GPO Vehicles

Make Morris
Body Builder TICO K 52E Crane
Use Stores Trucks
Registration Number  
Fleet Number  
Date of picture  

B 3850
Issue 1, 20.4.64

Description and Operation

1. General
This Instruction describes the Crane, Truck, 1 Ton (Tico K 52E). It is intended to be fitted to 50 cwt. and 4 ton stores carrying vehicles for general stores handling, including poles and cable drums up to 3 tons in weight.

Fig 9

2. Description
The crane is hydraulically operated by a pump attached to the vehicle power take off. It consists of a 3 section telescopic boom carrying the winch, mounted on a rigid central column housing the main ram (see Fig. 1). The base of the column provides the main reservoir tank for the hydraulic fluid and carries the hydraulic control valves and their operating levers. Hydraulic operation provides for:-

(a) raising and lowering the boom
(b) unlimited rotation of the boom in either direction
(c) raising and lowering the hook by means of the winch.

The crane is mounted on the vehicle chassis, immediately behind the cab.

3. The telescopic boom sections are extended manually but can be retracted manually or automatically, by winding in the hydraulically-operated winch rope. The winch, which is built into the base of the boom, has a drum capacity of 131 ft. of 5/16 in. steel rope, but is normally provided with only 82 ft. of the rope. A HYDRAULIC PUMP ENGAGED warning light is provided on the facia panel in the driver’s cab (see par. 7).

The maximum safe working loads are as given in par. 10.

4. Remote throttle control
A solenoid actuated rod operated by 2-way switches, one on each side at the rear and inside of the cab, is designed to increase the engine speed to give greater control when lifting heavy loads. The speed can be increased only when the hydraulic pump is engaged.

5. Stabilizers
Screw jack type stabilizer legs (see Fig. 1) are fitted on either side of the crane base to provide stability under load conditions.

6. Preparations for use
Before attempting to lift a load, place BOTH stabilizers in the ‘down’ position by carrying out the following operations for each stabilizer:-

(a) Remove the ‘R’ clip and locking pin
(b) Release stabilizer leg from securing chain
(c) Lock stabilizer in vertical position using locking pin and ‘R’ clip
(d) Extend foot by unscrewing the jack until it is approximately 1 in. clear of the ground. (On soft ground blocks must be used to prevent the jack from sinking into the ground.

7. With the engine running, engage the pump drive by depressing the clutch pedal and turning the selector lever. Release the clutch pedal slowly to take up the drive. The selector lever can be turned in either direction, but the warning light on the facia panel will indicate that the hydraulic pump is ‘engaged’.

NOTE:- Always ensure that the crane controls are in a neutral position before engaging the pump drive [see par. 9 (e)].

8. Continue as follows:-

(a) Unclip the lifting hook on wire rope from its stowage position on crane column (see Fig. 2)
(b) Traverse the boom to a central position over the vehicle platform (see par. 9).
(c) Slacken off the winch rope and extend the boom sections manually by slackening off the individual boom section locking screws and fully extending the sections in numerical order as required (see Fig. 1). This will ensure that the heavier sections are used when the boom is required to be only partially extended.

NOTE:- Always fit the locking pins and ‘R’ clips and tighten the locking screws after boom adjustment (see par. 12).

Fig 2

9. Operating the crane
NEVER permit the cable to run out beyond the safety margin. Stop operations immediately a red painted portion of the rope appears. Failure to do so will result in the danger of winding the rope on the drum in the reverse direction. This may cause damage to the automatic friction brake which is of the helix screw actuated disc type in which the braking effect is proportional to the suspended load. While it is possible to lift a load against the friction of the automatic brake (the brake will operate erroneously due to the reversal of the drum) when the control lever is restored to the neutral position the brake will be completely released and any suspended load will fall uncontrollably to the ground. If the rope winds unevenly it causes jerkiness in winching. The winch rope must be under load (provided manually if necessary) whenever the winch is operated, to prevent crossed turns.

  1. Select the operation required by moving the lever on either side of the vehicle (see Fig. 3) as indicated by the instruction plate fitted to the control arms (see Fig. 4).

