, change it.
6.1.3 The various drive mechanism should have the protection casing and can not be taken off
willfully.
6.1.4 Check the tightening state of the connection bolts frequently, if any loosing condition is
found, tighten them in time. Check the bolts of the fixed tower when the fixed tower is
compressed.
6.1.5 Check frequently to see whether the various devices run normally and whether there are
abnormal noises. If any malfunction is found, remove it in time.
6.1.6 When installing, disassembling and adjusting the slewing mechanism, attention should
be paid to ensure that the center line of the reducer of planet gear is parallel to the center line

Page No. 38
of the gear; their engaged surface should not less than 70%, and their clenching gap should be
reasonable.
6.2 Maintenance of hydraulic climbing system
6.2.1 The lubrication oil should be filled according to the requirements shown in lubrication
list, and oil should be filled over the working level, but not over the highest working level (If
there is no oil level indicator, we may add the oil above the zero level line of the liquid
temperature and level indicator 160-220mm). The oil should be changed every half a year
generally.
6.2.2 Turn on the power supply, observe the rotating direction of the motor, it should comply
with the direction labeled.
6.2.3 Check the connections of the rubber tube to see whether they are complying with the
sketch drawing. Check frequently the various tube connections to see whether they are
tightened or whether there is an oil leakage. It is not allowed to have the leakage of oil.
6.2.4 After adjusting the pressure of the overflow valve, do not change this pressure willfully.
Before every climbing operation, check the pressure with oil gauge to see whether it is
normal.
6.2.5 Frequently check the oil filter to see whether it has been plugged, and check the
adjusting value of the safety valve to see whether it has been changed after operation.
6.2.6 If leakage is found in oil pump and control valve, it should be repaired in time.
6.2.7 When the crane needs to start up in winter, it should be started and stopped for several
times. When the oil temperature has risen up and the action of the control valve is nimble, it
can be put into work normally.
6.2.8 When it is raining, the oil pump station shall be covered with plastic cloth to avoid
wetting and burning of the motor.
6.2.9 Fault hunting and removing
The fault removing method table
Fault Cause Removing method
After switched 1. The connector of Cables and 1. Check the circuit, connect them
on, motor un- air switch has loosed according to the drawing
running 2. The air switch is overload or 2. Open the cover of air switch,
short, make it de-connection or check the connector and the de-
burning off connector, repair or change
No pressure, 1. the wrong rotating direction of 1. Change the motor phase
or the pressure motor
has not 2. Oil is not clean, making the 2. Open valve core, clean with
reached the overflow valve plugged kerosene
rated value or
the pressure is 3. pipe break and oil leaking 3. remove pipe and welding
not stable 4. the connection of piping looses 4. tighten the connection and
or the gasket is damaged to leak change the gasket
5. plugging of the inlet of oil 5. clean the plugged things
pump filter

Page No. 39
 6. the oil pump has cracks due to 6. change the oil pump
overloading for long time
Unloading The core of the accurate filter is Open the core and the accurate
pressure plugged filter, clean them with kerosene or
0.3 MPa gas

6.2.10 After final assembly or overhaul, as the oil pump is started up for the first time, check
the inlet and outlet of the pump first to see whether they are connected correctly, and check
whether the rotating direction is correct and whether the oil absorbing pipe leaks or not, then
try to rotate by hand, finally start it up and test it in the required rotating speed.
6.3 Maintenance of the steel construction
6.3.1 During the transportation, it should be avoided that the components are deformed or
damaged due to impact.
6.3.2 In the period of operation, maintenance must be carried out regularly every one or two
weeks to avoid rusting, especially for the moment limiter, it should be checked frequently to
see whether it is sensitive and reliable. The other limiters such as the slewing brake limiter
and hoisting weight limiter should be frequently checked too.
6.3.3 Check frequently the connection bolts, weld seam and components to see whether they
are damaged, deformed or loosened.
6.3.4 Repaint the crane every one or two years.
6.3.5 The cage of jib trolley only allows carrying one person. The allowable load of the Cabin
is 150kg. These regulations are always neglected and could not be implemented strictly.
6.3.6 All above mentioned regulations and requirements should be paid special attention to,
check the hidden troubles of these parts. Be cautious in any operation.
6.4 Maintenance of the electric system
6.4.1 Frequently check to see whether all wires and Cabless are damaged. The damaged parts
should be wrapped or replaced in time.
6.4.2 Regularly check the connection and corrosion of the contact head of the contactor,
circuit breaker and controller. The crater on the surface of the moving and dead contacts head
should be grounded off. The dust and dirty things on the join iron should be cleaned off in
time.
6.4.3 When the overheating of motors occurs, stop it in time. After removing the fault, we can
operate it again. The lubrication of the bearing of motor should be in good state.
6.4.4 The control box and power distribution box should be always kept clean. The dust on
the electric equipment should be cleaned off in time.
6.4.5 The contact head of the limit switch of various safety devices should open and close
reliably.
6.4.6 Measure the protection earthing resistance twice (in spring and autumn) every year, and
ensure it is not more than 4Ω
6.4.7 In order to avoid the leakage of electricity, check the isolation resistance and ensured it
is not less than 0.5 MΩ every a period.

