ARIES

FORD F450-F550
PARTS AND SERVICE MANUAL

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 Contact Information
For parts and service please contact:

Auto Truck
1200 N. Ellis St.
Bensenville, IL 60106

Phone: 630-860-5600
Toll free: 1-877-284-4440
Fax: 630-860-5631
e-mail: [email protected]
web address: www.autotruck.com

Please have the following information at hand before calling:

Vehicle make
Model
Year
Unit number

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 Table of Contents

Operation 4

Alignment and Adjustment 7

Lubrication and Maintenance 10

Troubleshooting 11

Brake System Schematic 12

Shunt System Schematic 13

Parts Diagrams 14

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 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 speed on rail is 25 MPH.
• Recommended speed through a crossing is 5 MPH.
o 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.
o 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.
• Ensure that all necessary vehicle warning lights, strobe lights, flags and other required safety items are
working and in place before operating on track.
• When on rail do not operate cranes, aerial baskets, grab booms or other similar equipment unless their
stabilizer legs are properly engaged with the ground. Severe damage to the rail gear or the vehicle frame
will result.
• Do not steer on track - steering lock must be engaged.
• Sound horn when approaching road crossings.
• Watch for individuals on or around the track.
• Check your tire pressure - improperly inflated tires will seriously affect the load carrying capacity and
directional control of the vehicle.
• Watch for debris on the track. Even small obstructions could cause a derailment.
• Watch for overhead wires above or alongside the track.
• Watch for obstructions alongside the track. If in doubt do not proceed until you have checked
clearances on your vehicle.

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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 transmission into park or neutral. Set the parking brake.
4. Engage the PTO hydraulic pump or start the auxiliary hydraulic power source.
5. The rear will be placed on rail first.
a. Raise the rail gear up a bit to relieve the pressure on the lock hook.
b. Pull the T-handle for the lock to swing the hook out of the way.
c. Lower the rail gear into position on the rail.
d. Release the T-handle for the lock.
6. Check the alignment of the front rail wheels with the track - it might be necessary to adjust the position
of the vehicle.
7. The front rail gear will now be lowered.
a. Raise the rail gear up a bit to relieve the pressure on the pin lock.
b. Remove the both pins from the upper holes.
c. Lower the rail gear.
d. Install the lock pins in the lower holes.
8. Engage the steering lock.
9. Drive the vehicle forward and backward a few yards to check vehicle’s operation and brakes.
10. 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 into park or neutral. Set the parking brake.
3. Engage the PTO hydraulic pump or start the auxiliary hydraulic power source.
4. The front will be raised first.
a. Bump the rail gear down a bit to relieve the pressure on the lock pins.
b. Remove both pins from the lower holes.
c. Raise the rail gear into the road position.
d. Insert the lock pins into the upper locking holes.
5. The rear will now be raised.
a. Raise the rail gear
b. The hook lock will automatically swing out of the way of the raising rail gear and swing into
locking position.
6. Disengage the PTO hydraulic pump or auxiliary hydraulic power source.
7. Disengage the steering lock.
8. The vehicle is now ready to be driven on the road.

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 LOCK PIN LOCATIONS

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 Alignment and Adjustment
The alignment needs to be performed on a clean level solid surface. Position the vehicle on either 2x4s or a
piece of steel channel so that all road wheels are approximately 1.5” higher than the surrounding floor level.
Make sure that the 2x4s are long enough to support both the rail wheels and truck tires.

1. Set tire pressures to the maximum pressure as listed on the sidewall.

2. Set the position of the rear swing frame.
a. Loosen the stop bolt.
b. Fully extend the cylinder.
c. Adjust the swing frame stop bolts so they contact the swing frame plus ½ turn.
d. Tighten the lock nuts.
3. Suspension arms.
a. Suspension arms should be set to a horizontal position of 20° ±5°.
b. In the fully lowered position the arms should raise the truck frame by 1.5” maximum (measured
at a point no more than 12” from the rail wheel.
4. Adjust track gauge
a. Must be done before alignment.
b. Track gauge is adjusted by adjusting the position and/or number of washers on the stub axle.
c. Gauge is measured from the inside of the rail wheels. For both front and rear wheels 53” Min /
53.5”Max.
5. Using two (2) two standard railroad ties or equivalent, transverse to the vehicle, run a string line down
each side of the vehicle. String line should be positioned 6” from the rear wheel rim.
6. Measure the dimensions below, referring to the diagram on the following page. Make adjustments as
needed to bring the rail gear into spec. Use the adjustment slots on the suspension frame and spacer
washers on the rail wheels to bring the gear into alignment.
7. Tighten and torque the fasteners that were loosened during the alignment process.

