2011 ARIES LIGHT DUTY PARTS AND SERVICE MANUAL
Contents
1. 2011 ARIES LIGHT DUTY PARTS AND SERVICE MANUAL Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 Revised on 3 25 12 Contact Information For parts and service please contact Auto Truck 1420 Brewster Creek Blvd Bartlett IL 60103 Phone 630 860 5600 Toll free 1 877 284 4440 Fax 630 860 5631 E mail parts autotruck com Web address www autotruck com Please have the following information at hand before calling Vehicle make Model Year Unit number Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 2 Revised on 3 25 12 Table of Contents Operation 4 Alignment and Adjustment 7 Lubrication and Maintenance 11 Troubleshooting 12 Shunt System Schematic 13 Lower Rail Gear with Emergency Hand Pump 14 Parts Diagrams 17 Hydraulic Pump System Electrical Schematic 20 Hydraulic System Schematic Electric Hydraulic Pump 2 Hydraulic Schematic PTO Driven System 22 Torque Requirements 25 Torque Chart 26 Overview ARIES LIGHT DUTY rail gear 1s hydraulically actuated rail gear The hydraulic and mechanical systems are very simple The hydraulic system actuates the cylinders to raise or lower the railgear The gear has mechanical locks front and rear to prevent the gear from falling due to a hydraulic failure while in the road position The suspension consists of splined shaft embedded in an elastomer Attached to this splined shaft 1s the wheel arm which2. d pu pn Rear Gear To waji Uritue lm Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 6 Revised on 3 25 12 Alignment and Adjustment Setting Rail Pressure It is important the rail pressure is set within the limit of safe operation too little rail pressure can lead to derailing and too much rail pressure can cause premature tread and suspension wear Rail Pressure can be set by two methods Preload and by Scale For Preload 4 34 shims and a protractor are required For Scale a bottle jack with pressure gage are required Rail Pressure should be checked before putting your vehicle on track and if you have changed the weight of your truck by adding or subtracting equipment and or tools Adjustments Both the front and rear channels can be positioned vertically by loosening the 4 mounting bolts It 1s suggested to scribe marks on brackets before loosening in order to preserve the horizontal position of the gear The angle of the suspension arms can be changed by moving it on the splined shaft The shaft has a 60 tooth spline giving 6 degrees per tooth of adjustment or about vertical Keep in mind that changing suspension angle may require other adjustments to clear body work The suspension will not provide proper ride if angles exceed 45 degrees below horizontal the optimum ride for an empty vehicle is 25 degrees Checking Rail Pressure Checking rail pressure
3. 8 9125749065 1 8X5 00 GRADE 8 BOLT 9 30884516 SHIM 0 125X1 00IDX1 500D 94235 2 WHEEL 10 Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 19 Revised on 3 25 12 ELECTRICAL DRAWING PUMP ASSEMBLY J ONT _ T Z a CRG mr mr RED WIRE TO ROCKER SWITCH FROM vs CREE GREE mk BEA REE ap dE uh HAB CUNT RGSS Light Duty Aries Parts and Service Manual doc Created on 7 21 11 Revised on 3 25 12 BLACK WHITE BLACK RED RED 20 WHITE ES s el H FRONT Pape CREAR oe Ni mz WHITE BLACK Gh RED TO BATTERY Part RGEARLIGHT SWITCH WIRING FRONT AND REAR COTROLLERS GREEN 12 VOLT SWITCH POWER RED SOLEHOID TRIGSER WIRE WHITE LIP BLALK DOWN IN C amp R CONTROLS SREEN 12 VOLT SWITCH POWER RED SOLENOID TRIGGER WIRE GRANGE FRONT UP BLUEZFRONT DOWN BLACK REAR UP WHITE REAR OWN HYDRAULIC SCHEMATIC FOR ELEC HYD PUMP SYSTEM Cases uEW WSUcHMR a me 0 L3 7 Tuscia mis CITIES VRBIS fsa ame 0 Lii pecwce L7 i AAA Lr meae m o y rp uem mw wi eene baa Re 0000 AUTO TRUCK INC Hn 1200 M ELUS BENSENVILLE IL GOTOG SCHEMATIC HYDRAULIC FWF 8755 ARIESLD 2 ELECTRIC HYDRAULIC PUMP WAR ORDER f DRIN