Page No. 40
 6.5 Repairing
6.5.1 After the crane has run for a long period, an overhaul maintenance of it should be
carried out. The longest interval of overhaul maintenance should not exceed 7500 hours.
6.5.2 In various cases of repairing, do not use any substitute parts and materials unapproved
by the manufacturer of the crane; modifying the crane by any repairing works is also
forbidden.
6.5.3 After an overhaul maintenance, various working performance of the crane should keep
the same as the crane when it has just left the factory, and it should get the certification of
inspection.
6.5.4 When the crane will be left unused for a long period, it should be put in a certain place
after the lubrication, corrosion protection and raining protection for each required parts are
completed. The crane should be inspected once every year.
7 Attached Mode

7.1 Sketch of ACE TC5040 in Attached Mode

Note:- 1. The components of ACE TC 5040 for attached mode includes all components
for fixed mode includes all components for fixed mode,several supporting frames and

Page No. 41
 some standard section.
2. The orientation of leading beam of standard section should avoid building.
3. The center of fixed Tower Crane should be 3.5 mtrs. away from building.
The number of Wall Anchor Frame should be determined according to attached height.
Fixed tower is composed of lower fixed tower and several standard sections. Lower fixed
tower has 13 Nos. standard sections. The number of standard section of fixed tower is
determined by attached height. Total standard sections include all standard sections in base
section, lower fixed tower and tower standard section.
7.2 Wall Anchoring Diagram

7.2.1 Parameters

S.No. Wall Anchor Attachment Attached point

1 First attachment 11th Mast Section
2 Second attachment 20th Mast Section
3 Third attachment 28th Mast Section
4 Fourth attachment 37th Mast Section
5 Fifth attachment 43th Mast Section

Page No. 42
7.2.2 Operating Condition of Attached mode

Max. operating height with first attached

Fig. Operating Condition I

Page No. 43
 Max. operating height with second attached

Fig. Operating Condition II

Page No. 44
Max. operating height with third attached

Fig. Operating Condition III

Page No. 45
 Max. operating height with fourth attached

Fig. Operating Condition IV

Page No. 46
Max. operating height with fifth attached

Fig. Operating Condition V

Page No. 47
7.3 Attached Mode of model ACE TC5040
The max. hoisting height for ACE TC5040 tower crane is 140m in attached mode. Cross
beam in base section should be tightened on concrete foundation by weight blocks during
the crane operation in attached mode. The bolt pre-placed in concrete foundation refers to
concrete foundation drawing. The weight of foundation is 84t. The center of base is
3900~4200mm away from the building
7.3.1 Wall Anchor Frame (Fig. 3-5)
The Wall Anchor Frame is composed of two half frames and four brace rod, etc.
Two half-rectangle frames can be jointed as a complete attached frame by bolts. Four brace
rod are respectively hinged to four corners of the frame. Each brace rod has an adjusting
bolt for adjusting the length of brace rod. The lug on the end of each brace rod is hinged on
attached point on building. Four brace rods should be held in a horizon plane.
The Wall Anchor Frame for ACE TC5040 is designed according to the distance, 3.9 ~
4.2m, from tower center to building, so the tower can be located in above range by
adjusting the length of brace rods. You can contact the manufacture for special design, if
the adjusting range exceeds the above limit.
7.3.2 Structure of Wall Anchor Frame (Fig. 3-5)
The structure of Wall Anchor Frame is shown in Fig. 3-5. The Wall Anchor Frame is
composed of two half-rectangle frames, which can be jointed as a complete attached frame
during the installation, four brace rods and top plate device.

