Ford Chassis - 450/550 Series - Just Give Me The Damn Manual

Ford Chassis - 450/550 Series

Congratulations,and thank you for purchasing a Krystal Enterprises VehicleYou have taken ownership of a true luxury vehicle which is in a class all its own. We areproviding this manual to familiarize you with your new Krystal Enterprises Professional Bus. Thismanual shall serve as a reference document for the operations and maintenance proceduresthat shall be required throughout the life of your vehicle. This edition covers all our Ford Chassismodels, and is designed to be used in conjunction with the original chassis manufacturer’s owner’sliterature, as well as all other component manufacturers literature.IMPORTANT: PLEASE READ CAREFULLYFor your safety and the safety of others, we ask that you completely familiarize yourself withthis 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

TA B L E O F C O N T E N T SSAFETYPre-Trip Inspection (suggested minimum)General Vehicle Safety WarningsVapor Door Operational Safety Check ListAir Door Emergency Release ValveElectric Door Emergency Release LeverWheelchair Securement and Occupant Restraint SystemsAir Door Lock Pin AssemblyDual Overhead Parcel RackEmergency Egress Window OperationEmergency Roof Hatch ExitOPERATIONOverhead Control Panels AssembliesControls and Accessory FunctionsDrivers Overhead Control PanelAudio/Video PA ControlHIC900 Throttle Controller Operating ProceduresHIC900 Throttle Controller Wiring Diagram - DeiselHIC900 Throttle Controller Wiring Diagram - GasolineCLICK ON THE DESCRIPTION TO GO TO THAT PAGE4Krystal Enterprises810111213141617181920212223242526

TA B L E O F C O N T E N T SCharge Protection System ComponentsBattery Location - Primary and SecondaryE-450 Heated Mirror Switch and Mirror Control SwitchVideo Entertainment CenterBack-Up Camera Controls and OperationRear Step OperationRear Cargo Door Micro SwitchFoldaway SeatingBus Passenger SeatingStainless Steel Wheel LinersAir Conditioning AssemblyFloor HeatersMovable Wall - StandardMovable Wall - EZ MoveCompressed Air Supply AssemblyAir Operated - Single Plug DoorAir Operated - Double Plug DoorElectric Swing DoorsBraun Rear Door Wheelchair LiftRicon Rear Door Wheelchair LiftBraun UVL 600X Series (Under Vehicle) Wheelchair K ON THE DESCRIPTION TO GO TO THAT PAGEKrystal Enterprises5

TA B L E O F C O N T E N T SSPECIFICATIONStandard Chassis Specification for E450 Super Duty RV CutawayStandard Equipment on E450 Shuttle BusesStandard Chassis Specification for F550 Super Duty Cab & ChassisStandard Equipment on F550 Shuttle BusesGeneral Vehicle Dimensional Specifications-Body & Chassis by ModelGeneral Body Material and Construction MeasurementsAir Conditioning Charging ChartVehicle Manufacturers Identification LabelRidewell Air Suspension ChartPREVENTATIVE CARE & MAINTENANCEPreventative Maintenance ScheduleTROUBLE SHOOTINGBasic Troubleshooting Guide7086CLICK ON THE DESCRIPTION TO GO TO THAT PAGE6586061636466676869Krystal Enterprises

TA B L E O F C O N T E N T SASSEMBLIES & SCHEMATICS - AIR & ELECTRICE-450 Circuit Board AssemblyE-450 Shuttle Bus-Wiring DiagramE-450 Shuttle Bus - Drivers Side Wiring DiagramE-450 Shuttle Bus - Passenger Side & Rear Wiring DiagramF-550 Circuit Board Assembly Ver. 1F-550 Circuit Board Assembly Ver. 2E 450 & F-550 Circuit Board Assembly Ver. 3F-550 Shuttle Bus -Wiring DiagramMisc. Air & Electrical Diagrams and Schematics909293949698100107108PARTS - SERVICE - WARRANTY112VENDOR REFERENCE LIST116INDEX118KRYSTAL ENTERPRISES VEHICLE WARRANTY124CLICK ON THE DESCRIPTION TO GO TO THAT PAGEKrystal Enterprises7

Pre-Trip Inspection (suggested minimum)Any item not passing inspection, must be reported immediately, before operating vehicleFAILURE OF HIGHLIGHTED ITEM(S) TO PASS INSPECTION WILL CAUSE VEHICLE TO BE GROUNDEDItem8Inspection Procedure1Check preventative maintenance schedule: for services due at present mileage2Check operation of: drivers seat and seat belt3Check operation of: steering wheel and shift levers4Check operation of: turn indicators5Check operation of: foot pedals and parking brake6Check operation of: all gauges, for normal readings with engine running7Check operation of: dash indicator lights with key on, engine not started, then again withengine started8Check operation of ventilation system: heating, defrosters, fans and air conditioning9Check: horn, wipers, washers, and mirrors for cleanliness, adjustment, operation anddamage10Check condition of: fire extinguisher, warning reflectors and first aid kit11Check: all doors, glass and windows: for operation, cleanliness, and damage.12Check: all emergency exits for operation, warning devices, markings, to be free and clear13Check interior lighting: for operation and damage14Check Side Passenger Entry Door - Emergency Exit Operation & Sensitive Edge if equippedKrystal EnterprisesRETURN TO MENUPassFail