4. D 23170 WIHLJA 4 Aa LSH 3 D ya TAT HEHLIM 1 3 TH 8G LENN T 3 ya al E HIKIJA 3 Wa LSH 3 ete HIHIIA E TX Law J aes tC NIHLIA E TTE LZTW Y F ane oq Form number G199 ATG Light Duty Aries Rail Gear Alignment form Part RGEARLIGHT Light Duty Aries Parts and Service Manual doc Created on 7 21 11 Revised on 3 25 12 Rail Testing the Vehicle after Alignment 1 The vehicle must be tested on level tangent track 2 Apply a contrasting color of spray paint to the flanges and tread of the guide wheels 3 Set the vehicle on rail and drive for a short distance at normal operating speed 4 Stop the vehicle 5 Look at the guide wheels On a properly aligned vehicle the paint should be worn evenly across all the wheels 6 Looking at the front wheels if more paint is worn off the left wheel flange than the right the vehicle is said to be flanging left the opposite condition is known as flanging right a To correct a flanging right condition we want to add some toe in to right wheel That is to make F a bit greater than F 1 referring to the alignment diagram Loosen the suspension body to make this adjustment b If the gear is flanging left we want to add some toe in to the left wheel That is to make E a bit greater than E 1 referring to the alignment diagram Loosen the suspension body to make this adjustment 7 Repeat beginning at step 72 8 If there are still alignment issues repeat the
5. carries the stub axle hub rail wheel The clock position of the wheel arm on the splined shaft determines the load carried by the rail wheels Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 3 Revised on 3 25 12 Operation Safety and Tips for Safe Operation on Road Before road travel always ensure the rail gear is fully raised and the locks are properly engaged Make sure the steering lock is disengaged The steering and braking characteristics of your vehicle will be different due to the rail gear If you are driving the vehicle for the first time familiarize yourself with the steering and braking by driving the vehicle in a safe place before taking the vehicle on the road Be aware that your vehicle may have reduced ground clearance due to the rail gear Approach and departure angles may be different due to the rail gear This will affect the way you approach dips ditches inclines and other surface irregularities Do not use the rail gear as a hitch for towing vehicles or dragging objects Use the correct hitch points on the vehicle frame Safety and Tips for Safe Operation on Rail Traction is very limited while on rail Acceleration and braking must be done smoothly Pay attention to the speedometer it will over speed if the road wheels are slipping on the rail Traction is further reduced when the rail is wet or snow ice covered Max forward speed on rail is determined by your rail
6. on the electrical circuit Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 13 Revised on 3 25 12 Emergency Pump Operation Located under rear bumper Emergency pump components Emergency P p Pump ss Os Override Spools Insert the supplied handle into the emergency pump Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 14 Revised on 3 25 12 T Push and hol Pull and hold to raise front M 2E to lower front railgear E HE LP railgear Sie t i MN gt xt f h i i NRW TODA IT T t SAM NW WM WR hc i k THU EASY St 3 TM WT WIRE Y i 1 To raise the front railgear Push and hold the top red override button in while operating the hand pump 2 To lower the front railgear If for some reason it 1s necessary to lower the gear with the emergency pump pull out and hold the top red override button while operating the hand pump Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 15 Revised on 3 25 12 Pull and hold to lower rear to raise rear railgear railgear 3 Toraise the rear railgear Push and hold the bottom red override button in while operating the hand pump 4 To lower the front railgear If for some reason it 1s necessary to lower the gear with the emergency pump pull out and hold the top red override button while operating the hand pump Light Duty A
7. rail gear alignment 9 If the issues are still present after the alignment the vehicle frame and or suspension may have problems Check the rear vehicle wheels looking to make sure the wheels are square to the frame The rear end of the truck may have to be loosened and shifted back into alignment Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 10 Revised on 3 25 12 Lubrication and Maintenance Daily Check both front and rear units for general appearance and damage Check the hydraulic reservoir for fluid level Add oil as required Check for hydraulic oil leaks kinked or damaged hydraulic hoses Repair leaks and replace hoses as required Check that wheels rotate easily Check condition of rail wheels Weekly Check guide wheel equipment alignment See Alignment and Adjustment Section page 7 Check guide wheel flanges for wear or damage Inspect vehicles wheels studs lug nuts and tires for any type of damage or excessive wear Check all bolts for tightness See Torque Requirements page 25 Check grease zerks for damage and replace as necessary Grease all zerks Lubricate moving parts cylinder clevis pins main pivot pins locking pins etc After First 50 Miles of Receiving Vehicle At first 50 miles after installation or any time tires are changed or rotated torque wheel spacer lug nuts and vehicle wheel lug nuts to recommended specifications See Torque Requirements page 25 After Fi
