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Krystal Enterprises Bus Owners Manual

1. LEFT TURN LIGHT GREEN YELLOW ROUTE ALONG FLOOR LICENSE PLATE LIGHT LEFT TAIL LIGHT POWER STEP ON DRIVER SIDE BROWN BROWN LOOP PURPLE WHITE WHITE LOOP REAR DOOR AJAR YELLOW E BLACK YELLOW RUNNING LIGHT SBEEN Loop INTERIOR LIGHTS BROWN LOOP RUNNING LIGHT 5 DASH CONNECTION YELLOW BROWN 2 BROWN BACK UP ALA WHITE BLUE 2 WHITE BLACK RED LOOP GREEN YELLOW RUNNING LIGHT SIDE MARKER LIGHT CREEN 214 SPEAKER 4 prn E BROWN LOO as oe D BLACK WHITE FRONT A C LEFT REAR SPEAKER ORANGE PINK La GROUND BLUE WHITE BLACK 8 WHITE YELLOW _ FACTORY TRAILER PLUG e 3RD BRAK ee WHITE MS 2 FACTORY PLUG REAR A C E RED YELLOW 2 2 GREEN BLACK PURPLE e BLACK WHITE 2 BLUE 2 i WHITE BLAC WHITE RIGHT TAIL LIGHT PINK GREEN x E E il CREEN BLACK or NSER FANS OE GREEN WHITE b HITE RUNNING LIGHT PCM LUGGAGE COMPARTMENT LIGHT BLACK RED 257 BROWN LOOP BLACK YELLOW BROWN ORANGE WHITE LOOP San RED E STEPWELL LIGHT al STEP SWITCH WHITE LOOP N BROWN WHITE BLUE WHITE LOOP BLACK YELLOW S RUNNING LIGHTS BROWN LOOP 1 4 Y WHITE LOOP WHITE LOOP E R
2. Krystal Enterprises RETURN ENU 108 Air and Electrical Diagrams amp Schematics 4 SECOND TIMER 10 SECOND TIMER SENSITIVE EDGE HOSE 6 2 4 6 J 4 mE WHITE SENSOR SWITCHES 10AMP FUSE 1 85 E RANGE RED YELLOW 12v BATTERY POWER RED ORANGE FROM DOOR SWITCH RED AIR CYLINDER BROWN PANCE o cor AIR smu PROX SWITCH 5 PINK M 7 m ORANGE BLUE BLACK 2 680 A co B E BLUE a m TRANSISTOR AJ Ei ES AIR CYLINDER E WHITE E col AIR HOSE 4 LARGE Electrical Schematic for Doors with Sensitive Edge ref pg 57 Krystal Enterprises 109 Air and Electrical Diagrams amp Schematics
3. o 0 M GC 1 bun Low Blower Not Used mReda High Blower Green kKelay Irigger Not Used ae Ole Ge 2 7 Orange Condensor NO ew GL AIO REF FUSES Detail of A C Module wiring as shown in photos on pg 104 Krystal Enterprises 105 E 450 amp F 550 RELAY BUSS VER D HEATER FAN LOW HIGH IDLE SPARE REAR CONDENSER HEATER FAN HIGH 12 OfYld OL 9 GQNNOWDS LHM V9 9L S3 1nGOlIN ON OL 9 9 V9 9 GQNNOUDS LHM V9 9L HOLIMS 3GQONN 2 9 OL X 18 9HO VO 8l N 9fYld NIVW OL 518 2HO V9 9 3Sf14 NOILINOI OL 1 18 9HO VO 9 395078 35154 NOILINOI 9 TANVd HOLIMS OL Q3H TI3A 84 OL Q3H TI3A VO tl 3Sf1d NOILINO9I OL Q3H TI3A V9 VL 39078 35154 NOILINOI 94 TANVd HOLIMS OL 18 038 V9 81 1 OL 18 d3y V9 9 3Sf1d NOILINS OL 118 03 V9 tl 39078 35154 NOILINOI Gay 9 Krystal Enterprises RETURN TO MENU 106 F 550 Shuttle Bus Wiring Diagram 12 AWG WHITE 12 AWG ORANGE 12 AWG YELLOW 16 AWG YEL
4. RRVSIAL ENTERPRISES ER Congratulations and thank you for purchasing a Krystal Enterprises Vehicle You have taken ownership of a true luxury vehicle which is in a class all its own We are providing this manual to familiarize you with your new Krystal Enterprises Professional Bus This manual shall serve as a reference document for the operations and maintenance procedures that shall be required throughout the life of your vehicle This edition covers all our Ford Chassis models and is designed to be used in conjunction with the original chassis manufacturer s owner s literature as well as all other component manufacturers literature IMPORTANT PLEASE READ CAREFULLY For your safety and the safety of others we ask that you completely familiarize yourself with this manual and all other operators manuals before you operate this vehicle for the first time KRYSTAL ENTERPRISES 2701 East Imperial Highway Brea California 9282 800 KRYSTAL 579 7825 714 986 1200 TABLE OF CONTENTS SAFETY Pre Trip Inspection suggested minimum 8 General Vehicle Safety Warnings 10 Vapor Door Operational Safety Check List 11 Air Door Emergency Release Valve 12 Electric Door Emergency Release Lever 13 Wheelchair Securement and Occupant Restraint Systems 14 Air Door Lock Pin Assembly 16 Dual Overhead Parcel Rack 17 Emergency Egress Window Operation 18 Emergency Roof Hatch Ext 19 OPERATION Overhead Control Pane
5. CLOSE RELAY ERHEAD SWITCH L REL 1 6 H He E BN o RED m PILLER SWITCH E 450 Electrical Schematic for Swing Doors System ref pg 51 Krystal Enterprises 110 Air and Electrical Diagrams amp Schematics INTERIOR LIGHTS n DE Water DOOR OPEN RELAY DOOR CLOSED RELAY EM m Bes TN ME P gt gt O0 EXP 15 CLOSED FUSE HOLDER 12 VDC BATTERY F 550 Electrical Schematic for Swing Door System ref pg 51 Krystal Enterprises 111 PARTS SERVICE WARRANTY OBTAINING PARTS When parts are required for a warranty repair all parts will be handled by the KRYSTAL service Department All other Non Warranty parts needs can be handled by contacting the KRYSTAL PARTS DEPARTMENT directly at 1 800 845 4883 You may purchase parts directly over the counter or have them shipped to you usually within 24 hours In order to expedite your parts order please have your KRYSTAL ENTERPRISES serial number which starts with and is located on the drivers door jamb of all our vehicles UNDERSTANDING WARRANTY POLICY read the following sections carefully Should your bus require service
6. clean air compressor intake filter clean battery terminals lube door seals with silicon spray check for proper sealing gt re inspect torque settings on Ridewell Suspension System check air system for leaks and electrical connections lube Vapor door rotary drive mechanism check the torque of all door hardware on Vapor door systems gt inspect drive belts and replace if necessary AT 35 000 MILES 4200 HOURS DO THE FOLLOWING change engine oil and replace oil filter gt inspect tires for wear and inspect tread depth rotate tires Krystal Enterprises RETURN TO MENU 75 PREVENTIVE MAINTENANCE SCHEDULE AT 40 000 MILES 4800 HOURS DO THE FOLLOWING change engine oil and replace oil filter gt inspect tires for wear and inspect tread depth rotate tires inspect engine air filter clean battery terminals check the torque of all door hardware on Vapor door systems AT 45 000 MILES 5400 HOURS DO THE FOLLOWING change engine oil and replace oil filter gt inspect tires for wear and inspect tread depth gt rotate tires inspect engine air filter replace engine and frame mounted fuel filters gt inspect steering linkage suspension ball joints driveshafts and driveshaft guards gt inspect engine cooling system and hoses gt inspect brake system gt inspect exhaust system and heat shields gt inspect engine air filter check the torque of all door hardware on
7. Check your FORD Owner s Guide Supplement for special operating condition mainte nance requirements that may be applicable due to your specific vehicle operating profile Krystal Enterprises i User Notes Preventive Maintenance Additional User Notes Additional User Notes Krystal Enterprises 85 Basic Troubleshooting Guide The following section details basic troubleshooting techniques that will help you to understand and determine the best course of action regarding some commonly encountered problems PROBLEM POSSIBLE SOLUTIONS VIBRATION Noises or Vibration Acertain range of speeds indicates a damaged or otherwise out of at high speeds only or in a certain balance drive line Contact the Service Dept Only SELECT drive line range of speeds shops that are qualified to properly balance the multiple drive line ex tensions used in your bus The Krystal Service Dept can recommend one near you REAR A C BLOWER INOPERATIVE Check to make sure the FORD front A C unit is on If the rear A C is still not working call the Krystal Service Dept MOVING CARGO PARTITION TO Remove seats in front of the Partition Wall and loosen all four bolts ADD ADDITIONAL SEATING securing the wall Then go behind the wall and remove the channel nut Caution Do Not Exceed Weight on the floor this will allow the wall to be move back and then additional Distribution Payload Limitations seating can be installed Note torque Seat Bolts
8. Krystal Enterprises Vp Air Conditioning Charging Chart MODEL BY BTU S VENTING FREON CHARGE E40 Bus 1999 with ACC A C 68 000 BTU 4 vents 5 50 Ibs 40 000 BTU w FACTORY TIE IN w factory tie in 11 0 Ibs F550 Bus 2000 with ACC skirt condenser 68 000 BTU 4 vents 5 50 Ibs 86 000 BTU 6 00 Ibs 40 000 BTU w FACTORY TIE IN w factory tie in 11 50 Ibs F550 ALL with ACC front condenser 68 00 BTU 4 vents 4 25 lbs 40 000 BTU w FACTORY TIE IN w factory tie in 11 50 Ibs E450 2000 with Carrier 68 000 BTU 5 00 Ibs 40 000 BTU w FACTORY TIE IN w factory tie in 5 50 Ibs Roof Top Carrier A C 7 0 Ibs per compressor E450 w ACC 2004 2005 Models 68 000 BTU 5 25 5 40 000 BTU w FACTORY TIE IN 10 0 Ibs NOTE These figures may vary depending on atmospheric conditions Krystal Enterprises 68 Vehicle Manufacturers Identification Label E 450 MANUFACTURED BY KRYSTAL ENTERPRISES INC FORD MOTOR CO DATE OF DATE INC VEH MANUFACTURED VIN THIS VEHICLE CONFORMS TO APPLICABLE FEDERAL MOTOR VEHICLE SAFETY LT225 75RX16E TIRES STANDARDS IN EFFECT ON TH 16X6 0 552 6 MANUFACTURE GAWR REAR 9450 42060 RCRUM LT225 RX16E LEES ZU 80 GS KPa COLO VEHICLE BUS 550 MANUFACTURED BY INCOMPLETE VEHICLE MANUFACTURED BY KRYSTAL ENTERPRISES INC FORD MOTOR CO DATE OF DATE INC VEH MANUFACTURED MANUFACTURE
9. 12V OUT To Ground 25 HIC900 Throttle Controller Wiring Diagram GASOLINE User Interface To 12V Ford Gasoline Engine fused ignition Hot in Run DIESEL RPM N C PTO ii Ignition Fused Cj 12V O7 12V Set ETT T Orange Lt Blue Orange Yellow Gasoline Engine SEIC Wires GND f Ground 10K 10Turn Potentiometer PTO GND Ground PTO PTORPM PTO Indicator EPIO Select PTO Mode Vehicle SEIC Wiring Krystal Enterprises ED RETURN TO MENU Charge Protection System Components E 450 Charge System Fuse located behind panel amp Rear Ignition Power Fuse shown with kick panel removed E 450 Charge Isolator Solenoid located in engine compartment drivers side diesel version shown Gas version is located below primary battery Krystal Enterprises RETURN TO MENU F 550 Charge System and Rear Power Fuse located behind panel under steering column F 550 Charge Isolator Solenoid located in engine compartment drivers side 27 Battery Location Primary and Secondary gt E d ds es Safe Bi sa 2 j NEP on rw 2 pume i F 550 Primary Battery Location F 550 Diesel Engine Compartment F 550 Primary Battery Location E 450
10. 3 IGNITION CIRCUIT RELAY 4 FLOOR HEATER LOW SPEED RELAY OPTIONAL p 8 FLOOR HEATER HIGH SPEED RELAY OPTIONAL 6 INTERIOR LIGHT RELAY 1 2 7 INTERIOR LIGHT RELAY 2 ENTRY DOOR OPEN RELAY 3 9 igo O 8 EXTERIOR LIGHT RELAY CLEARANCE E gt 9 TRANSMISSION INTERLOCK RELAY 1 2 _ TRANSMISSION INTERLOCK RELAY 2 5 10 23 24 25 26 2 50 AMP FLOOR HEATER RELAY POWER OPTIONAL 3 40 AMP AIR DOOR COMPRESSOR amp SOLENOID IRD Hl 2 20 FOR IGNITION CIRCUIT BREAKER mm 12 5 40 AMP INTERIOR LIGHT CIRCUIT BREAKER t 6 20 AMP ENTRY DOOR SOLENOID amp STEP LIGHT Front A C Board 2 20 AMP REAR STEP CIRCUIT BREAKER 20 AMP EXTERIOR LIGHT BREAKER CLEARANCE LIGHTS Minute s 5 15 AMP LUGGAGE LIGHT CIRCUIT BREAKER uu LightTimer 15AMP SPARE OR PA SYSTEM OPTION 7 20 READING LIGHT CIRCUIT BREAKER as 2x 23 EJ 15 AMP FLOOR HEATER VALVE OR HEAT PUMP 20 35 z 75 G3 FRONT A C LOW SPEED RELAY X 20 AMP FUSE FRONT A C HIGH SPEED RELAY 35 FUSE Ow Or FRONT A C CONDENSOR RELAY 35 AMP FUSE HE Ue SU 21 22 BE ol S GO FRONT A C COMPRESSOR RELAY 7 5 FUSE _ E ELO REAR A C LOW SPEED RELAY 20 FUSE 222 5 6 6 6 6 REAR A C HIGH SPEED RELAY X 35 FUSE mE REAR CONDENSOR RELAY 3