Fig. 7-2 Structure of Wall Anchor Frame

Page No. 48
Eight pressure units (Fig. 7-3) set on attached frame can push the pressure block by
adjusting bolt, thus to press the standard section tightly.

Fig. 7-3 Pressure Unit

The hinge joint structure between Wall Anchor Frame and building is shown in (Fig.7-4).
The Wall Anchor Frame has two long and two short brace rods, each lug on its end is
directly hinged on the building.

Fig. 7-4 Hinge joint structure on Wall Anchor Frame and building

The user and installation company should design and arrange the supporting operation of
the crane and building based on the size and structure of supporting device and the strength
and load data that supplied.

Page No. 49
 Fig. 7-5 shows double-lug base plate for connecting building. You can re-design it based on engineering
practice provided that the original design is hardly carried out.
4 Round Bar Ø30-270 E250 B,IS:2062 4
3 Nut Hex M20 IS:1364 16
2 Anchor Bolt M20X400 IS: 5624 8
1 Plate 25x260x580 E250 B,IS:2062 1
S.No. Name Specification Material & standard Quantity Remark

Fig. 7-5 Double-lug base for connecting building

7.4 Operating Instruction

The sequence of installation of ACE TC5040 in attached mode is almost the same as the fixed
mode; only the Wall Anchor Frame is required to be installed on an appointed position. Its
installation sequence goes as follows:
7.4.1 Mount base section on special concrete foundation.
7.4.2 Successively fit lower standard sections in order.
7.4.3 Hoist the climbing frame covered on lower standard section.
7.4.4 Hoist slewing unit and Tower Head.
7.4.5 Hoist counter jib.
7.4.6 Hoist hoisting jib.
7.4.7 Hoist counter block and other work same as the fixed mode.
7.4.8 Check and make sure that whole crane is normal, then start climbing operation.
7.4.9 Fit Wall Anchor Frame as fixed tower has been climbed to the attached point.
7.4.10 The operation height of fixed tower above Wall Anchor Frame should not exceed the
required value after the Wall Anchor Frame has been fitted.

Page No. 50
7.4.11 Four brace rods of each set of Wall Anchor Frame should hold in a horizon plane as
possible. The attached point on building should be in same level of relevant Wall Anchor
Frame.
7.4.12 Ensure that brace rod, Wall Anchor Frame and fixed tower are firmly connected with
each other, and all bolts are tightened. The adjusting bolt should be tightened after brace rod
has been adjusted. During operation, all connective parts should be regularly checked and the
loose joint should be tightened in time.

7.5 Attached Size

The max. hoisting height for ACE TC5040 tower crane is 140m in attached mode. To keep
the operation stability and whole rigidity of the crane, free range in upper fixed tower
should be shorted as possible, so Wall Anchor Frames should be arranged according to the
whole fixed tower height. The relative position of Wall Anchor Frame is shown in (Fig.7-6).

Fig. 7-6 Relative position of Wall Anchor Frame

Page No. 51
7.6 Measurement and tensioning
The theodolite should be used to measure the verticality of mast axial line during
installation. The verticality should not exceed 4/1000 over total height, and it can be
aligned by adjusting the length of four brace rods.
7.7 Strength of concrete foundation
The user and installation company should calculate strength and verify bearing capacity of
concrete foundation, then confirm the construction method before the fixed tower is
installed in attached mode. The calculation output must meet the requirements of the
foundation load list as follows.
Foundation load list

Load Item Operating

P1 vertical load (KN) 700
P2 horizontal load (KN) 26
M overturning moment (KN·m) 1350
MK torque moment (tKN·m) 200

User and Installation Company should consider adopting maximum load on attached
point when they intend to install Wall Anchor Frame connection base.
8 Performance of associated facilities
8.1 Slewing Ergometer (Fig. 8-1)

