9-22 Published 08/16/19 Control # 112-05
CRANE INSTALLATION 500E2 SERVICE MANUAL
AFTER FRAME MODIFICATION
If additional suspension reinforcing is required, as may be
the case with a truck frame that tapers down to
approximately 6 inches (15.24 cm) deep through the
suspension, a channel may be fabricated through the
suspension for additional strength. To do this, install the
angle as described in the previous step, making sure that the
long leg of the angle extends to the top of the truck frame. A
bar of the same material strength, thickness, length and
flange width as the reinforcing angle is then added to the top
of the truck frame. The bar is butt welded to the top of the
forward reinforcing, then skip-welded with 6 inches (15.24
cm) of weld, 6 inches (15.24 cm) no weld, etc., along both
edges of the bar, front to back. Length of after frame (AF)
may have to be modified for crane installation. If AF is too
long, cut off excess and remove any crossmembers from
back of truck frame. If AF is too short, the frame will have to
be lengthened. Use channels fabricated from 100,000 psi
(758 MPa) yield material that are the same size as the truck
frame. Weld these channels to the ends of the existing truck
frame channels. Bevel the ends of the channels to get 100%
weld joints with Grade 90 weld material. Fabricate an inner
channel of the same thickness as the truck frame channels
to span the weld joint for at least 12 inches (30 cm) on each
side of joint. Plug weld this channel to the inside of the truck
frame, then skip weld the inside edge of the top and bottom
flanges to the truck frame flanges
CRANE MOUNTING PROCEDURE
The following is a suggested sequence of steps required to
successfully mount the crane on the truck. This is only one of
several possible ways to mount the crane and is offered as
an aid to planning the mounting of the crane.
Crane Component Installation Sequence
• Position Torsion Box and mark frame locations for
Hydraulic Reservoir and ASH
• Remove Torsion Box
• Install hydraulic pump
• Locate and drill holes for Hydraulic Reservoir
• Install Hydraulic Reservoir
• Install pump lines to Reservoir
• Position Torsion Box
• Install ASH
• Install Truck Bed
• Install Frame Assembly
• Install Outriggers
• Route and connect hydraulic hoses to Reservoir and
Main Control Valve
• Install Boom
• Install hoist cable
• Fill hydraulic reservoir
Torsion Box and ASH Stabilizer Installation
1. Determine installation position for the crane considering
the operating area of the crane, space for saddle tanks,
truck frame crossmembers, or anything that might affect
installation and be sure the frame is clear of any
obstructions that might interfere with proper installation.
2. Center the subbase on chassis at the proper location.
3. If subbase does not fit tightly on truck frame at all
locations, do not force them together to remove gaps
since they will not affect the units stiffness or strength.
Add spacers as required to level truck bed before
attaching it to the torsion box.
Install Torsion Box
Install outriggers on crane frame as shown in illustrated parts
pages. Attach the appropriate hoses to the outrigger
cylinders. Cycle the outriggers to fill with oil completely and
install the latch plate to hold outriggers in place during travel.
Mount the Turret and Torsion Box to the
Frame Assembly
Position the turret assembly and the torsion box on the frame
assembly so that the mounting bolts can be attached through
the plates attaching the assemblies to the frame
(Figure 9-1).
Turret Mounting
1. If not already applied, apply channel molding (15,
Figure 9-1) to both holes where the turret assembly will
sit. Tap molding until snug. Trim excess molding as
needed.
2. Position the turret assembly.
3. Install the standard SAE washer (4) against the head of
the 1-1/4 inch bolt (3).
4. Install the Direct Tension Indicator (DTI) crush washer
(7) with the bumps facing away from the SAE washer
(4), facing toward the hardened washer (14).
NOTE: Do not allow the DTI crush washer to turn during
tightening of fastener or damage may occur to the
bumps on DTI crush washer causing improper
tension.
NOTE: The DTI crush washer cannot be re-used and must
be replaced if the studs become loose or are
removed.
5. Install the DTI hardened washers (14).
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