11. AT 10 000 MILES 1200 HOURS DO THE FOLLOWING change engine oil and replace oil filter gt inspect tires for wear and inspect tread depth rotate tires gt inspect engine air filter clean battery terminals check the torque of all door hardware on Vapor door systems AT 15 000 MILES 1800 HOURS DO THE FOLLOWING change engine oil and replace oil filter gt inspect tires for wear and inspect tread depth rotate tires AT 5 000 MILES 600 HOURS DO THE FOLLOWING Krystal Enterprises fe PREVENTIVE MAINTENANCE SCHEDULE gt inspect engine air filter replace engine and frame mounted fuel filters gt inspect steering linkage suspension ball joints driveshafts and driveshaft guards inspect engine cooling system and hoses gt inspect brake system inspect exhaust system and heat shields gt inspect automatic transmission fluid and external filter element check wheels for end play and noise gt inspect and lubricate 4 x 2 ball joints E 450 only inspect and lubricate steering idler arms replace cabin air filter if equipped gt inspect half shaft boots if equipped gt re inspect torque settings on Ridewell Suspension System clean air compressor intake filter lube door seals with silicon spray check for proper sealing check air system for leaks and electrical connections lube Vapor door rotary drive mechanism check the torque of all door hardware on Vapor door sys
12. Do Not Exceed Weight Distribution Payload Limitations Krystal Enterprises 36 Stainless Steel Wheel Liners INSTALLATION REMOVAL INSTRUCTIONS CAUTION Wheel liners should only be removed using the Wheel Liner Tool provided with your vehicle Damage could occur if the supplied tool is not used Jam Nut Cover Pop Out Center Hub Center Wheel Liner Tool Emblem NOTE When removing or installing never remove the original equipment lug nuts 1 TO REMOVE simply place the Wheel Liner Tool over the Jam Nut Covers 2 Remove Jam Nut Covers from each wheel and remove Liners Jam Nut Cover Assy 1 TO INSTALL determine the correct placement of liners for proper hand hole Hub Center V alignment Emblem 2 Install Liner over studs then install Jam Nut Covers w built in jam nuts onto the studs Using the Wheel Liner Tool tighten all Jam Nuts X SEE MANUFACTURERS LITERATURE FOR ADDITIONAL INFORMATION Rear Wheel Liner Installation Tool Krystal Enterprises RETURN TO MENU Air Conditioning Assembly E 450 amp F 550 1 O ACC Front Air Conditioning Optional ACC Rear Air Conditioning These units also provide heat when A C This unit only operates when the dash is turned on is not required by toggling switch on the AIC only No Heat overhead control panel These units are operated by the driver using the co
13. Vehicle Manufacturers Identification Label 68 Ridewell Air Suspension Chart 69 PREVENTATIVE CARE amp MAINTENANCE Preventative Maintenance Schedule 70 TROUBLE SHOOTING Basic Troubleshooting Guide 86 Krystal Enterprises TABLE OF CONTENTS ASSEMBLIES amp SCHEMATICS AIR amp ELECTRIC E 450 Circuit Board Assembly 90 E 450 Shuttle Bus Wiring Diagram 92 E 450 Shuttle Bus Drivers Side Wiring Diagram 93 E 450 Shuttle Bus Passenger Side amp Rear Wiring Diagram 94 F 550 Circuit Board Assembly Ver 1 96 F 550 Circuit Board Assembly Ver 2 98 E 450 amp F 550 Circuit Board Assembly Ver 3 100 F 550 Shuttle Bus Wiring Diagram 107 Misc Air amp Electrical Diagrams and Schematics 108 PARTS SERVICE WARRANTY 112 VENDOR REFERENCE LIST 116 INDEX 118 KRYSTAL ENTERPRISES VEHICLE WARRANTY 124 Krystal Enterprises Pre Trip Inspection Suggested minimum Any item not passing inspection must be reported immediately before operating vehicle FAILURE OF HIGHLIGHTED ITEM S TO PASS INSPECTION WILL CAUSE VEHICLE TO BE GROUNDED Check operation of turn indicators Check operation of foot pedals and parking brake Check operation of all gauges for normal readings with engine running Pass Fail EMEN EMEN NENN EBEN EMEN Check operation of dash indicator lights with key on engine not started then again with engine started Check operation of ventilation system heating defrosters fans and air conditioni
14. 16 Ga Red Battery To Pin 1 On Fuse Block E To Battery 8 Ga Red T ns hs 5 Pin Connector 6 Pin Connector Krystal Enterprises 92 RETURN MENU 450 amp F 550 HIGH SIDE RELAY SWITCHING MODULE Ver 3 SPARE FUSES INTELLITEC RELAY MODULE 1 s High Side Switching Lm gt rm or gt lt OFS OXZ YE 30 129 429 ass 955 azz m x Hx 59 5 000009 ee 6 Pin Connector 5 Pin Connector Krystal Enterprises RETURN TO MENU NEM 103 450 amp F 550 Front amp Rear A C Module 2 2 As used 2004 amp later models DESCRIPTION COMMENT 7 5 amp Compressor Fuse 30 amp Condensor Fuse 35 High Side Fuse Compressor Relay Condenser Relay x 420000 High Side Relay 20 amp Low Side Fuse DEREN Low Side Relay These modules are used to control all A C functions for the front and rear A C units Each unit requires one 1 module each These modules are mounted in the header above the driver behind the driver s control panel Krystal Enterprises We Front Rear A C Module Wiring Diagram LOIN ect Siege jog lower Yellow Low Blower REF RELAYS
15. 22 Overhead Parcel Rack 17 P PARTS 112 113 114 115 Passenger Seating 35 PA Control Audio Video 23 Pre Trip Inspection 8 PREVENTATIVE MAINTENANCE SCHEDULE 70 Processing Warranty Claims 114 115 R Rear Step 32 Ricon Rear Door Wheelchair Lift 54 Krystal Enterprises INDEX Ridewell Air Suspension Chart 69 E S Safety Check List Vapor Air amp Elect Door 11 Seating Std Passenger amp Foldaway 34 35 SERVICE Warranty 112 113 114 115 116 Single Plug Door System 46 47 Specification for E450 Std Chassis 58 59 Specification for F550 Std Chassis 61 62 Standard Equipment on E450 60 Standard Equipment on F550 63 Suspension Chart Ridewell Airride 69 owing Door System 50 Switches mirror micro pressure door step 22 29 33 45 46 48 T TOWING 113 Troubleshooting Guide 86 V Vapor Air amp Electric Door Safety Alerts 11 VEHICLE SAFETY WARNINGS 10 Vendor Reference Listing 116 Krystal Enterprises ds INDEX Video Entertainment Center 30 W WARNING DEVICE 22 Warning Lights low air low battery door open 21 WARRANTY 112 113 114 115 WARRANTY POLICY 112 WARRANTY REPAIRS 114 115 WARRANTY SERVICE 113 Wheelchair Lift Braun amp Ricon 52 53 54 55 56 57 Wheelchair Securement ADA 14 15 Wheel Liners Stainless Steel 36 Wiring Diagram E 450 92 93 94 Wiring Diagram F 550 107 Krystal Enterprises fes 124 KRYSTAL ENTERPRISES LIMITED WARRANTY Krystal Enterprises hereinafter referred to
16. Diesel Primary Battery Location E 450 2004 and Older Models E 450 2005 and Newer Models 2005 E 450 Primary amp Secondary Slide Out Battery Compartment Located on Curb Side of Vehicle Under Floor Auxiliary Battery curb side for E 450 amp F 550 E 450 diesel shown E 450 Diesel Engine Compartment E 450 2004 and Older Models Krystal Enterprises 450 Heated Mirror Switch and Mirror Control Switch CAUTION Leaving the heated mirror switch on in hot weather may cause mirror to crack Heated Mirror Switch This switch controls the ON OFF activation of the heated mirror function Mirror Control Switch This switch includes a center toggle switch that allows the operator to switch from right to left mirror The center posi tion of the toggle defeats all mirror operations When either the left or right mirror is engaged the 4 arrow switches allow the mirror to move in 4 different directions for precise adjustment Krystal Enterprises RETURN TO MENU 29 30 Video Entertainment Center Basic Operating Instruction Bulkhead mounted TV and DVD The TV may be viewed with or without using the DVD For specific detailed information see Manufacturers DVD Operating Instructions 1 Turn on the TV using the power on the TV or the button on the remote Note TV must be set to Video 1 for DVD to work 2 To view video push the TV Video button to switch between TV and DVD
17. END MO m VIN THIS VEHICLE GVWR 19000 LB 8618 KG CONFORMS APPLICABLE GAWR FRONT 6000 LB 2721 KG 225 70R19 5 F TIRES GVWR 14050 LB 6349 KG GAWR FRONT 4600 LB 2086 KG WITH FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT THE 19 5 6 0 1 95 LEE 655 6 E MANUFACTURE GAWR REAR 13500 LB 6123 KG WITH SHOWN ABOVE 225 70R19 5 TIRES DUAL PAINT CODE o 19 5x6 0 GUAJ 95 KPa COLD VEHICLETYPE BUS INCOMPLETE VEHICLE MANUFACTURED BY LABEL EXPLANATION K This is your permanent Krystal Vehicle Identification number VIN This is your DMV Vehicle Identification Number GVWR This is the gross rated weight capacity of your vehicle GAWR Front This is the rated weight capacity of the front axle GAWR Rear This is the rated weight capacity of the rear axle Date Incomplete Vehicle Manufactured This is the date the chassis was produced by FORD Date Of Manufacture by Krystal This is the date the vehicle was completed by KRYSTAL Paint Code This is the master number for the paint specification and color used on your vehicle Tires Rims This indicates the required tire and rim sizes and air capacities for your spe cific vehicle Krystal Enterprises RETURN TO MENU Ridewell Air Suspension Chart Note bolt nut assemblies join ing the Ridewell hangers to the HANGER 1 100 FT LB 1490 N m FORD frame must be torqued HANGER 750 1020
18. THIS FUNCTION SHOULD NOT NORMALLY BE DISABLED Charge Protection will remain in effect until which time any of the above stated ENABLING CONDITIONS are no longer met or until you manually dis engage the BCP button on the DRIVERS OVERHEAD CONTROL PANEL see photo at right TO DEACTIVATE AUTOMATIC BATTERY CHARGE PROTEC TION OR FAST IDLE Do the following Press the Manual Engage button the DRIVERS OVERHEAD CONTROL PANEL and release Fast Idle system will only be turned off when the button is re leased To exit AUTOMATIC CHARGE PROTECTION Mode simply depress the service brake pedal See the Off Road Engineering literature for specific details regarding other operating parameters WARNING USE OF HIGH IDLE CONTROL IS REQUIRED FOR PROPER CHARGING SYSTEM OPERATION Fast Idle Switch is shown as mounted on Driver s Overhead Control Panel ref page 20 Krystal Enterprises 24 HIC900 Throttle Controller Wiring Diagram DIESEL User Interface To 12V fused ignition Hot in Run 2 B EI 10K 10Turn Potentiometer Ground RPM1 DIESEL RPM RPM2 GAS RPM RPM3 PTO BVP 12V VAR GND PTO ENGAGE PTO GND Ford Diesel Engine N C O gt Ground Ground Vehicle SEIC Wiring Diesel Engine SEIC Wires Purple Lt Blue F Series Orange Yellow PTO RPM Ignition Fused Hot in Run 12V High Idle switch wire optional Krystal Enterprises RETURN TO MENU