  2. Avoid sudden or jerky operation by engaging the controls smoothly. Winching, slewing (traversing), or arm Lowering operations can be made very slowly and gently if required by partial movement (inching) of the control lever, hut this method MUST NOT he used for raising the boom, which requires positive but smooth control lever action.

  3. The winch can be used for a vertical lift with the arm in any position but when it is necessary to ‘winch-in’ from any angle, the arm must be completely lowered, Non-compliance with this instruction may result in damage to the crane structure.

  4. Use of the remote throttle control to increase engine speed will assist the smooth operation of the crane when dealing with heavy loads.

  5. Always return the controls to the neutral position after each operation.

  6. The driver of the vehicle is responsible for the safe handling of the load. The operation of the crane by other unauthorized persons is prohibited.

10. Safe working loads
The plate fitted to the head of the crane shows the safe working loads at various boom lengths. These are as follows and must NEVER he exceeded Under any circumstances.

  1. Section 1 only extended (on two part rope) - 2500 lb. (22.25 cwt.

  2. Sections 1 and 2 extended (on two part rope) - 1700 lb. (15.25 cwt.

  3. Sections 1, 2 and 3 extended (on single part rope) - 1300 lb. (11.5 cwt.) No other combinations should be used.

NOTE:- Safe working load on (a) and (c) cannot be exceeded because the hydraulic relief valve will operate, preventing application of greater loads. This will not happen on (b) when it is possible to overload and great care must be taken to prevent overload under these conditions.

These loads apply to the boom and tackle and must not be exceeded. The safe working loads stamped on the hooks (15 and 25 cwt. respectively) apply only to the hooks.

11. Two part rope

(a) Winch out 4 or 5 ft. of rope under manual load.
(b) Attach the hook to the anchorage on the underside of boom section No. 1 (see Fig. 5).
(c) Remove the ‘R’ clip, spindle and pulley wheel from the large hook assembly.
(d) Reassemble the parts so that the large hook is suspended in the loop of the wire rope.

12. Safety precautions

(a) Do not move the vehicle with:-
(i) stabilizer legs in ‘down’ position
(ii) hydraulic pump ‘engaged’ (check warning light)
(iii) winch hook in other than ‘stowed’ position.

(b) Do not:-
(i) carry out loading or unloading operations with the vehicle steps down
(ii) operate in an area with overhead obstructions. Keep clear of overhead power wires particularly
(iii) allow the load to pass over any person’s head including the operator himself, particularly when loading poles
(iv) allow a load to pass out of sight of the operator. If this cannot be avoided a man must be used to watch the load and signal requirements to the crane operator
(v) use the crane unless the vehicle handbrake is ‘on’ and if necessary chock the vehicle road wheels
(vi) operate the crane without the engine running.

(c) Lock-pins and ‘R’ clips, where fitted, must be secured after each operation.

13. Responsibility for maintenance
The maintenance will be the responsibility of the Workshop Supervisor/Mechanic-in-Charge, to whom all defects and queries should be referred.

Fig 5

14. Attachments
Attachments suitable for use with the crane are:-

Pole Timber Grab (Crane Type) (see Mechanical Aids, J 1030)

Chains, Sling, with Claw Hooks (see Mechanical Aids, B 1009)

Chains, Sling, with 4 Stirrups [see Mechanical Aids, B 9010]. This Instruction will shortly be replaced by Mechanical Aids, B 1010.

15. Types of load
Types of load which can be handled are as follows:-

(a) Lifted.

(i) Poles up to 45 ft. medium
(ii) Cable drums up to 1 ton in weight
(iii) Loading pots
(iv) Cabinet and pillar shells
(v) Frames and covers (including unit type)
(vi) Any bulky item which is unsuitable for palletising.

(b) Hauled (Winched) (see Fig. 6).

(i) Cable drums up to 3 tons in weight
(ii) Light wheeled vehicles up to 3 tons in weight.

Fig 6

16. Instructions on the handling of poles and cable drums will be issued separately.

References:- Mechanical Aids, B 1009, B 1010, B 9010, J 1030.


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Last revised: January 11, 2007