8. HINEER D a e 0 039 C0 DRAW By BUTTER REF Note FWF 9755 Power Unit consist of the following parts Qty Part No Description 2 4499 AC Front Rear Pendant Controller 1 3000457 Interior Pendant Controller 1 8060 CC Reservoir Breather 1 1611 AA Suction Filter 1 4795 AA Solenoid 2 EF 1142 Valve Coils 1 K 40 Seal Kit for Pump Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 21 Revised on 3 25 12 Z J E lt x E VIA ae e A J a A Q e T c en SEE WORK ORDER z as z2 elo LTD oz oy Oe fs O DA EB a Ema cz eO om PTO DRIVEN HYDRAULIC SCHEMATIC 3 8 CHECK VALVE SINGLE SECTION DIRECTIONAL VALVE VDM64HPMOT ARIESLDCHEV ARIES LIGHT DUTY HYRAIL RETURN MANIFOLD RETURN FILTER FSPIO7IEDNN Iug ang UM pan wng Hadi SA 300d Hod eo BASHA dz EA SAHI od mE H ai o Ed 0052 OL Sd ODA DL ANH WA 135 OTe NAN 135 a4 i _l AA m H Part RGEARLIGHT Light Duty Aries Parts and Service Manual doc Created on 7 21 11 22 Revised on 3 25 12 GREASE GUARD OPTION 02836LBF GREASE GUARD SHUNT OPTION 01589CDF SHUNT ASSY S
9. NSORS TO PREVENT POSSIBLE DAMAGE Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 25 Revised on 3 25 12 FASTENER TORQUES GRADE 8 WET Mota Wat is defined as any lubricant or plating present an either fastener or part tn which it is ttached Fraction Decimal Va 20 250 20 10 Va 25 250 2B 10 B16 18 313 18 20 B B 24 413 24 20 AB 16 FS 16 30 AB 24 FS 24 EI NIE 14 A38 14 50 N16 436 20 BO 5 13 4500 13 BO M4 20 500 20 an A185 12 564 12 110 wE 18 5643 18 130 BB 11 25 11 160 BB 18 25 1B 180 4 10 F50 10 280 15 F50 16 310 78 98 B75 9 450 FTjB 14 FS 14 BD 1 8 1 00 8 EBU 1 12 1 00 12 750 1 14 1 00 14 Tao Mote All critical mounting hardware using Grade B fasteners wil ba fightened fo the proper forque specihcatian per the torque sheet wiiess fhe Body Manufacturer or the component supplier states off erwiss Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 26 Revised on 3 25 12
10. PRING LOADED ESAE o JE T MEET OBA ere SE o LA WZai WA Qiao ERRAT UBIPA CLAMP PIPE CUSHIONED Light Duty Aries Parts and Service Manual doc Created on 7 21 11 25 Revised on 3 25 12 02836RBF BOLTING STRIP BRKT 028350BF SHUNT BRKT 01589CDF SHUNT ASBY I r Part RGEARLIGHT SWEEP OPTION 02645VBF RUBBER SWEEP 02836GBF SWEEP MTG BRKT Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 24 Revised on 3 25 12 BOLT TORQUE REQUIREMENTS Guide Wheel lug nut torque 1 2 20 x 1 875 Stud 90 ft Ibs Bearing Flange Bolts 10mm 1 25 x 55mm 41 ft Ibs Wheel Arm Spline Bolt 1 2 20 90 ft Ibs Suspension Body Mounting Bolts 3 8 16 30 ft Ibs Main Frame Mounting Bolts 5 8 11 160 ft Ibs Pivot Pin Retaining Bolts 5 16 18 20 ft Ibs CHEVROLET WHEEL SPACERS Wheel spacer lug nuts Chevrolet Inner 14mm studs 140 ft Ibs Vehicle wheel lug nuts Chevrolet Outer 14mm studs 140 ft Ibs FORD WHEEL SPACERS Wheel spacer lug nuts Ford Inner 14mm studs 165 ft Ibs Vehicle wheel lug nuts Ford Outer 20mm studs 300 ft Ibs WARNING e NEVER USE ANTI SEEZE ON LUG NUTS OR WHEEL STUDS e NEVER USE IMPACT WRENCH TO TIGHTEN LUG NUTS ALWAYS HAND TIGHTEN AND CHECK WITH TORQUE WRENCH e LOOSE LUG NUTS CAN LEAD TO METAL FATIQUE AND ULTIMATELY TO FAILURE OR BROKEN STUDS e INFORM TIRE SHOP THAT THIS VEHICLE MAY BE EQUIPPED WITH TPMS SE