Fig. 8-1 Slewing Ergometer

Page No. 52
8.1.1 Special feature
It is a device used for limiting hoisting load with 4 micro switches fixed in ring structure.
Under loading, the metal pulling ring will cause elastic deformation and push the micro
switch to control loading limitation and ensure safety.
8.1.2 Main technical specifications
a. range of loading: 5000N ~20000N single ring
b. accuracy of overload protection weight: ±2.5%
c. number of micro switches: 4
d. diameter of pulley: φ340
e. dead weight: 25kg.
8.1.3 Operating method
Fit the limiter in the front of slewing mast and repeatedly adjust the screws in ring structure
as desired loading limitation, then lock the nuts on adjusting screws.
8.2 Hoisting mechanism reducer
8.2.1 Reducer
Reducer is used in hoisting mechanism for ACE TC5040 tower crane.
8.2.1.1 Drive power: 30kW
8.2.1.2 Drive ration: i =15.69
8.2.1.3 Operation conditions
8.2.1.3.1 reducer can perform forward and reversed motions.
8.2.1.3.2 reducer conforms to intermittent periodic duty.
8.2.1.2.3 The connection mode of output shaft is gear connection.
8.2.1.2.4 The working ambient temperature is from -20 to 40.
8.2.1.3.5 N100 gear oil (grease) is used in this model of reducer.
8.3 Slewing mechanism reducer
Planetary gear reducer is a new type of speed reducer, which is widely used. The gear and
main stressed components are made from high-quality alloy steel, and the teeth of gear are
quenched and grinded, so the reducer has many good qualities, such as, compact structure,
advanced technical performance and greater output torque.
8.3.1 Model Description (Data)
8.3.2 Operation conditions
8.3.2.1 Planetary reducer is suitable to successive running, and it can perform forward and
reversed motions.
8.3.2.2 The bolt connected reducer and major unit should be twisted tightly.
8.3.2.3 The reducer should be filled with lubricating oil top up before running. And refill

Page No. 53
the lubricating oil along with the output of inside air and dropping of hydraulic surface in
time
8.3.2.4 The reducer has been filled with lubricating grease before it leaves the factory. You
may assuredly use, as long as serious leakage does not occur. The same kind grease should
be refilled 100ml every half a year
8.3.2.5 Lubricating oil should be preheated before startup,if ambient temperature is below 0.
8.3.2.6 Adopting the Mos2 lithium grease to lubricate.
8.4 Drawing mechanism reducer
Planet reducer is used in drawing mechanism for ACE TC5040 tower crane.
8.4.1 Model Description (Data)
8.4.2 Operation conditions
8.4.2.1 Planet reducer is suitable to successive running, and it can perform forward and
reversed motions. Its input has the feature of unidirectivity.
8.4.2.2 The coaxiality within reducer and mating parts should be guaranteed during
assemblage.
8.4.2.3 EP220 gear oil (grease), or alternated by N46, is used as machine oil.
8.4.2.4 The working ambient temperature is from -20 to 40.
8.5 Motor
8.5.1 Hoisting motor
8.5.1.1 Hoist motor is a variable frequency adjustable speed three-phase asynchronous
motor, its speed can be adjusted by regulating its power supply’s frequency. Test using
range of motor is as follow:
a: The motor can be used in indoor and outdoor dusty environments.
b. full voltage running;
c. altitude: less than 1000m;
d. ambient temperature: less than40;
e. protection levels: IP44.
8.5.1.2 Motor’s power-speed relations table
Motor Rated revolutions per minute Power
(r/min.) (kw)
Hoisting 1388 24
Motor 700 24
150 5.4
8.5.1.3 Performance data
a. Rated voltage is 380V, and reference frequency is 50Hz;
b. Under rated voltage and reference working system, its high speed rated current is
47A, middle speed rated current is 53A, low speed rated current is 50A;
c. Motor insulation grade is F-level. Total raising temperature is 80K. The allowable