19. activate the monitor 2 Automatic which activates the monitor when ever the ignition is turned to accessory or the E engine is started SEE MANUFACTURERS LITERATURE FOR ADDITIONAL INFORMATION Krystal Enterprises RETURN TO MENU 31 Rear Step Operation Rear Step Switch Guard SEE MANUFACTURERS LITERATURE FOR ADDITIONAL INFORMATION Rear Step Operational Schematic REAR DOOR DISABLE SWITCH For the double rear step shown above and the single rear step operation is the same The schematic this page explains the electri cal operation of both steps The power switch allows you to enable or disable step operation When the step is enabled opening the rear door automatically extends the step Note See Manufacturers literature regarding periodic lubrication requirements gt REAR DOOR MICRO SWITCH Krystal Enterprises 32 RETURN TO MENU Rear Cargo Door Micro Switch XR Y uw M 4 The switch is located at the rear cargo door upper hinge shown at left and above It operates the rear interior lights and d also activates the door ajar light on the front overhead control T panel This switch works in conjunction with the rear step allowing the power switch shown on previous page to enable or disable Rear Door and Hinge
20. check air system for leaks and electrical connections lube Vapor door rotary drive mechanism check the torque of all door hardware on Vapor door systems Krystal Enterprises RETURN TO MENU PREVENTIVE MAINTENANCE SCHEDULE gt inspect drive belts and replace if necessary AT 95 000 MILES 11400 HOURS DO THE FOLLOWING change engine oil and replace oil filter gt inspect tires for wear and inspect tread depth rotate tires inspect engine air filter check the torque of all door hardware on Vapor door systems AT100 000 MILES 12000 HOURS DO THE FOLLOWING change engine oil and replace oil filter gt inspect tires for wear and inspect tread depth rotate tires inspect engine air filter clean condenser coils clean battery terminals check the torque of all door hardware on Vapor door systems Krystal Enterprises 83 SUPPLEMENTARY PREVENTIVE MAINTENANCE INFORMATION In addition to the required Preventative Maintenance information included in the previous schedule the following specific exceptions should be noted Yellow Coolant Must be changed every 5 years or 100 000 miles whichever comes first then after initial change every 3 years or 50 000 miles Rear Axle Lubricant Must be changed every 50 000 miles Transfer Case Fluid Must be replaced every 60 000 miles Change Rear Wheel Drive Axle Fluid On Dana axles using synthetic fluid fluid must be changed every 150 000 miles
21. end of the pump handle onto the back up pump release valve and turn clockwise to close valve 2 Insert handle into back up pump and pump until platform reaches floor level To Fold Platform Up 1 Repeat step 2 above until fully upright Note Refer to Operator s Manual for Detailed Operating amp Maintenance Procedures Krystal Enterprises RETURN TO MENU 53 Ricon Rear Door Wheelchair Lift Lift Motor Assy ATTENTION Basic User Instructions When the green light is i helt needs semita Passenger Loading and Unloading Do not exceed the 800 pound load capacity of the lift Prior to lift operation the lift should be inspected for proper function If any problems exist DO NOT USE LIFT Contact Ricon Corp at 1 818 322 2884 for repair Passengers loading from the ground level should back onto the platform All passengers loading onto the platform should be positioned centrally on the platform facing outward from the vehicle with the wheelchair locks locked and restraint belt fastened Electric wheelchairs should be turned off UNFOLD The UNFOLD function deploys the lift from the upright position with the platform extended flat at floor level with the roll stop vertical FOLD The FOLD function raises the lift from the horizontal floor level position bringing the platform back to a full upright position DOWN The DOWN function lowers the platform to the ground level and ex tends the roll stop to a flat posit
22. for Opening and Closing the E Z Move Wall shown on the previous page may also be found mounted on the back of the Movable Wall Follow the instructions for Open Position with luggage com partment or Close Position no luggage compartment SAFETY ALERT ALL CLAMPS MUST BE LOCKED DOWN BEFORE OPERATING VEHICLE Krystal Enterprises E Z Move Wall Clamp Assemblies 7 Ls if LH amp RH Lower Clamp Assembly Center Lower Clamp Assembly LH amp RH Ceiling Clamp Assembly LH shown RH shown SAFETY ALERT ALL CLAMPS MUST BE LOCKED DOWN BEFORE OPERATING VEHICLE Krystal Enterprises Compressed Air Supply Assembly Over Temperature Sensor Solenoid Switch On the F 550 shown above The air supply compressor assembly is locat ed beneath the floor hatch between the passenger seats midway back on the right side of the vehicle On the 450 the air supply com pressor is located beneath the first right hand side passenger seat 45 46 Air Operated Single Plug Door 4 Way Valve Entry Door Ajar Switch Closing Cushioning Valve Closing Speed Valve Opening Speed Valve Opening Cushioning a Valve Single Plug Door System Secondary Entry Door CAUTION Never attempt adjustment of door shown partially open Used on ai the Boomerang Arm call KRYSTAL SERVICE operated door systems located on passenger Air Door Speed Adjustme
23. tires for wear and inspect tread depth gt rotate tires gt inspect engine air filter clean battery terminals check air system for leaks and electrical connections check the torque of all door hardware on Vapor door systems AT 85 000 MILES 10200 HOURS DO THE FOLLOWING change engine oil and replace oil filter gt inspect tires for wear and inspect tread depth rotate tires gt inspect engine air filter check the torque of all door hardware on Vapor door systems Krystal Enterprises RETURN TO MENU 81 82 PREVENTIVE MAINTENANCE SCHEDULE AT 90 000 MILES 10800 HOURS DO THE FOLLOWING change engine oil and replace oil filter gt inspect tires for wear and inspect tread depth gt rotate tires inspect engine air filter gt replace engine and frame mounted fuel filters gt inspect steering linkage suspension ball joints driveshafts and driveshaft guards gt inspect engine cooling system and hoses gt inspect brake system inspect exhaust system and heat shields check wheels for end play and noise gt inspect and lubricate 4 x 2 ball joints E 450 only gt inspect and lubricate steering idler arms replace cabin air filter if equipped gt inspect half shaft boots if equipped clean air compressor intake filter clean battery terminals lube door seals with silicon spray check for proper sealing gt re inspect torque settings on Ridewell Suspension System
24. 5 FUSE Circuit Breakers REAR A C COMPRESSOR RELAY 7 5 FUSE Krystal Enterprises E 450 amp 550 Modular Circuit Board Assembly Ver 3 9 9229 OOOO 909090909 9 0000 999 G Krystal Enterprises RETURN MENU E 450 amp 550 Modular Circuit Board Assembly Ver 3 Legend 6 interior Lights 15 fuse max 23 Battery Fuse Block Module 8 Heater Fan RelayLow 25 Air Comp 1GN 15 amp fuse max 16 ga Purple 280 9 high ide Reay 26 Heater Fan HIGH 15 amp fuse max 14 ga Red Bk See detailed diagrams of items 1 amp 17 Low High Side Switching Modules on pages 102 103 Krystal Enterprises 450 amp 550 LOW SIDE RELAY SWITCHING MODULE Ver 3 D 6 PIN CONNECTOR Door Switch 18 Ga Wht to 5 min timer 18 ga Wht BIk E To 16 Ga Blu Wht 420 Heat Valve Trigger 18 Ga Grn BIk Cc 5 RELAY MODULE NTELLITEC Low Side Switching FUSE BLOCK T e mo i so gt gt Or ES OZ az ys Qm 4 Heat Valve 14 Ga Grn 400 55 lt 50 TJU Goes 2 19 NU NT Coil 3 Not Used EE Output 3 Not Used 5 PIN CONNECTOR To Interior Light Switch 18 Ga Yel to 5 min timer side 18 Ga Yel BIk with oo Interior Lights 14 Ga Yel 350 B E To Interior Light Switch 18 Ga Yel Interior Llghts 14 Ga Yel 350 5 Coil Common
25. 50 Super Duty RV Cutaway indo Power Assisted Door Mirrors Heated Power Remote 10 x 7 Whees 16 5 8 Hole Stamped Steel 22 158 24 176 28 209 Krystal Enterprises RETURN TO MENU 59 Standard Equipment on E450 Shuttle Buses 6 8 Liter Fuel Injected V 10 Gas Engine e Ribbed Rubber Aisle Power Steering Mid High Seats with Level 3 Fabric 4 Wheel ABS Power Disc Brakes 53 000 BTU A C System Heavy Duty Dual Batteries AM FM Stereo Cassette w CD amp Clock Electronic 4 Speed Auto Transmission Power Cab Door Locks Radial Tires LT225 75R16 Power Cab Windows e 50 States Emissions Back up Alarm 55 Gallon Fuel Tank e Valance Lighting Adjustable Tilt Steering Wheel Air Actuated Sedan Entry Door Cruise Control Full Body Undercoating Engine Oil Cooler Base White Body Color Transmission Oil Cooler Power Remote Heated Mirrors Automatic High Idle Controller e 80 Tinted Windows w UV Protection e Drive Shaft Guards e 200 Amp Alternator Gas e 063 Aluminum Exterior Side Walls Dual 110 Amp Alternator Diesel Welded Steel Cage Frame Brake Interlock for wheelchair only Cab Running Boards S S Wheel Inserts Captains Chairs Driver Co Pilot Movable Luggage Partition KK28 3 4 Resin Laminated Floor Rear Luggage Door w Electric Step KK28 2 Fiberglass Insulation e Sedan Style Wheel
26. 550 Overhead Control Panel E 450 with PA in Console Krystal Enterprises Controls Indicator and Accessory Switches WARNING e LOW BATTERY VOLTAGE ENM 000 HOURS The Hour Meter accumulates the number of hours your igni tion has been turned on When the Low Air warning light is lit this indicates the normal operating air supply has fallen below safe operating levels Discontinue Operation The Low Battery Light indicates a low battery condition exists and the Charge Protect System needs to be engaged DESTINATION SEEN STEP HEATER LIFT CEILING LIGHTS Thi WIR OTRO This switch must be on or off the optional ceiling lights Krystal Enterprises to power the optional Wheelchair Lift This switch operates optional Destination Sign when equipped RETURN TO MENU This switch operates the optional in step heater when equipped 21 Drivers Overhead Control Panel INTERIOR READING CLIMATE CONTROI ENTRANCE LIGHTS LIGHTS DOOR REAR FAN FRONT FAN MODE 1 Interior Lights 6 Front Fan Control hi low off 2 Reading Lights optional 7 Climate Control Mode cool off heat 3 Door Switch open or close passenger door Note Cool mode A C on both front amp rear Heat mode Heat from front unit only 4 Door Open Indicator Light WARNING DEVICE 8 Entrance Door Ajar Light WARNING DEVICE 5 Rear Fan Control hi low off