11. is best checked on rail simulated or actual it can be checked on flat concrete surface but if done this way it will require an additional 1 00 under the vehicle tires to account for the guide wheel flanges Setting the rail pressure is done by pre loading the suspension by placing the truck on shims and setting the guide wheels to contact the track the pre load is set The empty vehicle with driver is set for 74 of pre load This amount of pre load corresponds to the required minimum load of 350 Ibs To check for proper minimum rail pressure e Make sure the truck is in the lightest condition that it will be used on rail This is best done with a person in the driver s seat e Place the vehicle on rail with the vehicle s tires on 74 shims e Verify that the guide wheels are in contact with the rail The contact should be light using both hands you should be able turn the wheel against the rail if you can t you may have the pressure too high e Ifthe guide wheels are not in contact your rail pressure is too low Measure the gap between the rail wheel and the rail If the rail pressure is too high e Shim the truck up another 2 e Ifthe guide wheels are still in contact with the rail you can adjust the angle of the suspension arms upward by one 6 degree spline See the adjustments section for details You can continue to add shims to determine how many 6 degree adjustments to make Light Duty Aries Parts and Service Manua
12. l doc Part RGEARLIGHT Created on 7 21 11 T Revised on 3 25 12 If the rail pressure is too low e Ifthe gap is greater than 2 you should adjust the suspension arm downward by one 6 degree spline per 1 2 you should round up to insure adequate pressure g p p y p q p If the rail pressure is different from right to left e Sometimes the pressures are not even from right to left make sure the load in the vehicle is not the cause before adjusting the rail gear e Spacers under the suspension can be used to address problems with asymmetrical rail pressure e Moving the mounting channel can also address this condition e Ifthe difference is in the order of 2 you can use the suspension arm adjustments to correct this Setting Pressure by scale or bottle jack Rail gear pressure may also be set by the use of a jack with a pressure gauge the rail wheel load of each wheel is Rail Wheel Minimum Rail Load each Max Rail Load each Front Rail gear 450 Ibs 700 Ibs Rear Rail gear 350 Ibs 700 Ibs Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 8 Revised on 3 25 12 5 5H IT 1 1 S IH3HHEITZ2 JI VA4LH vu AH LL3423H4J 211487 ALI IHBI Lv Ag C34B 17 Bsp ull mai iq rap T HEHLI T H TOS ISDnH H JAT T HEHLIM T 9 759 LANN 9 4aI PMIHIIA FH 1903 LSTH 1 59 31 E NIHLIA H TWAA LSN 9 yi aT l HIHLI 4 Tea L 4 ee 3 2771 MIHLIA 3 iK LSH 3 E
13. ries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 16 Revised on 3 25 12 PARTS HYRAIL PILOT UNIT FRONT REAR Light Duty Aries Parts and Service Manual doc Created on 7 21 11 17 Revised on 3 25 12 Part RGEARLIGHT CHEVROLET APPLICATION Complete set Front Rear 2 D5000598 CYLINDER 3 00 BORE 5 75 STROKE 2 3 02811PBF_ LOCKINGASSEMBLY 2 4 02835PBR WHEELARMASSEMBLY 4 WHEEL 10 00 STEEL 4 6 02499CBF HUBASSEMBLY 4 BRB IND Nh 1 O0281CBF FIXED FRAME 2011 FRONT ARIESLD 1 8 02811QBF DERAIL SKID BOLT ON ARIES LIGHT DUTY 4 9 02835IBE INSULATOR SEALED BEARING BOLT 16 10 02835 BF INSULATOR SEALED BEARING SHAFT 4 11 02835KBF INSULATOR SEALED BEARING FLANGE 8 Big mA FORD APPLICATION Complete set Front Rear 2 CYLINDER 3 00 BORE 5 75 STROKE 8 O2499CBF HUBASSEMBY 4 028110BF DERAILSKID BOLT ON ARIES LIGHT DUTY 4 9 02835BF INSULATOR SEALED BEARING BOLT 16 11 02835KBF INSULATOR SEALED BEARING FLANGE 8 Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 18 Revised on 3 25 12 02399CDF HUB ASSEMBLY MOTE TIGHTEN ITEMS 2 AMD B WITH IMPACT GUN ONCE FULL CONTACTIS MADE ALLOW IMPACT GUN TO IMPACT AND ADDITIONAL 2 3 TIMES V ay 6 HUB132 MOUNTED NTNBEARING 1
14. road s work rules and environmental conditions Not to exceed 45MPH Recommended speed through a crossing is determined by your work rules Not to exceed 5MPH Be aware that flange ways can fill with dirt and gravel and cause the rail wheel flange to move on top of the rail Traveling through spring rail frogs spring switch or self guarded frogs require you to STOP before moving through If possible someone should remain on the ground to guard against derailment and direct the track car operator through the spring side of the frog Recommended speed in reverse is 10 MPH Max Be aware of engine temperature while in reverse overheating may result from decreased airflow through the radiator Do not exceed the speed limits imposed by the railroad for your type of vehicle Remember that the recommended maximum speed is for first class track in good condition Actual track conditions will determine the safe operating speed which in many cases will be lower than the maximum speed Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 4 Revised on 3 25 12 Placement of Vehicle on Rail 1 Find a suitable road crossing to position the vehicle on rail If necessary set up cautionary devices to ensure safety 2 Position the vehicle with the road wheel tires on the rails and the rail wheel flanges positioned centrally above the railhead Backing into position is usually easier 3 Put the vehicle s tran