Page No. 54
 temperature of bearing is 95.
d. The performance parameters of motor will be changed to affect motor running, if its
voltage fluctuation exceeds 5% or power frequency fluctuation exceed 1%..
8.5.1.4 Maintenance
a. Motor shell should keep clean to avoid affecting heat dispersion.
b. Prevent from collision during transportation or installation.
c. Check and ensure the dielectric resistance of motor should not be less than 0.5MΩ
before operation.
d. Rotate spindle, which should be turned freely.
e. Check periodically whether the mounting bolts of all places are tight or not.
f. Generally, Mos2 lithium grease, lubricated bearing in motor’s two ends, should be
refilled every half a year.
g. Motor shell should earth reliably.
h. Do not permit motor startup in low-speed directly before it has not yet stopped, if it
is running in high-speed.
8.5.2 Slewing motor
8.5.2.1 Slewing motor for ACE TC5040 tower crane is frequency adjusting speed moment
motor with cooling fan, model YLEW112M-6-95N.m. This motor can be stably started and
braked, and with larger overloading capacity, so it is suitable for slewing mechanism of
crane.
8.5.2.2 Model Description (Data)
8.5.2.3 Normal operation conditions
8.5.2.3.1 Ambient temperature: -20~ +40.
8.5.2.3.2 Altitude: not more than 1000m.
8.5.2.3.3 Relative humidity: not more than 85%.
8.5.2.3.4 Rated voltage: AC380V.
8.5.2.3.5 Frequency: 50Hz.
8.5.2.3.6 Protection levels: IP44.
8.5.3 Drawing Motor
Drawing motor for ACE TC5040 tower crane is frequency adjusting speed moment motor
with double speed, 3.3/2.2kw.
8.6 Slewing Bearing
8.6.1 Main structure parameter and dimension
8.6.1.1 Model: HSW.35.1250A
8.6.1.2 Tooth number: Z = 117;
8.6.1.3 Modulus: m = 12;
8.6.1.4 Diameter of roller: φ35;
8.6.1.5 Outline dimension (external×internal×height): 1449.6×1090×120.
8.6.2 Technical Requirements
8.6.2.1 The internal rings of finished products should be freely and stably turned round

Page No. 55
leftward or rightward each other. Do not let seizing-up, abnormal noise and shock occur.
8.7 Multi-functional travel limiter (Fig. 8-1)

Fig. 8-1 Multi-functional travel limiter

8.7.1 Structure and working principle

The multi-functional travel limiter is composed of high precision and large drive ration
speed reducer, and the mechanisms synchronized with its output shaft, and memory control
mechanism, etc. The working principle is as follows, that is, when the controlled
mechanism, which is connected with the input shaft of the limiter, is running, the limiter
will record its slewing angle (or number of circle). If the recorded data reaches a given
value, memory cam actuates immediately to shut off micro switch, so the whole
mechanism accomplishes travel limiting.
8.7.2 Adjustment Method (Fig.8-1)
8.7.2.1 Convert the crane to controlled condition under its no load condition.
8.7.2.2 Take apart upper shell, check and tighten screw (2-M3×55), meanwhile loosen nut
(M5), push micro switches (WK) manually one by one, verify whether the state of micro
switches (WK) which controlled travel limitation are correct.
8.7.2.3 Adjust shaft 4Z to push the micro switch 4WK by the cam 4T, to accomplish
instantaneous engagement. Then tighten nut M5.