27. 9 Rear Door Ajar Light WARNING DEVICE Krystal Enterprises a Audio Video PA Control Radio Input R Audio From 2 4 7 n R int Spkr Ext Spkr STOP REPLAY L int Spkr Monitor Trigger Audio From VCP O 9 9 C9 C2 ds FRONT VIEW REAR VIEW 8 VCP Play starts the tape playing 5 Mode enables PA indicator light will be on 12 VCP Rewind rewinds tape 6 VCP Mode enables VCP indicator light will be on 13 Paging Mode Internal or External press button once to engage system press again to toggle between internal external SEE MANUFACTURERS LITERATURE FOR ADDITIONAL INFORMATION Krystal Enterprises HIC900 Throttle Controller Operating Procedures Quick Reference Guide BCP Battery Charge Protection Mode Note This system has been set up for Automatic Battery Charge Protection which becomes active whenever the following enabling conditions are met ENABLING CONDITION Vehicle NOT moving 0 MPH Service Brake NOT pressed Vehicle Transmission Range in Park Clutch NOT pressed RPM s inside of safe operating range Transmission Fluid Temperature below 240 Engine Coolant Temperature below 230 Brake Lights Functional Foot Off Accelerator Pedal AUTOMATIC BATTERY CHARGE PROTECTION Any time your vehicle is Powered up Charge Protection is auto matically engaged
28. A Module 4 from left to right 1 Rear Condenser 20A 2 Front A C Mode 15A OO BATTERY PNT IO REAR STEP IGNITION 1 AIR COMPRESSOR IGNITION MODE RELAY POWER 20AMP REAR CONDENSOR IGN REAR A C HIGH FRONT CONDENSOR IGN FRONT LOW SPARE SW PANEL IGH SPARE 1 25 REAR STEP POWER 2 10AMP LUGGAGE LIGHT POWER 3 20AMP AIR COMPRESSOR POWER 4 20AMP AIR COMPRESSOR POWER 5 SPARE 6 7 B 9 20AMP POWER HIGHSIDE MODULE 15 POWER TO PANEL LED SPARE Battery amp Ignition Fuse Legend SPARE 10 SPARE E 450 Shuttle Bus Wiring Diagram
29. Assy step operation Krystal Enterprises Sane 33 34 Foldaway Seating Fold Forward a a Lift Rearward E Lever A A Lig Push Release Lever B T Pull Towards Aisle Until Down Lock Push in IVY NIT RE Lever D T Truss 7 Lock i Os UI To Lower 1 Rotate the Truss Lock to unlock the assembly then push Lever D and pull the top of the seat toward the aisle until it is locked in the down position 2 Push lever forward and lift the back cushion until the lever A has snapped back into the locked position Rotate Clockwise To Lock Counter Clockwise to Unlock To Raise 1 Push lever A forward and fold the back cushion down against the seat cushion until lever has snapped back into locked position 2 Push lever upward and lift the seat into the fold away position and rotate the Truss Lock to lock the assembly in place Krystal Enterprises RETURN TC Bus Passenger Seating Moving or Adding Bus seating is mounted into the floor of the vehicle as shown in the photo to the left To move or add seating 1 Remove the black plastic track cover so the track is exposed 2 Next remove the nut from the base NOTE Nut must be perpen dicular to the track when the seat is re attached to the seat track CAUTION Bolts must be torqued to 35 ft Lbs Caution When Adding Seating
30. ENU TO INTERIOR LIGHTS swing Door System Electrical Schematic OVERHEAD SWITCH 4 DOOR CLOSED RELAY BY 00 N DC Motor DOOR OPEN REL 15 AMP CLOSED OPEN nu 12 VDC BATTERY FUSE F 550 Schematic Krystal Enterprises RETURN TO MENU L E f l Y TN l Py E 450 Schematic For Larger Schematics See Electrical Section pg110 111 51 Braun Rear Door Wheelchair Lift User Instructions Passenger Loading and Unloading Do not exceed the 800 pound load capacity of the lift Prior to lift operation the lift should be inspected for proper function If any problems exist DO NOT USE LIFT Contact Braun Corp at 1 800 THE LIFT for repair Passengers loading from the ground level should back onto the platform All passengers loading onto the platform should be positioned fully within the yellow boundaries facing outward from the vehicle with the wheelchair locks locked gripping handrails if able Electric wheelchairs should be turned off UNFOLD The UNFOLD function deploys the lift from the upright position with the platform extended flat at floor level with th
31. GHT IS LIT CHECK ALL DOORS FOR PROPER CLOSURE NEVER OPERATE THIS VE HICLE UNTIL THE PROBLEM HAS BEEN RESOLVED THIS BUS IS NOT DESIGNED TO TOW ANOTHER VEHICLE OR TRAILER DO NOT ATTEMPT TO TOW OR PULL ANOTHER VEHICLE WITH THIS BUS Krystal Enterprises Vapor Air amp Electric Door Operational Safety Check List ATTENTION WHEN OPERATING A VEHICLE WITH A VAPOR DOUBLE PANEL AIR OR ELECTRIC ACTUATED PASSENGER ENTRANCE DOORS THE FOLLOWING PRECAUTIONS SHOULD BE TAKEN AIR DOORS The Emergency Release Valve System must be checked on a daily basis Once the emergency release valve has been actuated by turning the red handle counter clockwise it should be possible to open the doors by pushing outward with your hand after about 5 seconds The Obstruction Sensing System Sensitive Edge must be checked on a daily basis Only when the door is closing can reversing be actuated The reversing motion should be shut off at about 10 to 30 mm before the final closing position If the reversing process actuates too late the sensi tivity of the differential pressure switch should be adjusted again Call the KRYSTAL SERVICE DEPT ELECTRIC DOORS The Emergency Release Lever System must be checked on a daily basis Once the emergency release lever has been actuated by pushing the red handle from right to left as indicated on the sticker it should then be possible to open the doors by pushing the panels outward with your hand K
32. H DETAIL FOR 2005 PRESSURE SWITCH 2 s TO OPTIONAL AIR RIDE amp NEWER MODELS l O ek VALVE ONE WAY VALVE SCHRADER VALVE 4 WAY SOLENOID VALVE NATURAL eo ae DOOR SWITCH ELECTRONIC PANEL CLOSE VALVE CUSHIONING YELLOW BLUE m TEE 22225 LEGEND MINI YLON TUBING DRYE WIRE CLOSE B p 0 706 DOOR MOTOR BRAKE HOSE PRE COOLER 21 LG OPEN a SPEED CONTROL VALVES F PRE FILTER DRYER OPEN VALVE CUSHIONING Krystal Enterprises 47 RETURN TO MENU Air Operated Double Plug Door ATTN Double Plug Air Door Speed Factory Set If adjustments become necessary do not attempt adjustments Contact the Krystal Service Dept at 1 800 Krystal 579 7825 CAUTION Emergency Release Valve System must be checked a daily basis Secondary Entry Door Once the emergency release valve has been actuated b
33. IGHT REAR SPEAKER RIGHT SPKR RIGHT FRONT SPEAKER RUNNING LIGHT RED YELLOW RED YELLOW RED YELLOW BROWN LOOP BLACK WHITE BLACK WHITE BLACK WHITE LON RUNNING LIGHT E E DOOR KEY SWITCH BROWN LOOP 227 INTERIOR LIGHT PINK WHITE YELLOW ae SIDE RUNNING LIGHT P WHITE BLUE WHITE 1 BLUE WHITE RIGHT TURN LIGHT WHITE BLUE WIRE LOOPS BACK UNDERNEATH ITSELF amp RUNS ALONG FLOOR ON PASSENGER SIDE Ref Drwg 300 042 Krystal Enterprises RETURN TO MENU E 450 Shuttle Bus Drivers Side Wiring Diagram Rear Door Ajar 10 warning light 12 5 Charge Solenoid pass through leed See Detail D harness configuration In rear of bus Left Turn Light route along floor on driver side Condenser Fans Reference Table 1 Running Light 8 Rear A C 3rd Brake Light located on left rear 2 Running Light 9 Luggage Compart used only upon customer request 3 Running Light ment Light 4 Side Marker Light 10 Step Switch 5 Running Light 11 Right Rear Cabin 6 Left Rear Cabin Speaker ui Speaker 12 Running Light pass through harness to factory plug 7 Microswitch 13 Running Light Ref Drwg 300 042 Krystal Enterprises RETURN TO MENU 93 E 450 Shuttle Bus Rear Wiring Diagram DETAIL D Rear Harness Configuration Right Tail Lights Power Step License Plate Running Light Left Tail Light Back u
34. INK EXTERIOR LIGHTS KEY SWITCH OPARE 6 AWG GREEN HEATER VALVE sn BH E 6 AWG BROWN WHITE EXT LIGHTS RELAY 16 AWG BLACK GND 6 AWG ORANGE IGNITION RELAY LEFT REAR TURN LIGHT 6 AWG BLUE A C COMPRESSOR _ 16 AWG RED YELLOW 16 AWG GREEN WHITE 16 AWG BLACK WHITE 16 AWG BLACK YELLOW LOOP 16 AWG BLACK WHITE 16 AWG BLACK WHITE 16 AWG BLUE WHITE PWR 16 AWG WHITE BLACK 6 AWG BLACK YELLOW BACK UP ee vere 16 AWG RED YELLOW 16 AWG BLACK GND PAE 16 AWG PINK 16 AWG WHITE beer 8 AWG WHITE PWR COMPRESSOR FACTORY RADIO 16 AWG BROWN WHITE i COMPRESSOR DOOR OPEN 16 AWO RED D Eon fen T UNDERNEATH CHASSIS D E 16 AWG BROW 16 AWG WHITE BLUE REAR STEP 16 AWG WHITE 12 AWG BLUE 12 AWG RED 16 RED LUGGAGE DOOR LIGHT is 1 is 12 AWG YELLOW RIGHT TURN SIGNAL LIGH 12 AWG RED 12 AWG WHITE 2 CONDENSER FANS FLOOR HEATER UNDERNEATH CHASSIS CONDENSOR FANS COMPRESSOR Krystal Enterprises 107 RETURN TO MENU Air and Electrical Diagrams amp Schematics Double Plug Air Door Schematic ref pg 49
35. LOW RED 16 AWG BLUE WHITE 16 AWG BROWN LOOP EXTERIOR LIGHT READING CABIN LIGHT RIGHT REAR SPEAKER 16 AWG YELLOW LEFT CABIN LIGHT 16 AWG BROWN LOOP 16 AWG BROWN LOOP 16 AWG ORANGE LEFT READING LIGHT 16 AWG WHITE LOOP EXTERIOR LIGHTS 16 AWG WHITE GND EXTERIOR LIGHTS 16 AWG WHITE 16 AWG BROWN EXTERIOR LIGHTS 14 AWG WHITE BLACK 14 AWG PINK LEFT FRONT SPEAKER __ 16 AWG BROWN LOOP EXTERIOR LIGHTS 16 AWG BROWN EXTERIOR LIGHTS 16 AWG BROWN 16 AWG WHITE EXTERIOR LIGHTS 16 AWG WHITE BLACK 6 AWG PINK LEFT REAR SPEAKER 16 AWG BROWN LOOP 16 AWG WHITE LOOP EXTERIOR LIGHTS 16 AWG RED YELLOW 16 AWG BLACK WHITE FRONT RIGHT SPEAKER AWG BROWN LOOP 12 GROUND WIRES 16 AWG BLACK YELLOW LOOP 16 AWG RED LOOP 16 AWG WHITE EXTERIOR LIGHTS 16 AWC WHITE 14 AWG ORANGE READING LIGHTS RIGHT 14 AWG YELLOW CABIN LIGHTS RIGHT 16 AWG BLACK YELLOW LOOP MICROSWITCH 14 AWG WHITE GROUND 6 AWG BLUE WHITE 16 AWG WHITE LOOP 6 AWG WHITE 16 AWG BROWN LOOP DOOR SWITCH LUGGAGE DOOR LIGHT ie wee 16 AWG BROWN LOOP 16 AWG P
36. N m 120 ft Ibs dry or 90 ft Ibs 500 FT LB lubricated GRADE5 360FT LB If any bolts are found to be bien i Hr loose or damaged replace with GRADES 160FT LB 2 20 SAE GRADE 8 hardware 190 FT LB This sticker is located on 100 FT LB your chassis Suspension 90 FT LB a 2 25 FT LB After suspension has been in operation for approxi mately 6 000 miles 10 000 KLMS all fasteners must be re tightened to specified torque Repeat every 15 000 miles 25 000 KLMS DO NOT OVER TORQUE Krystal Enterprises RETURN TO MENU 70 PREVENTATIVE MAINTENANCE SCHEDULE The following Maintenance Schedule is provided as a convenient reference for the specified systems and components which require periodic service These schedules are not intended to be a complete list of all possible services to be performed on a regular basis nor is it suggested that more frequent services not be considered Because of the different types of operations coaches are subjected to the severity of service must be considered when establishing maintenance intervals Therefore any such intervals given in the following schedule must be adjusted according to the particular type of operation in which your particular vehicle will be used The intervals given are Krystal Enterprises Inc recommendations and should be considered as maximum intervals It should be noted that maintenance inspection and service opera