Dimension Max difference Comment

Measurement
A1 vs A2 1/16” Truck frame or spring hanger to string line
B1 vs B2 1/16” Rear wheel hub to string line
C1 vs C2 1/16” to 1/8” toe-in Use 2’ straight edge across wheel to take
measurement
D1 vs D2 1/16” to 1/8” toe-in Use 2’ straight edge across wheel to take
measurement
E1 vs E2 1/16” zero toe desired Use 2’ straight edge across wheel to take
measurement
F1 vs F2 1/16” zero toe desired Use 2’ straight edge across wheel to take
measurement
G1 vs G2 ¼” Center of rail wheel to string line
H1 vs H2 ¼” Center of rail wheel to string line

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 Rail Testing the Vehicle after Alignment

1. The vehicle must be tested on straight level 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. The paint should be worn evenly across all the wheels on a properly aligned
vehicle.
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 C1 a bit greater than C2 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 D1 a
bit greater than D2 referring to the alignment diagram. Loosen the suspension body to make this
adjustment.
7. Repeat beginning at step #2.
8. If there are still alignment issues repeat the 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 truck frame.
The rear end of the truck may have to be loosened and shifted back into alignment.

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 Lubrication and Maintenance
Daily
Check the rail gear for general appearance and damage.
Check the hydraulic 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 grease zerks for damage and replace as necessary.
Grease all zerks.
Lubricate moving parts, cylinder clevis pins, main pivot pins, locking pins etc.

Monthly
Check rail wheel lug nut torque.

12 Months or 9000 On-track Miles

Clean and repack rail wheel bearings.
Drain and refill hydraulic fluid.

Recommended Hydraulic Oils

Mobil AW32 or equivalent

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 Troubleshooting
Condition 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 or rail unit brakes partially applied
Damaged pivot arm or rail wheel axle
Vehicle leaning to one side Load not balanced, overloaded to one side
Suspension body damaged
Vehicle suspension damaged.
Insufficient rail gear ground clearance when in the Locks not properly engaged.
road position Overloaded vehicle
Vehicle derails Rail gear out of alignment
Vehicle speed is excessive
Track gauge incorrect
Vehicle out of alignment
Rail wheels worn or damaged
Tire air pressure incorrect
Rail gear doesn’t lower or raise Lock pins or hook engaged
Vehicle overloaded
Hydraulic cylinder rod bent
Insufficient lubrication on pivot pin
Incorrect pressure relief valve setting
Low oil level

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 HYDRAULIC BRAKE WIRING DIAGRAM

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 SHUNT WIRING DIAGRAM (OPTIONAL)

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 Parts Diagrams

TYPICAL WHEEL ASSEMBLY

ITEM PART NUMBER DESCRIPTION QTY
1 95153 NUT; SPINDLE 8
2 800262 COTTER PIN 8
3 95111-1 AXLE SPACER; 1/8” THICK; CHAMFER 4
4 95111-2 AXLE SPACER; 1/8” THICK; NO CHAMFER 8
4a 95111-3 AXLE SPACER; 3/16” THICK; NO CHAMFER 8
5 94077-6 STUB AXLE 4
6 19664 SEAL; DOUBLE LIP 4
7 95137 BEARING ROLLER TAPERED 8
8 M10X25 SCREW CAP; M10 X 25mm
8a WLM10M21 LOCK WASHER; M10
9 1255 ROTOR; DISC; FOR 10” WHEEL 4
10 610281 STUD; WHEEL; 24
11 94095 HUB
12 94235 WHEEL; RAIL; 10”; 6-HOLE 4
14 611051 NUT; WHEEL 24
15 95136 WASHER; SPINDLE 8
16 0012417 CALIPER; BRAKE; PASSENGER SIDE 2
16a 0012418 CALIPER BRAKE; DRIVER SIDE 2
16b 9812419 BRAKE PAD KIT
17 95123 HUBCAP 4
17a 95123G GASKET HUBCAP 4
01975ABF caliper mounting bracket 2
h43504-2 brake hose 2
M6X12 HUB CAP BOLT 4