Page No. 56
8.7.2.4 Convert the mechanism to another controlled condition, loosen nut M5 and regulate
the adjusting bearing 1Z to actuate cam 1T to push micro switch 1WK, to accomplish
instantaneous engagement. Then tighten nut M5.
8.7.2.5 Run the whole mechanism under no load condition over and over again to verify
whether the memory position is correct or not. Confirm the mechanism meets all the
requirements, and then cover the shell.
8.7.2.6 Verify frequently whether the memory position has been changed during
mechanism running normally, in order to correct in time.
8.7.3 Main technical specifications
8.7.3.1 Working ambient conditions
a. ambient temperature: -20 ~ +40.
b. relative humidity: not more than 90%
c. altitude: not more than 2500m
8.7.3.2 Drive ration: 1:46-1:2,10-1:274.
8.7.3.3 Accuracy of repeated locating: angle error of memory cam is no more than 0.05rad (
8.7.3.4 Rated voltage: AC125/250V.
8.7.3.5 Rated current: 6~10A.
8.8 Ganged Console in Cabin
8.8.1 Structure and working principle
The ganged control system of ACE TC5040 tower crane is composed of left and right
consoles and an adjusting seat. The seat can be removed or installed. There is a set of drive
mechanism in left and right console separately. Two sets of contact head are fitted beneath
drive mechanism. The zero-position self-locking device fitted on control handle is capable
of avoiding false operation. Hold the ball-headed handle, pull the self-locking handle
forward and backward manually, cause the fan-shaped cam to drive the shaft of little gear
cam on a contact head set, and then shut off the corresponding contact head. The moving
range of handle relates to the speed of controlled mechanism, that is, the larger range of
handle moves, the faster the speed of the mechanism is. The back spring strains
immediately to cause zero-position self-locking, when hand leaves handle.
The relation of moving direction of mechanism and handle is as in the following:
Mechanism moving direction Handle moving direction
Left console Jib trolley inward,Jib trolley outward Backward,Forward
Slew right, Slew left Right, Left
Right console Hook up/ Hook down Backward Forward

8.8.2 Function and name of control switches (Fig.8-2)

8.8.2.1 Engage power supply switch QF2 and push the start button QN to ignite the
pressure watch for normally supplying power.
8.8.2.2 Set the select switch “SA3” to “slewing” position, then pull left control handle left

Page No. 57
 or right, the slewing mechanism correspondingly slews left or right.

Fig. 8-2 Ganged Console View

8.8.2.3 Set the select switch “SA3” to “brake” position, the slewing mechanism is locked.
8.8.2.4 Pull the shifting handle forward or backward on right console, and engage second
gear to perform low speed up and down.
8.8.2.5 Pull the shifting handle forward or backward on right console, and engage second
gear to perform middle speed up and down.
8.8.2.6 Pull the shifting handle forward or backward on right console, and engage third
gear to perform high speed up and down.
8.8.2.7 Push button “STOP”, so the auto-switch QA2 fitted in Cabin is shut off and the
crane is STOP.
8.8.2.8 Engage switch “SA2” to ignite the anti-collision light, when the height of crane
exceeds 30m.
8.8.2.9 Engage switch “SA1” to ignite the ceiling light in Cabin, due to less illumination or
night operation.
8.8.3 Performance and technical data
8.8.3.1 Operation conditions
a. Temperature is between –20 to 40,and its average is not more than +35 within 24
hours.
b. Altitude is not more than 2000m.
c. Air around mounting place should be clean.
d. Pollution grade is assigned to 3 levels. Installation grade is assigned level .
8.8.3.2 Working System
This control system is suitable for 8-hours working system and repeated short-time

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working system. Under repeated short-time working system, the continuity of supplying
power is 40%, rated operating frequency is 600 times per hour, and the force of handle
operating is not more than 3kg.
8.8.3.3 Machine Service Life
The service life of contact head mechanism is 1.5 million times and of operation
mechanism is 3.0 million times.
8.8.4 Operation and maintenance
8.8.4.1 Check to see whether the wiring connection in ganged console conforms to electric
schematic diagram, before operation.
8.8.4.2 The driver should not operate until pulling the zero-self-locking handle manually.
8.8.4.3 Check to see whether all wire lead and terminal connecting end are tight, and
should be tightened in time, if there are any looseness.
8.8.4.4 Generally, the ganged console should be clean by alcohol and cotton every year.
9 Drawing Paper and lists
9.1 Foundation (Supply by consumer)

Fig 9-1 Concrete Foundation Outrigger type

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 Fig 9-2 Concrete Foundation (embedding type)

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 9.2 Lubrication list
Item Component Lubricant Method (hours) Additional
Description Requirement

1 Hoisting EP220 gear oil Refill appropriate amount every Level must be
mechanism 240 working hours, renew the oil corrected
reducer every 1500 working hours
2 Slewing EPL-2 Lithium Grease Refill 100ml every half a year
mechanism
reducer
3 Drawing EP220 gear oil Refill appropriate amount every
mechanism 240 working hours, renew the oil
reducer every 1500 working hours
4 All pulleys EPL-2 Lithium Grease Refill appropriate amount every
240 working hours
5 All wire ropes Graphite/EPL2 Grease Boiling in oil every overhaul or
medium maintenance
6 All bearings EPL-2 Grease Refill appropriate amount every
excluding motor 160 working hours, cleanup the
bearings oil every half a year.
7 Motor bearings EPL-2 Grease Renew the oil every 1500
working hours
8 Hydraulic Oil Hydr.oil grade 46 Renew the oil every half a year
tank