37. TAL ENTERPRISES BUS If the selling Dealer is unable to remedy the situ ation the original retail customer should contact the Warranty Department of Krystal Enterprises If the selling Krystal Enterprises KRYSTAL ENTERPRISES LIMITED WARRANTY dealer does not perform repair work on premise the Dealer must call the Krystal Warranty Department for instructions on proceeding with the repair via an authorized repair facility the bus was not purchased from a Krystal Authorized Dealer the original retail customer must contact the Krystal Warranty Department to receive information and prior authorization for any needed repair work Provided that prior authorization was obtained from the Warranty Department of Krystal Enterprises all labor costs associated with the repair or replacement of defective parts will be paid by Krystal Krystal reserves the right to make a physical inspection of the bus by authorized factory personnel following any complaint prior to any repair Krystal shall have no liability for any defect or damage caused by the original owner s use of parts or services which are not authorized by Krystal or for any parts or paint which have been subject to misuse neglect or accident or have been subject to external mechanical or chemical influences especially stone chips airborne rust or industrial fall out This Limited Warranty DOES NOT cover loss to time Inconvenience loss of use of any vehicle cost of rented replaceme
38. TIMER 10 SECOND TIMER SENSITIVE EDGE HOSE amp 4 1 WHITE 1OAMP FUSE 4 L 1 za 3 ORANGE 10 12 BATTERY POWER RED ORANGE AIR CYLINDER FROM DOOR SWITCH RED BROWN ORANGE cot PROX SWITCH PINK k ORANGE NBLUE a BLACK 1 R 680 H BLUE TRANSISTOR _ AIR HOSE Double Plug Door System w Sensitive Edge doors shown partially open AIR CYLINDER BLUENWHITE 02 cw HOSE LARGE Electrical Schematic for Doors with Sensitive Edge For Lar er Schematics See Electrical Section pg 108 109 Electric Swing Doors Electric door motor Cover For removal of door motor cover 1 Remove black rubber strip from molding channel 2 Remove exposed screws in aluminum channel 3 Remove screws from 3 corners of cover EMERGENCY EXIT PUSH HANDLE LEFT aH PUSH DOORS OUT Emergency Exit Lever Decal NOTE LEVER MUST BE CHECKED DAILY PRIOR TO VEHICLE OPERATION Electric Door Adjustment Procedure Door Speed Is Factory Set If adjustments become necessary do not attempt adjustments Contact the Krystal Service Dept at 1 800 Krystal 579 7825 Krystal Enterprises RETURN TO M
39. Vapor door systems check wheels for end play and noise Krystal Enterprises i PREVENTIVE MAINTENANCE SCHEDULE gt inspect and lubricate 4 x 2 ball joints E 450 only inspect and lubricate steering idler arms replace cabin air filter if equipped gt inspect half shaft boots if equipped clean air compressor intake filter lube door seals with silicon spray check for proper sealing gt re inspect torque settings on Ridewell Suspension System check air system for leaks and electrical connections lube Vapor door rotary drive mechanism check the torque of all door hardware on Vapor door systems AT 50 000 MILES 6000 HOURS DO THE FOLLOWING change engine oil and replace oil filter gt inspect tires for wear and inspect tread depth rotate tires inspect engine air filter clean battery terminals check the torque of all door hardware on Vapor door systems clean condenser coils AT 55 000 MILES 6600 HOURS DO THE FOLLOWING change engine oil and replace oil filter Krystal Enterprises RETURN TO MENU 77 PREVENTIVE MAINTENANCE SCHEDULE gt inspect tires for wear and inspect tread depth rotate tires inspect engine air filter check the torque of all door hardware on Vapor door systems AT 60 000 MILES 7200 HOURS DO THE FOLLOWING change engine oil and replace oil filter gt inspect tires for wear and inspect tread depth gt rotate tires inspect eng
40. Video 3 To view tapes select VCP then press the DVD power button on the remote 4 The DVD buttons on the remote will now Operate all the functions of the DVD SEE MANUFACTURERS LITERATURE FOR ADDITIONAL INFORMATION ON BOTH COMPONENTS Back Up Camera Controls and Operation NOTE To reverse image LCD Monitor located in bulkhead above passenger seat on E 450 or in dash area on passenger side of F 550 Monitor Controls 1 Power Button glows dimly when system is connected fully manual be coming bright upon activation 2 AIB input Select Button toggles active display between AV1 and AV2 inputs 3 Day Night Mode Button toggles intensity of LCD screen for day or night operation day maximum intensity night less intensity 4 Picture Adjustment Menu Button accesses on screen display to adjust brightness contrast color tint Use the Volume control to adjust each up or down as indicate by a bar graph at bottom on screen 5 Volume Button controls output volume of built in speaker when feature is connected Also used in Picture Adjustment Mode on monitor push button on back of camera E Back Up Camera located on rear of vehicle System Operation This system consists of two major components 1 The Back Up Camera 2 LCD Monitor The system may be connected two ways 1 Fully manual requiring the power button on the LCD Monitor to be pushed to energize the system and
41. Y 2 READING LAMP RELAY PARCEL RACK BUSSES ONLY IGNITION CIRCUIT RELAY FLOOR HEATER LOW SPEED RELAY OPTIONAL 2 5 FLOOR HEATER HIGH SPEED RELAY OPTIONAL amp INTERIOR LIGHT RELAY 1 5 INTERIOR LIGHT RELAY 2 ENTRY DOOR OPEN RELAY 4 EXTERIOR LIGHT RELAY CLEARANCE TRANSMISSION INTERLOCK RELAY 1 5 TRANSMISSION INTERLOCK RELAY 2 2 40 AMP DOOR COMPRESSOR amp SOLENOID BREAKE 03 20 AMP FOR IGNITION CIRCUIT BREAKER 5 40 INTERIOR LIGHT CIRCUIT BREAKER 12 6 20 AMP ENTRY DOOR SOLENOID amp STEP LIGHT 07 20 REAR STEP CIRCUIT BREAKER 20 AMP EXTERIOR LIGHT BREAKER CLEARANCE LIGHTS 19 15 AMP LUGGAGE LIGHT CIRCUIT BREAKER 15AMP SPARE OR PA SYSTEM OPTION 3 20 READING LIGHT CIRCUIT BREAKER 2 15 AMP FLOOR HEATER VALVE OR HEAT PUMP BREAKE Power 3 FRONT A C LOW SPEED RELAY 20 FUSE Solenoid 2 95 6 7 IRD MODULE lt Relays 9 1016 20 20 1119 UJ CU 5 P 7 9 LightTimer 23 24 25 26 153 1415161718 19 20 2122 20 35 35 75 QIO QIIOQIQ e On OO 0 U le ae 6 Circuit Breakers Front A C Board 97 F 550 Circuit Bo
42. ard Assembly Ver 2 um i 8 1 y d 7 uf 5 MINUTE LIGHT TIMER F 550 circuit board located above driver Krystal Enterprises i F 550 Circuit Board Ver 2 Electrical Diagram CD HEATER VALVE REALY 2 READING LAMP RELAY PARCEL RACK BUSSES ONLY
43. as Krystal Enterprises and Krystal is the final stage manu facturer of an incomplete vehicle which is manufactured and separately warranted by the incomplete vehicle manufacturer This limited Warranty thus does not extend to any part or portion of the incomplete vehicle except as specifically required by any applicable Federal law or regulation Krystal Enterprises warrants to the original purchaser of each new Krystal Enterprises bus that all parts ex cept electronic parts which are warranted by their original manufacturer installed by Krystal will be free from defects in material and workmanship under normal use and service for one 1 year with unlimited mileage from the date of purchase by the original retail customer Krystal Enterprises further warrants to the original purchaser of each new Krystal Enterprises bus the body structure which is defined as the cage skin front and rear caps and floor structure to be free from defects in material and workmanship under normal use and service for five 5 years or 100 000 miles whichever comes first from the date of purchase by the original retail customer In the event of a Warranty claim Krystal reserves the right to replace or repair the defective part The original retail customer must return the bus to the original selling Authorized Dealer for the necessary authorization and parts THE DEALER MUST OBTAIN PRIOR TO PERFORMING ANY WORK A REPAIR AUTHORIZATION NUMBER R A N ON ANY KRYS
44. chair Lift Door KK22W amp Commercial Grade Carpet KK24W Krystal Enterprises Standard Chassis Specification for F550 Super Duty Cab amp Chassis M 6 8 Liter Fuel Injected V 10 Gas Engine 6 0 Liter Power Stroke V 8 Diesel PY ies Fore Dual HOA Krystal Enterprises Standard Chassis Specification for F550 Super Duty Cab amp Chassis ess i A Winds Pere Door Temperature Fuel Gage Indicator Lights Mirrors 0 59 0 0050 500 Heated Power Remote 10 x 7 Wmes 0 Krystal Enterprises ee Standard Equipment on F550 Shuttle Buses 6 8 Liter Fuel Injected V 10 Gas Engine e Ribbed Rubber Center Aisle Power Steering Mid High Seats with Level 3 Fabric 4 Wheel ABS Power Disc Brakes 68 000 BTU A C System w Dual Compressors Heavy Duty Dual Batteries AM FM Stereo Cassette Electronic 4 Speed Auto Transmission gas only Power Cab Door Locks e Radial Tires LT225 70R19 5 Power Cab Windows 50 States Emissions Back up Alarm 40 Gallon Fuel Tank w 19 Gallon Aux Tank Valance Lighting All Season Radial Tires LT225 75R16F Air Actuated Sedan Style Entry Door Adjustable Tilt Steering Wheel Full Body Undercoating Cruise Control Base White Body Color Engine Oil Cooler Power Remote Side View Mirrors Transmission Oil Cooler e 80 Tinted Windows w UV Protection Automatic High Idle Controller 200 Amp Alternato
45. e roll stop vertical FOLD The FOLD function raises the lift from the horizontal floor level position bringing the platform back to a full upright position DOWN The DOWN function lowers the platform to the ground level and extends the roll stop to a flat position for wheelchair egress UP The UP function raises the roll stop to full vertical position before raising the platform from ground level to the floor level position for unloading CAUTION Never raise or lower lift if roll stop is malfunctioning CAUTIONI Back up Pump Lift Control YOU MUST READ AND UNDERSTAND THE MANUFACTURERS Pump Handle OPERATORS MANUAL BEFORE EVER OPERATING THIS LIFT Release Valve Krystal Enterprises E Braun Rear Door Wheelchair Lift Lift Closed Lift Extended Emergency Back Up Operation In the event of an electrical system failure turn counterclockwise until the platform this lift system provides for full manual op reaches floor level eration Locate the back up pump release 2 Turn the release valve clockwise to stop valve and the hand pump handle on the the platform make sure valve is tight but motor housing not over tight To Unfold the Platform 1 Place the To Lower Platform and Roll Stop slotted end of the pump handle onto 1 Repeat step 1 in the previous procedure the back up pump release valve and to lower the lift to the ground level To Fold Roll Stop and Raise Platform 1 Place the slotted