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 Front and Side View of Front Attachment

ITEM PART NUMBER DESCRIPTION QTY

20 02032FBF SWING FRAME
21 FS21NSA SUSPENSION BODY 4
22 94232 WHEEL; RAIL; 10”; 6-HOLE 4
98320a765 LOCK PIN; FRONT 2
VDM64HPCYL HYDRAULIC CONTROL VALVE; FRONT ONLY 1
VDM64HPMOT HYDRAULIC CONTROL VALVE; REAR ONLY 1

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 Side View of Rear Attachment

Rear View of Rear Attachment

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ITEM PART NUMBER DESCRIPTION QTY
30
31 02089DBF SWING FRAME 1
32 02089BBF PIVOT BRACKET (SPECIFY DRIVER OR PASSENGER) 2
33 02089CBF REAR CYLINDER MOUNTING BRACKET 1
34 02018MBF PIN; PIVOT 2
35 02089PBF REINFORCEMENT LINK 2
36 02155EBF LOCK ASSEMBLY 1
37 FS21NSA SUSPENSION BODY 2
38 FS100-04329-0048 T HANDLE LOCK CABLE 48” LONG 1
39 BMC2007CB90-SPL HYDRAULIC CYLINDER 2
40 02104BBF PIN; LOCK 2

Shunt (Optional)

ITEM PART NUMBER DESCRIPTION QTY

1 WR1/2X8 SHUNT WIRE CABLE SOLD EACH 16PCS
2 182501-11 PAIR OF WIRE BLOCKS; ONE THREADED ONE NOT 2
3 182501-10 PLASTIC INSULATOR BLOCK 16
4 02183DBF CURB SIDE SHUNT BRACKET 1
5 02183CBF STREET SIDE SHUNT BRACKET 1

Shunt Bracket

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 CUP BRUSH STYLE SHUNT

5 01589CDF CUP BRUSH SHUNT 1

6 UB1PA CLAMP AND INSULATOR 2
7 3ACO8 CUP BRUSH 1
NOTE: QTYS LISTED ABOVE ARE PER SHUNT.

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 FASTENER TORQUES – GRADE 8 “WET”
Note: Wet is defined as any lubricant or plating present on either fastener or part to which it is
attached.

Fastener Size Torque (ft-lbs.)

Fraction Decimal
¼ - 20 ______________ .250 - 20 ______________________________ 10
¼ - 28 ______________ .250 - 28 ______________________________ 10
5/16 - 18 ____________ .313 - 18 ______________________________ 20
5/16 - 24 ____________ .313 - 24 ______________________________ 20
3/8 - 16 _____________ .375 - 16 ______________________________ 30
3/8 - 24 _____________ .375 - 24 ______________________________ 30
7/16 - 14 ____________ .438 - 14 ______________________________ 50
7/16 - 20 ____________ .438 - 20 ______________________________ 60
½ - 13 ______________ .500 - 13 ______________________________ 80
½ - 20 ______________ .500 - 20 ______________________________ 90
9/16 - 12 ____________ .563 - 12 ______________________________ 110
9/16 - 18 ____________ .563 - 18 ______________________________ 130
5/8 - 11 _____________ .625 - 11 ______________________________ 160
5/8 - 18 _____________ .625 - 18 ______________________________ 180
¾ - 10 ______________ .750 - 10 ______________________________ 280
¾ - 16 ______________ .750 - 16 ______________________________ 310
7/8 - 9 ______________ .875 - 9 _______________________________ 450
7/8 - 14 _____________ .875 - 14 ______________________________ 500
1 – 8 _______________ 1.00 – 8 _______________________________ 680
1 – 12 ______________ 1.00 – 12 ______________________________ 750
1 – 14 ______________ 1.00 – 14 ______________________________ 760

Note:
All critical mounting hardware using Grade 8 fasteners will be tightened to the proper torque
specification as per the torque sheet unless the Body Manufacturer or the component supplier
states otherwise.

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