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9.3 Prime components weight list

item Number Name Qty Unit Gross Note

weight weight
1 501301F00000 Counter jib 1 1760 1760
2 501302000000 Hoisting mechanism 1 1614 1614
3 501303000000 Counter jib tie bar 2 136 272
4 501304000000 Tower Head 1 1328 1328
5 501305000000 Moment limiter 1 11 11
6 501306000000 Cabin 1 369 369
7 501307000000 Drawing mechanism 1 250 250
8 501308000000 Hoisting jib tie bar 1 1197 1197
9 501309000000 Hoisting jib 1 4120 4120
10 501310000000 Jib trolley 1 225 225
11 501311000000 Hook 1 156 156
12 501350000000 Wall Anchor Frame as 990 5X990
required
13 501313000000 Slewing mechanism 1 500 500
14 501314000000 Slew Mast 1 1118 1118
15 501315000000 Upper Bracket 1 1297 1297
16 501316YD0000 Lower Bracket 1 1655 1655
17 501317YD0000 Climbing crane 1 3350 3350
18 501318000000 Electric equipment 1 ≈ 200 200
19 501319YD0000 Standard Mast 1 10600 10600
20 501320000000 Base section 1 615 615
21 501301F03000 weight block 4 2500 10000
weight block 2 1250 2500
22 Deadweight of crane 31t Excluding counter
block, weight block
and Wall Anchor
Frame

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 9.4 Bearing List

Item Description model Qty Application place

1 Ball Bearing 2215 1 Jib trolley (holder pulley)

2 Ball Bearing 6212-Z 20 Climbing frame (leading pulley)

3 Ball Bearing 6013-2RS 2 Jib trolley (side roller)

4 Ball Bearing 6208-Z 10 Hoisting jib (pulley)

5 Ball Bearing 6004-Z 8 Jib trolley (roller)

6 Ball Bearing 6207-Z 8 Tower Head, hook and trolley (pulley)

7 Ball Bearing 6205-Z 4 Hoisting jib (anti-torsion unit)

8 Thrust Ball Bearing 51308 1 Hook

9 Thrust Ball Bearing 51308 1 Jib

9.5 Wire Rope List

Application place Standard and Dia. of Qty. Tot. length of single rope
specification rope
Hoisting mechanism 12mm,18x7, Steel Core 12 1 Confirm the length based on the
height of the crane ordered
Drawing mechanism 8mm, 6x19, Fiber Core 8 2 100m & 60m

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9.6 Electric Equipment Installation

Fig. 9-6 Electric equipment Installation Drawing

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9.7 Circuit diagram

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 9.8 Power Diagram

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9.9 Electric Schematic Diagram

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 9.10 Electric Panel Box

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9.11 Electric Connection diagram

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 9.12 Electrical Joystick

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Counter Weight-I -2500kg - 04 Qty
Counter Weight-II -1250kg - 02 Qty
9.13 Counter Weight

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 Technical Requirement
1. Use welding rod AWS E6013 or Mig wire AWS ER70 S-6.
2. The Density of Concrete should control in 2.4t/m, and check the weight of finished product
.the allowable deviation of weight is ± 2%.
3. The Grade of concrete is M30.
4. The hole of No.3 should be cleaned after dry.

9.14 Tools along with tower crane

To ensure successfully raising and removing the tower, there are reserved tools as follows:

S.No. Description Specification Qty.