15. rst 50 Track Miles Torque Guide Wheel Lug Nuts to Recommended specifications See Torque Requirements page 25 Annually Perform annual inspections as required 12 Months or 9000 On track Miles Drain and refill hydraulic fluid Recommended Hydraulic Oil ATF Dexron III Recommended Pump Pressure Setting Pre set at 2500 PSI Replacement Tires and Wheels Use only Auto Truck approved replacement rims to ensure proper fit and function For wheel torque recommendations See Torque Requirements page 25 Use only Goodyear 245 70R19 5 tires inflate to 95 PSI Chevrolet Use only Goodyear 225 70R19 5 tires inflate to 95 PSI Ford Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 11 Revised on 3 25 12 Troubleshooting Possible Cause Hydraulic cylinder movement slow or uneven Oil viscosity too high Low oil level Slow engine speed if pump is driven from vehicle gearbox PTO PTO not engaged Oil flow restricted to pump Noisy pump oil foaming erratic cylinder movement Air leak on inlet side of pump Worn pump Incorrect oil viscosity Oil restricted to pump Low oil level Overheating Incorrect oil viscosity Worn pump Restriction in hydraulic line Incorrect pressure relief valve setting Rail guide wheels flanging to one side Rail guide wheels out of alignment Vehicle brakes partially applied Damaged pivot arm or rail wheel axle Vehicle leaning to one side Load not balanced overloaded to one side s
16. smission in park or neutral Set the parking brake 4 Turn on the Equipment Power switch to energize the pump 5 Lower the rear rail gear into position on the rail 6 Check the alignment of the front rail wheels with the track it might be necessary to adjust the position of the vehicle 7 Once the front 1s positioned centrally over the railhead lower the front gear 8 Check to make sure all four rail wheels are positioned on the rail properly before moving 9 Engage the steering lock 10 Drive the vehicle forward and backward a few yards to check vehicle s operation and brakes 11 Vehicle is now ready for rail travel Removal of Vehicle from Rail 1 Find a suitable road crossing to remove the vehicle from the rail 2 Put the vehicle s transmission in park or neutral Set the parking brake 3 Raise the front gear first 4 Raise the rail gear into the road position Note the unit has an automatic mechanical lock pin on Front and Rear units in the Raised position only 5 Raise the rear rail gear 6 Turn off the Equipment Power switch 7 Disengage the steering lock 8 The vehicle is now ready to be driven on the road Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 5 Revised on 3 25 12 LOCK PIN LOCATIONS 02811PBF LOCKING ASSEMBLY RAILGEAR Front Gear Automatic Locking pins Note Could be located on either side of channel dep AA Ha Bm
17. uspension body damaged Vehicle suspension damaged Insufficient rail gear ground clearance when in the Overloaded vehicle road position Vehicle derails Rail gear out of alignment Vehicle speed 1s excessive Track gauge incorrect Vehicle out of alignment Rail wheels worn or damaged Tire air pressure incorrect Rail gear doesn t lower or raise Vehicle overloaded Hydraulic cylinder rod bent Insufficient lubrication on pivot pin Incorrect pressure relief valve setting Low oil level Light Duty Aries Parts and Service Manual doc Part RGEARLIGHT Created on 7 21 11 12 Revised on 3 25 12 SHUNT WIRING DIAGRAM OPTIONAL SEN RELAT SWITCH DUX CD 0 BLACK WHITE CAB MOUNTED T 0 10 CA WA 10 GA P Ea _ amp MAOO TAN 4 O o x a DOO oa 10 GA OG BLACK YELLOW 10GA Shunt test Connect meter between terminals 5 and 11 1 Ignition key is off and shunt rocker switch is off truck should be shunting with less than 3 ohms resistance 2 Ignition key is on and shunt rocker switch 1s on truck should be shunting with less than 3 ohms resistance 3 Ignition key is on and shunt rocker switch is off truck 1s not shunting and the ohmmeter should read an open circuit or infinity Please refer to the electrical diagram that came with the vehicle for further information
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