46. e vehicle ID tag on the drivers door jamb on the invoice so your claim s can be processed without any problems You will be reimbursed within 30 days Send all invoices to the service manager at KRYSTAL ENTERPRISES Attn Service Department Manager 2 01 East Imperial Highway Brea California 92821 Krystal Enterprises RETURN TO MENU im Vendor Reference Listing Vendor Warranty Period FORD ROADSIDE ASSISTANCE 1 800 241 3673 24 HOUR HOTLINE SHURFLOW WATER PUMPS 1 800 854 3218 SONY STEREO 1 800 282 2848 Krystal Enterprises 16 Vendor Reference Listing Vendor Warranty Period TRANSPEC WORLDWIDE 1 810 274 9400 gt OOO Krystal Enterprises INDEX A A C Module Frt amp Rear 2004 104 Accessory Switches 21 Air and Electrical Diagrams amp Schematics 108 Air Conditioning 37 Air Conditioning Charging Chart 67 Air Door Lock Pin 16 Air Schematic Single amp Double Plug Doors 47 49 Audio Video PA Control 23 B Back Up Camera 31 Battery Location 28 Body Materials amp Construction Measurements 66 Braun Rear Door Wheelchair Lift 52 Cargo Door Micro Switch 33 Caution Safety Alerts 10 14 16 17 46 Charge Protection 24 25 26 27 Circuit Board Assembly E 450 90 Circuit Board Assembly F 550 Ver 1 amp 2 96 98 Krystal Enterprises s INDEX Circuit Board Assembly Ver 100 Compressed Air Supply amp Schematic single amp double plug door 45 47 49 Construction Ma
47. em is covered under the KRYSTAL WARRANTY depends in some cases on several factors The KRYSTAL SERVICE DEPARTMENT determines coverages ahead of time on a case by case basis either over the phone or at our Brea California facil ity HAVING NON WARRANTY REPAIRS PERFORMED If the service manager has determined that the repair is not covered or you are sure that it is not covered we would be happy to recommend a shop in your area or schedule an appoint ment with the KRYSTAL SERVICE DEPARTMENT whichever is more convenient HAVING WARRANTY REPAIRS PERFORMED There are three 3 methods 1 Repair is done at the KRYSTAL SERVICE DEPARTMENT in Brea California 2 Repair is done at a KRYSTAL authorized service facility near you 3 Repair is done at a shop of your choice with prior approval of the KRYSTAL SERVICE DEPARTMENT Krystal Enterprises RETURN TO MENU PARTS SERVICE WARRANTY HAVING WARRANTY REPAIRS PERFORMED con t If either method 2 or 3 as described on the previous page are to be used you must obtain pre authorization and a KRYSTAL ENTERPRISES SERVICE DEPARTMENT repair autho rization number R A N in advance of performing any repairs Both requirements my be accomplished from a single phone call to the KRYSTAL SERVICE DEPARTMENT at 1 800 045 4883 If method 3 is used simply pay for the work and mail a copy of the invoice with the repair authorization number and your KRYSTAL vehicle ID number which is found on th
48. engine oil and replace oil filter Krystal Enterprises RETURN TO MENU 19 80 PREVENTIVE MAINTENANCE SCHEDULE gt inspect tires for wear and inspect tread depth gt rotate tires inspect engine air filter clean battery terminals check the torque of all door hardware on Vapor door systems AT 75 000 MILES 9000 HOURS DO THE FOLLOWING change engine oil and replace oil filter gt inspect tires for wear and inspect tread depth rotate tires inspect engine air filter replace engine and frame mounted fuel filters gt inspect steering linkage suspension ball joints driveshafts and driveshaft guards gt inspect engine cooling system and hoses inspect brake system inspect exhaust system and heat shields check wheels for end play and noise gt inspect and lubricate 4 x 2 ball joints E 450 only inspect and lubricate steering idler arms replace cabin air filter if equipped gt inspect half shaft boots if equipped clean air compressor intake filter Krystal Enterprises RETURN TO MENU PREVENTIVE MAINTENANCE SCHEDULE lube door seals with silicon spray check for proper sealing gt re inspect torque settings on Ridewell Suspension System lube Vapor door rotary drive mechanism check the torque of all door hardware on Vapor door systems clean condenser coils AT 80 000 MILES 9600 HOURS DO THE FOLLOWING change engine oil and replace oil filter gt inspect
49. fuse located in the FORD fuse panels Krystal Enterprises Troubleshooting Notes PROBLEM POSSIBLE SOLUTIONS Krystal Enterprises 90 re 450 Circuit Board Assembly 2 Circuit Board located compartment above driver Krystal Enterprises 5 MINUTE LIGHT See fuse amp relay legend on next page 450 Circuit Board Electrical Diagrams Low Side Switching Controller High Side Switching Controller SPARE FUSES 4 SPARE FUSES Relay Module Legend Module 1 5 RELAY MODULE 2 Module 2 seu 8 30A 25A 20A 30A all amperage are maximum E E E 5 IE E p Module 1 from left to right INTELLITEC 25 ax ax aR aA INTELLITEC ax 5 SE ax ax 1 Door Switch 10A Module 3 2 Spare 15A 00888898l0 3 Spare 10A 4 Interior Lights 15A 5 Interior Lights 15A Module 2 from left to right 20A 15 1 Heat Valve 10A Relay Fuses Relay Fuses 2 Rear A C Low 15A Oi OBOR EOR VO e goo Oi OX Power 3 A C Compressor 10A Solenoid 4 Spare 15A 5 Spare 15A Module 3 from left to right 1 Front A C High 30A 2 Front A C Low 25A 3 Front Condenser 20A 4 Rear A C High 30
50. g Seating Do Not Ex ceed Weight Distribution Payload Limitations a m E Z Move Wall Operating Instructions Movable Wall to the open position with luggage compartment 1 Release the top two clamps located on the ceiling 2 Enter bus through the rear door and release bottom clamp 3 Push the movable wall at the upper most centrally located handle to the stop 4 Release the divider clamp and slide out each divider half Rotate the clamp assembly into the seat track and engage clamps SAFETY ALERT 5 Engage the top two clamps into the locked position SAFETY ALERT SAFETY ALERT Clamps must be locked down before operating vehicle Movable Wall to the closed position luggage compartment 1 Release the top two clamps located on the ceiling 2 Enter bus through the rear door 3 Release and rotate the clamp assembly divider out of the seat track Slide the divider to the stop and engage the divider clamp to lock down the dividers 4 Pull the movable wall at the upper most centrally located handle to the stop 5 Engage the bottom clamp into the receiver located in the floor SAFETY ALERT 6 Close the rear door Enter the bus walk to the rear and engage the top two clamps into the locked position SAFETY ALERT SAFETY ALERT Clamps must be locked down before operating vehicle Krystal Enterprises RETURN TO MENU E Z Move Wall Open Rear To Open and Close E Z Move Wall Instructions
51. hicle Wheelchair Lift Lift Closed In the event of an electrical system failure the UVL system provides for full manual operation Locate the manual release cable manual down valve and the hand pump on the power pack To move platform from STOW pull the manual release cable Twist the handle to lock in the released position The plat Lift Extended E form can now be pulled outward To raise the platform make sure the manual down valve is turned fully clock wise Pump the hand pump handle until you reach the desired platform height To lower the platform turn the manual down valve SLOWLY counter clockwise to lower the platform To lower the front Lift Lowered mergency Back Up Operation Lift Raised barrier remove the release pin at the barrier actuator end Lift will not continue operating unless release pin is re inserted fully To move platform to STOW po sition first be sure the platform is at STOW height Pull and lock the manual release cable Push the platform inward to re engage release cable mechanism Note Refer to Service Manual for Maintenance Adjustment and Trouble Shooting Procedures Krystal Enterprises RETURN TO MENU 57 Standard Chassis Specification for E450 Super Duty RV Cutaway 6 0 Liter Power Stroke V 8 Diesel Fast Idle Controller Gas Penntex Diesel Ford or InterMotive Krystal Enterprises i standard Chassis Specification for E4
52. ine air filter replace engine and frame mounted fuel filters gt inspect steering linkage suspension ball joints driveshafts and driveshaft guards gt inspect engine cooling system and hoses gt inspect brake system inspect exhaust system and heat shields change automatic transmission fluid and external filter element check wheels for end play and noise lubricate 4 x 4 hub needle bearings lubricate 4 x 2 wheel bearings replace wheel bearing grease seal gt inspect and lubricate 4 x 2 ball joints E 450 only Krystal Enterprises di PREVENTIVE MAINTENANCE SCHEDULE inspect and lubricate steering idler arms replace cabin air filter if equipped gt inspect half shaft boots if equipped clean air compressor intake filter clean battery terminals lube door seals with silicon spray check for proper sealing gt re inspect torque settings on Ridewell Suspension System check air system for leaks and electrical connections lube Vapor door rotary drive mechanism check the torque of all door hardware on Vapor door systems gt inspect drive belts and replace if necessary AT 65 000 MILES 7800 HOURS DO THE FOLLOWING change engine oil and replace oil filter gt inspect tires for wear and inspect tread depth rotate tires inspect engine air filter check the torque of all door hardware on Vapor door systems AT 70 000 MILES 8400 HOURS DO THE FOLLOWING change
53. ion for wheelchair egress UP The UP function raises the roll stop to full vertical position before raising the platform from ground level to the floor level position for unloading CAUTION Never raise or lower lift if roll stop is malfunctioning CAUTIONI Back up Pump Lift Control YOU MUST READ AND UNDERSTAND THE MANUFACTURERS OPERATORS MANUAL BEFORE EVER OPERATING THIS LIFT Pump Handle Release Valve not shown Krystal Enterprises RETURN MENU Ricon Rear Door Wheelchair Lift Lift Closed Lift Extended Lift Lowered Emergency Back Up Operation In the event of an electrical system failure counterclockwise 74 turn until the platform To Fold Roll Stop and Raise Platform this lift system provides for full manual op reaches floor level 1 Place the slotted end of the pump handle eration Locate the back up pump release 2 Turn the release valve clockwise to stop onto the back up pump release valve and valve and the hand pump handle on the the platform make sure valve is tight but turn clockwise to close valve motor housing not over tight 2 Insert handle into back up pump and To Deploy the Platform 1 Place the To Lower Platform and Roll Stop pump until platform reaches floor level slotted end of the pump handle onto the 1 Repeat step 1 in the previous procedure To Stow Platform Up back up pump release valve and turn to lower the lift to ground level 1 Repeat step 2 above unti
54. l Overhead Parcel Rack CAUTION Do not overload Parcel Racks Do not fasten parcels to retainer bars Overhead Parcel Rack right side shown Krystal Enterprises 17 Emergency Egress Window Operation Lift up on lever to disengage latch 100 MOGHIM EXIT Windows with Emergency Exit stickers are designated emergency exits Follow the directions on the sticker Lift levers and push window out Krystal Enterprises Emergency Roof Hatch Exit SEE MANUFACTURERS LITERATURE FOR ADDITIONAL INFORMATION 4 BLACK TAB 4 5 HANDLE OUT For Emergency Exit T PUSH UP 1 This is Dual Purpose hatch used for Emergency Egress and Ventilation purposes SUGGESTED MAINTENANCE Periodically inspect attaching fasteners for evidence of loosening due to tampering and regularly clean surface with a mild soap and water CAUTION When removing graffiti it is the customers responsibility to ensure cleaning solutions are compat ible with the materials used on Safety Vents Solutions containing acetone ether lacquer thinner or other sol vents can destroy the high strength properties of many engineering plastics AVOID these cleaners EMERGENCY EXIT OPEN VENT HANDLE 9 For Ventilation Krystal Enterprises RETURN TO MENU 19 Overhead Control Panels Assemblies F