1 Cutting pliers insulated 8" Combination Plier 1
2 Nose pliers insulated 6" Long Nose Plier 1
3 D spanner Set up to 30x32 1 set
4 Ring spanner Set Up to 24x27 1 Set
5 Hammer Ring Spanner 46mm 2
6 Adjustable Spanner 15”Adjustable-wrench (Phosphated) 2
7 Screw Driver Flat Screw Driver 6x150 1
8 Screw Driver Flat Screw Driver 8x250 1
9 Screw Driver Flat Screw Driver 10x300 1
10 Star Screw Driver Philips head 5x75 1
11 Star Screw Driver Philips head 6x150 1
12 Round Hammer 4.5kg 1
13 Half Round File 200mm 1
14 Line Tester Screw driver Tester (500V) 1
15 Grease Gun 1kg 1
16 Allen Key- 4mm 1
17 Allen Key- 5mm 1
18 Allen Key- 6mm 1
19 Oil Can 250ml 1
20 Mast aligning Pin 350mm 1

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Maintenance schedule:-
1. Rope Checking :-
The hoisting and Trolley rope must be checked for wear & tear or damages at every 7 days of
working.
2. Level checking :-
The foundation level must be checked at every 15 days of working. If the level is out by 4mm
or above, them immediately an additional anchor support to be fitted between 12-20 mtrs of
height. And while dismantling:- The tower crane should be dismantled above this anchor
support and then remove this support & then remove the support & balance masts.
3.Greasing(grade EPL-2 only) :-
Greasing of the following points must be done at every 6 days of working and cross check by a
supervisor. Any excess grease on machine parts must be cleaned immediately.
a. Hoisting rope, trolley rope and hoist rope arresting point(rotating assy.) at jib end.
b. Hoisting pulley, guide pulley, winch bearing.
c. Trolley pulley, trolley rollers and hook block pulleys.
d. Slewing gear internal and external.
e. climbing frame rollers when height increasing or decreasing.
4. Oil Changing:-
a. The hoist gear box oil must be replaced (gear oil EP-220 Grade)at every 2000hrs of working.
b. The slew gear box oil must be replaced (gear oil EP-220 Grade)at every 2000hrs of working.
c. The hoist break cylinder oil must be replaced (Hydraulic oil Grade-46)at every 2000hrs of
working.
5. Brake Checking:-
a. Hoisting brake must be checked every day for functioning and liner clearance. The liner
clearance(2-3mm)must be adjusted if required and the check nut must be tightened.
b. Trolley brake must be checked every 15 days of working for functioning ,liner clearance(1-
1.5mm)and check nut tightness.
6. Electrical:-
a. All electrical connectors must be checked for tightness and proper insulation at every 15 days
of working.
b. 2 nos. Good earthing must be done at lower mast and must be checked at every 15 days.
c. Slew battery condition and charging must be checked at every 15 days.

Page No. 73
 ACTION CONSTRUCTION EQUIPMENT LTD.
5th FLOOR, TDI CENTER, JASOLA,
NEW DELHI – 110076
PHONE : +91-11-40549900
FAX : +91-11-40549922
Email : marketing@ace-cranes.com
www.ace-cranes.com

WARRANTY
1. The company warrants that if any defect is reported an its machinery within the
warranty period defined below at Serial no.-2, the company shall examine the
part/parts and if satisfied that the defect is due to faulty material or workmanship, shall
repair or replace the part/parts free of charge provided all the parts claimed as
defective shall be returned to manufacturer's plant at Dudhola Palwal, Freight charges
prepaid.
2. The warranty is for a period of 6 months from the date of installation of machine of the
first buyer.
3. The liability of the company is limited to replacing or repairing the part/parts against
the accepted claims. The company accepts no liability for any loss or damage direct or
consequential or for any accident resulting from defective material, faulty
workmanship or otherwise.
4. The benefits of this warranty do not apply to:

• Any part/parts which in the opinion of the company, has/have been repaired or altered
or has/have failed due to natural wear or tear or because of wrong use of the oil or has
been damage due to negligence or improper storage or damage due to abuse, or
accident. The company's decision in this regard shall be final.

• Normal replacement of service items like lubricants, filter elements,o-rings and fan-
belt etc.

• Loss oil due to leakage or any other consequential damage to part/parts thereof.

5. Proprietary components and accessories like electrical equipments, motor etc. used on
machines are covered by standard warranty of manufactures of such component.

NO REPRESENTATIVE OF THE MANUFACTURER HAS AUTHORITY TO

CHANGE THIS WARRANTY OR THIS CONTRACT ANY MANNER WHAT SO
EVER.

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