55. l fully upright Note Refer to Operator s Manual for Detailed Operating amp Maintenance Procedures Krystal Enterprises 55 Braun UVL 600X Series Under Vehicle Wheelchair Lift User Instructions Passenger Loading and Unloading Do not exceed the 750 pound load capacity of the lift Prior to lift operation the lift should be inspected for proper function If any problems exist DO NOT USE LIFT Contact Braun Corp at 1 800 THE LIFT for repair Passengers loading from the ground level should back onto the platform All passengers loading onto the platform should be positioned in the center of the platform facing outward from the vehicle with the wheelchair locks locked UP The UP function deploys the lift from stow position and raises the platform to floor level DOWN The DOWN function deploys the lift form the stowed position lowers the platform to ground level and lowers the front barrier after reaching the ground STOW The STOW function raises or lowers the platform to the stowed level and then moves it inward to the stow position DOOR CLOSE Optional The DOOR CLOSE function only operates when automatic door openers are installed The function only operates when the platform is stowed or fully extended at ground level CAUTIONI YOU MUST READ AND UNDERSTAND THE MANUFACTURERS Lift Control OPERATORS MANUAL BEFORE EVER OPERATING THIS LIFT Pump Motor Pump Handle Krystal Enterprises Braun Under Ve
56. ls Assemblies 20 Controls and Accessory Functions 21 Drivers Overhead Control Panel 22 Audio Video PA Control 23 HIC900 Throttle Controller Operating Procedures 24 HIC900 Throttle Controller Wiring Diagram Deisel 25 HIC900 Throttle Controller Wiring Diagram Gasoline 26 Krystal Enterprises TABLE OF CONTENTS Charge Protection System Components 27 Battery Location Primary and Secondary 28 E 450 Heated Mirror Switch and Mirror Control Switch 29 Video Entertainment Center 30 Back Up Camera Controls and Operation 31 Rear Step Operation 32 Rear Cargo Door Micro Switch 33 Foldaway Seating 34 Bus Passenger Seating J9 Stainless Steel Wheel Liners 36 Air Conditioning Assembly 37 Floor Heaters 38 Movable Wall Standard 40 Movable Wall EZ Move 42 Compressed Air Supply Assembly 45 Air Operated Single Plug Door 46 Air Operated Double Plug Door 48 Electric Swing Doors 50 Braun Rear Door Wheelchair Lift 52 Ricon Rear Door Wheelchair Lift 54 Braun UVL 600X Series Under Vehicle Wheelchair Lift 56 Krystal Enterprises TABLE OF CONTENTS SPECIFICATION Standard Chassis Specification for E450 Super Duty RV Cutaway 58 Standard Equipment on E450 Shuttle Buses 60 Standard Chassis Specification for F550 Super Duty Cab amp Chassis 61 Standard Equipment on F550 Shuttle Buses 63 General Vehicle Dimensional Specifications Body amp Chassis by Model 64 General Body Material and Construction Measurements 66 Air Conditioning Charging Chart 67
57. ng _ EBEN EMEN EMEN EMEN EMEN Check horn wipers washers and mirrors for cleanliness adjustment operation and damage Check condition of fire extinguisher warning reflectors and first aid kit Mem EN ee _8_ 2 13 12 13 14 Krystal Enterprises RETURN TO MENU Pre Trip Inspection Suggested minimum FAILURE OF HIGHLIGHTED ITEM S TO PASS INSPECTION WILL CAUSE VEHICLE TO BE GROUNDED Check all tires and wheels for tread depth cracks amp bulges missing lug nuts and air pressure 80 psi for E 450 and 95 psi for F 550 Pass mu mu mu E 20 Checkollevl 0000 Check transmission fluid level mu mu mu mE uM NN mu un 16 17 18 Check engine coolant level Check power steering fluid level Check operation of audio and video system if applicable Check wheelchair lift for proper function or damage and securement station equipment 21 22 23 24 25 26 27 28 29 Krystal Enterprises RETURN TO MENU GENERAL VEHICLE SAFETY WARNINGS NO STANDEES ARE ALLOWED AT ANY TIME WHILE THE VEHICLE IS IN MOTION DISCONTINUE OPERATION OF THE VEHICLE IF THE LOW AIR WARNING LIGHT COMES ON OR UNTIL THE PROBLEM WITH THE SYSTEM CAN BE RESOLVED DISCONTINUE OPERATION OF THE VEHICLE IF ANY CRITICAL ITEM ON THE PRE TRIP INSPECTION LIST FAILS TO PASS OR UNTILALL PROBLEMS HAVE BEEN RESOLVED IF ADOOR AJAR WARNING LI
58. nt Procedure door post 1 Remove the air motor cover located in the stepwell 2 Using the photo on this page identify the speed control valves Using a 3 8 wrench loosen the locknuts on both valves 3 Operate the door and adjust both valves until the opening and closing speeds are equal and acceptable Then tighten both locknuts 4 Using a flat blade screwdriver adjust the opening and closing cushioning valves on the air motor then replace cover Krystal Enterprises RETURN TO MENU Compressed Air Schematic Single Plug Door 4 WAY SOLENOID VALVE gt DOOR SWITCH ELECTRONIC PANEL WIRE RED SOLENOID LOCATED AT STEPS CLOSE VALVE CUSHIONING YELLOW RED PWR COMPRESSOR CLOSE rr SOR n OLDER MODELS B OPEN EET SPST FIXED TEMPERATURE SNAP DISC CONTROL EMERGENCY RELEASE SPEED CONTROL VALVES or 2 Sipe wats AR PEN VALVE CUSHIONING 18AWG VIOLET TO IGNITION SOURCE TANK PRESSURE SWITC
59. nt of an emergency evacuation Are complete system operational instructions in either printed or decal form located within the vehicle compartment to serve as a reference CAUTION Never utilize the Occupant Restraint System unless you are fully trained if you re not sure what to do always call your Kinedyne Representative for Assistance Krystal Enterprises d Lap Belt Attachment Typical Wheelchair Securement Methods With the wheelchair and occupant facing toward the front of the vehicle center the wheelchair between the floor tracks or plates As you position the wheelchair remember that the securement straps need to have approximately a 45 angle from the floor tracks or plates to where they attach to the frame Also keep in mind the proper extension and place ment of the occupant restraint shoulder belt Apply the wheel locks or turn off Typical 4 Point Restraint with Lap amp Shoulder Belt Rear Strap Attachment For Specific Operating Instructions and System Care and Maintenance Refer to Your Kinedyne Literature K Air Door Lock Pin Assembly SECURITY PIN ONLY REMOVE DURING BUS OPERATION __ EEEUBITY REMOVE DURING BUS OPERATION CAUTION Security Pin must be removed during bus operation Pin is only to be used for security if bus is not in operation Krystal Enterprises RETURN TO MENU Dua
60. nt vehicle or lodging or mileage expense in connection with any warranty repairs NO PERSON IS AUTHORIZED TO ALTER OR CHANGE IN ANY WAY THE TERMS AND CONDITIONS OF THE ABOVE STATED LIMITED WARRANTY Krystal Enterprises RETURN TO MENU 125 126 It is the policy of KRYSTAL ENTERPRISES INC to incorporate product improvements to our products whenever possible or practical to do so We reserve the right to make changes and or improvements at any time without incurring any obligation to make such changes on previously sold products Additionally the information and specifi cations contained within this manual are current at time of printing Subsequently all information contained in this manual is subject to change at any time without notice Please note that this manual applies to all FORD models and explains standard equip ment as well as many options and may include equipment not presently installed on your vehicle KRYSTAL ENTERPRISES INC Copyright 2005 Rev 2 Krystal Enterprises
61. ntrols on the Overhead Control Panel see page 22 For information on A C charging specifications see the A C Charging Chart on page 67 Krystal Enterprises TO MENU Rear Floor Heater Assembly E 450 amp F 550 Both units are turned on when the heat mode is selected on the Drivers Overhead Control Panel see page 22 Krystal Enterprises THIS PAGE IS INTENTIONALLY BLANK Krystal Enterprises 39 Standard Movable Wall Front View When Adding Seating Do it Distribution Payload Limit Loc 4j c Movable Wall shown above in the forward position Krystal Enterprises Standard Movable Wall Rear View The standard movable wall can be moved by doing the following 5 With assistance on both sides of the wall push evenly on both 1 Remove the seats from in front of the wall sides and slowly move the wall to the desired position 2 From the baggage compartment side remove the plastic track 6 When securing wall make sure to re torque all bolts to 35 ft Ibs cover on both the side wall and floor to expose the track Note if seats are installed seat bolts must also be torqued to 35 ft 3 Disengage the top latches at the outside corners of the wall Ibs 4 From the front side of the wall loosen the bolts 7 Replace all plastic track covers and engage top latches Krystal Enterprises RETURN TO MENU 2 42 E Z Move Wall Open Front Caution When Addin
62. p Alarm Ground Wires Trailer Plug Connection attach harness to factory plug routed along chassis Ref Drwg 300 042 Krystal Enterprises 94 RETURN MENU THIS PAGE IS INTENTIONALLY BLANK Krystal Enterprises RETURN TO MENU 95 F 550 Circuit Board Assembly Ver 1 MINUTE LIGHT TIMER us XA Leer epis j ae nidi eie Le ER D F 550 circuit board located above driver Krystal Enterprises F 550 Circuit Board Ver 1 Electrical Diagram FRONT A C HIGH SPEED RE LAY N 35 FUS FRONT A C CONDENSOR RE LAY 35 AMP FU SE FRONT A C COMPRESSOR RELAY N 7 5 FUSE Krystal Enterprises CD HEATER VALVE REAL
63. ply a thin bead of white exterior silicone and smooth the bead with your finger for a smooth appearance REAR ELECTRIC STEP INOPERATIVE Check to make sure the step switch is turned on This switch is located inside the cargo area on the right hand sidewall If this will not power up the step call the Krystal Service Dept The rear step should be lubricated every 30 days to ensure proper operation of the step REAR STEREO CD INOPERATIVE Check to make sure all connections are tight Also remove the stereo and check the fuse located on the backside of the stereo Krystal Enterprises er 88 Basic Troubleshooting Guide PROBLEM POSSIBLE SOLUTIONS CANNOT REMOVE WATER FROM Make sure fresh water tank has water in it and the water pump switch LAVATORY is in the on position NOTE Always be sure to turn the water pump switch off when not in use Failure to do so could cause a steady drain on the auxiliary battery or could cause damage to the water pump The fresh water fill is located under the bus at the rear of the vehicle PASSENGER LIGHTS INOPERATIVE Check to make sure the switch on the overhead control panel is turned on NOTE There is a 5 minute light timer for the interior lights which will automatically turn them off when the door is open The interior light switch needs to be turned on for at least 10 seconds to reset the timer BACK UP ALARM INOPERATIVE Check to make sure reverse lights are coming on if not check the
64. r Gas Drive Shaft Guards Dual 110 Amp Alternator Diesel 063 Aluminum Exterior Side Walls e Vented Emergency Escape Hatch Welded Steel Cage Frame S S Wheel Inserts e Cab Running Boards Movable Luggage Partition KK30 KK33 Captains Chair Driver amp Co Pilot Rear Luggage Door w Electric Step KK30 KK33 3 4 Resin Laminated Floor e Sedan Style Wheelchair Lift Door KK30W 8 2 Batted Fiberglass Insulation KK33W e Commercial Grade Carpet Krystal Enterprises General Vehicle Dimensional Specifications Body amp Chassis by Model GVWR Interior Body Length without Luggage Clear Door Opening Double Plug 4072 4072 4072 4072 4072 Clear Door Opening Swing Doors 4 4 4 Clear Door Opening Wheelchair Lift Door Exterior Width excluding Mirrors 96 967 ge 9 9 Exterior Width including Mirrors 9 9 9 2 2 2 975 975 975 Krystal Enterprises i General Vehicle Dimensional Specifications Body amp Chassis by Model cont Features Models gt KK22 KK24 KK28 KK30 1st Step from Ground 11 11 1215 1275 18 31 1124 Riser Height 6 Movable Wall Depths approx 450 36 40 30 32 28 36 Z 40 36 IA UVL Wheelchair Lift Door Opening NA NA 427 4 Krystal Enterprises ee General Body Materials and Construction Measurements PaT Pxs
65. related to the converted areas of the vehicle read this section first before taking any action By doing so you will clearly understand the KRYSTAL SERVICE PROCESS and avoid possible delays NEVER initiate a warranty repair without prior approval of the KRYSTAL SERVICE DEPARTMENT Not following this procedure could void your warranty reimbursement for that particular repair Krystal Enterprises PARTS SERVICE WARRANTY WHO SHOULD PERFORM WARRANTY SERVICE ON YOUR VEHICLE If there is any doubt as to whether or not a repair is related to the KRYSTAL WARRANTY call the KRYSTAL SERVICE DEPARTMENT at 1 800 845 4883 this may save you time wasted at a chassis dealer or another shop for a problem appropriately solved by con tacting KRYSTAL SERVICE DEPARTMENT If the problem is conversion related then it can either be repaired at our Brea California facility or by a shop that we recommend in your area or by a shop of your choice This procedure is true of both warranty and non warranty repairs Depending on the nature of the problem it may be necessary to have the warranty repair done at our Brea California facility CAUTION ABOUT TOWING If it becomes necessary to tow your bus a flat bed rig is preferred UNDER NO CIRCUMSTANCES should the bus be towed by lifting the rear end serious frame damage can occur Krystal Enterprises m 114 PARTS SERVICE WARRANTY WARRANTY VERSUS NON WARRANTY Whether a particular probl
66. rystal Enterprises RETURN TO MENU Air Door Emergency Release Valve PRIOR TO VEHICLE OPERATION CAUTION For Emergency Door Opening turn the red valve counter clockwise this will NOTE VALVE MUST BE CHECKED DAILY release the door after about 5 seconds EMERGENCY USE ONLY then the door can be pushed open Krystal Enterprises ls Electric Door Emergency Release Lever Electric Door Motor Cover EMERGENCY EXIT PUSH HANDLE LEFT EMERGENCY EXIT DOORS OUT Emergency Exit Lever Decal LEVER MUST BE CHECKED DAILY PRIOR TO VEHICLE OPERATION EMERGENCY EXIT PUSH HANDLE LEFT PUSH DOORS OUT EMERGENCY USE ONLY Emergency Exit Lever Krystal Enterprises EL 13 Wheelchair Securement and Occupant Restraint Systems Pre Trip Inspection 5 each securement station properly equipped with four securement straps a lap belt and a shoulder belt Are all straps and belts in good working condition Any defects such as cut frayed contaminated or damaged webbing improperly functioning buckles or hardware or broken or worn parts require re placement of the entire strap or belt assembly Are all floor anchorages i e tracks or plates clear of dirt or debris to allow for proper system fitting attachment Is there a clean dry container in the vehicle to allow for storage of the system when not in use Is the vehicle equipped with a web belt cutter for use in the eve
67. tems AT 20 000 MILES 2400 HOURS DO THE FOLLOWING change engine oil and replace oil filter gt inspect tires for wear and inspect tread depth Krystal Enterprises RETURN TO MENU 73 PREVENTIVE MAINTENANCE SCHEDULE gt rotate tires gt inspect engine air filter clean battery terminals check the torque of all door hardware on Vapor door systems AT 25 000 MILES 3000 HOURS DO THE FOLLOWING change engine oil and replace oil filter gt inspect tires for wear and inspect tread depth rotate tires gt inspect engine air filter check the torque of all door hardware on Vapor door systems clean condenser coils AT 30 000 MILES 3600 HOURS DO THE FOLLOWING change engine oil and replace oil filter gt inspect tires for wear and inspect tread depth rotate tires replace engine air filter replace engine and frame mounted fuel filters gt inspect steering linkage suspension ball joints driveshafts and driveshaft guards gt inspect engine cooling system and hoses Krystal Enterprises PREVENTIVE MAINTENANCE SCHEDULE gt inspect brake system inspect exhaust system and heat shields change automatic transmission fluid and external filter element check wheels for end play and noise gt inspect and lubricate 4 x 2 ball joints E 450 only inspect and lubricate steering idler arms replace cabin air filter if equipped gt inspect half shaft boots if equipped
68. terials amp Measurements 66 D Dimensional Specifications Boby amp Chassis 64 Double Plug Door System 48 49 E E 450 amp F 550 Modular Circuit Board Assembly Ver 100 E 450 Circuit Board Assembly 90 E 450 Shuttle Bus Wiring Diagram 92 E 450 Shuttle Bus Drivers Side Wiring Diagram 93 E 450 Shuttle Bus Rear Wiring Diagram 94 Electrical Diagram E 450 circuit board relays breakers 91 Electrical Diagrams amp Schematics misc enlargements 107 111 Electrical Schematic sensative edge swing door 49 108 109 Emergency Egress Window 18 Emergency Release Lever 11 13 Emergency Release Valve 8 11 12 48 Emergency Roof Hatch 19 Krystal Enterprises INDEX F F 550 Circuit Board Assembly Ver 1 96 F 550 Circuit Board Assembly Ver 2 989 F 550 Circuit Board Ver 1 Electrical Diagram 97 F 550 Circuit Board Ver 2 Electrical Diagram 99 F 550 Shuttle Bus Wiring Diagram 107 Foldaway Seating 34 G GENERAL VEHICLE SAFETY WARNINGS 10 H Heated Mirror Switch 29 High Idle Controller 24 25 26 Hour Meter 21 Identification Label Vehicle Manufacturers 68 Idle Controller 24 25 26 L LCD Monitor ref back up camera 31 Low Air warning light 21 Low Battery Light 21 Krystal Enterprises me INDEX M Micro Switch 33 Mirror Control Switch 29 Mirror Switch 29 Movable Wall 40 42 O Obstruction Sensing System Sensative Edge 11 Occupant Restraint Systems ADA 14 Overhead Control Panel 20
69. tions of shorter intervals are always preferable to longer intervals Krystal Enterprises PREVENTIVE MAINTENANCE SCHEDULE THE FOLLOWING PAGES SPECIFY THE MINIMUM REQUIREMENTS THAT ARE NECESSARY TO PROPERLY MAINTAIN YOUR VEHICLES SYSTEMS AND COMPONENTS CHECK EVERY DAY all items Pre Trip inspection see page 8 side passenger door emergency release valve operation side passenger entry door operation locking damage and adjustment emergency roof hatch emergency egress window latches function of all interior and exterior lights check all seat belts for proper operation tire pressure E 450 80 psi F 550 95 psi fluid leaks from transmission engine power steering engine coolant gear oil fuel CHECK EVERY MONTH gt windshield washer fluid level and drain fuel filter water separator door linkage and pivot arm lubrication and lube rear Kwikee step if equipped and clean air intake filter for A C system tires for wear and tread depth Krystal Enterprises 71 PREVENTIVE MAINTENANCE SCHEDULE change engine oil and replace filter gt inspect tires for wear and inspect tread depth gt rotate tires inspect engine air filter gt inspect torque specifications on Ridewell Suspension System lube door seals with silicon spray check for proper sealing lube Vapor door rotary drive mechanism check the torque of all door hardware on Vapor door systems
70. to 35 ft Ibs EXTERIOR LIGHTING E 450 One or all exterior clearance lights inoperative please refer to the FORD wiring schematic in the Krystal Electrical Schematic Manual F 550 Exterior running lights work off of the Krystal relay board SLIDER WINDOWS HARD TO If any of the windows start to stick during opening or closing simply OPEN AND CLOSED spray both side tracks with silicone spray and work the windows a few times to lubricate the tracks This should be done approximately every three months Krystal Enterprises Basic Troubleshooting Guide PROBLEM POSSIBLE SOLUTIONS PAGING SYSTEM INOPERATIVE Check the 5 amp fuse on the circuit board above the driver Wiring schematics and instructions for the paging system are located in this manual on page 23 NO TELEVISION RECEPTION If the TV has power but you cannot pickup any stations make sure VCP mode button on the P A System is engaged and the VCP power button is engaged REAR VCP amp TV INOPERATIVE Check to make sure all connections on the back of both units are tight Check the fuse located at the front face of the TV and on the backside of the VCP EXTERIOR SEALANTS CRACKING If the exterior seams of the bus ever crack or start lifting simply clean OR LIFTING the area with rubbing alcohol or mineral spirits completely After this has been done you can remove the old silicone by using a sharp knife or razor cutter Clean the area again with the above cleaners and ap
71. y turning counter clockwise it should be possible Switch used air to open the doors by pushing outward with your hand after about 5 seconds operated door systems located on passenger The Obstruction Sensing System Sensitive Edge must be checked on a daily basis agor BOs Only when the door is closing can reversing be actuated The reversing motion should be shut off about 10 to 30 mm before the final closing position If the reversing process actuates too late the sensitivity of the differential pressure switch would require re adjustment Call the KRYSTAL SERVICE DEPT Krystal Enterprises 48 Been nm Compressed Air Schematic Double Plug Doors SOLENOID WIRE RED PWR COMPRESSOR SPST FIXED TEMPERATURE SNAP DISC CONTROL WIRE VIOLET SOLENOID MAIN PC BOARD s Lem PRESSURE SWITCH v ONE WAY VALVE TO AIR DOOR ACTUATOR TO OPTIONAL AIR RIDE SCHRADER VALVE LEGEND MI NYLON TUBING Nm DRYER WIRE X 20 706 BRAKE HOSE cxx PRE COOLER 21 L6 PRE FILTER DRYER Air Schematic for Double Plug Doors 4 SECOND

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