Pre-Trip Inspection (suggested minimum)Any item not passing inspection, must be reported immediately, before operating vehicleFAILURE OF HIGHLIGHTED ITEM(S) TO PASS INSPECTION WILL CAUSE VEHICLE TO BE GROUNDEDItemInspection Procedure15Check Side Passenger Entry Door: for damage and proper closing operation16Check exterior lighting: for operation and damage17Check exterior: for cleanliness, markings and damage18Check fuel cap: in place and secure19Check all tires and wheels: for tread depth, cracks & bulges, missing lug nuts, and airpressure 80 psi for E-450 and 95 psi for F-55020Check: oil level21Check: transmission fluid level22Check: engine coolant level23Check: power steering fluid level24Check: brake fluid level25Check: belts for tension and wear26Check operation of: cameras, if applicable27Check operation of: PA system, if applicable28Check operation of: audio and video system, if applicable29Check wheelchair lift: for proper function or damage and securement station equipmentPassFailKrystal EnterprisesRETURN TO MENU9

GENERAL VEHICLE SAFETY WARNINGSNO STANDEES ARE ALLOWED,AT ANY TIME, WHILE THE VEHICLE IS IN MOTION.DISCONTINUE OPERATION OF THE VEHICLE, IF THE LOW AIR WARNINGLIGHT COMES ON, OR UNTIL THE PROBLEM WITH THE SYSTEM CAN BERESOLVED.DISCONTINUE OPERATION OF THE VEHICLE, IF ANY CRITICAL ITEM ONTHE PRE-TRIP INSPECTION LIST FAILS TO PASS, OR UNTIL ALL PROBLEMSHAVE BEEN RESOLVED.IF A DOOR AJAR WARNING LIGHT IS LIT,CHECK ALL DOORS FOR PROPER CLOSURE. NEVER OPERATE THIS VEHICLE UNTIL THE PROBLEM HAS BEEN RESOLVED.THIS BUS IS NOT DESIGNED TO TOW ANOTHER VEHICLE OR TRAILERDO NOT ATTEMPT TO TOW OR PULL ANOTHER VEHICLE WITH THIS BUS.10Krystal EnterprisesRETURN TO MENU

Vapor Air & Electric Door Operational Safety Check ListATTENTIONWHEN OPERATING A VEHICLE WITH A VAPOR DOUBLE PANEL AIR OR ELECTRICACTUATED PASSENGER ENTRANCE DOORS, THE FOLLOWING PRECAUTIONSSHOULD BE TAKEN.AIR DOORSThe 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), itshould 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 atabout 10 to 30 mm before the final closing position. If the reversing process actuates too late, the sensitivity of the differential pressure switch should be adjusted again. Call the KRYSTAL SERVICE DEPT.ELECTRIC DOORSThe 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 asindicated on the sticker), it should then be possible to open the doors by pushing the panels outwardwith your hand.Krystal EnterprisesRETURN TO MENU11

COUNNOTE:EAir Door Emergency Release ValveTER CLO CKWISVALVE MUST BE CHECKED DAILY,PRIOR TO VEHICLE OPERATIONCAUTION!EMERGENCY USE ONLY12For Emergency Door Opening, turn thered valve counter clockwise, this willrelease the door after about 5 seconds,then the door can be pushed open.Krystal EnterprisesRETURN TO MENU

Electric Door Emergency Release LeverElectric Door Motor CoverEMERGENCY EXITPUSH HANDLE LEFTPUSH DOORS OUTEMERGENCY EXITPUSH HANDLE LEFTPUSH DOORS OUTEmergency Exit Lever DecalNOTE:EMERGENCY EXITPUSH HANDLE LEFTLEVER MUST BE CHECKED DAILY,PRIOR TO VEHICLE OPERATIONPUSH DOORS OUTEMERGENCY USE ONLYEmergency Exit LeverKrystal EnterprisesRETURN TO MENU13

Wheelchair Securement and Occupant Restraint SystemsPre-Trip Inspection Is each securement station properly equipped with four securement straps, a lap belt, and a shoulderbelt?Are all straps and belts in good working condition? Any defects such as cut, frayed, contaminated ordamaged webbing, improperly functioning buckles or hardware, or broken or worn parts, require replacement 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 fittingattachment?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 event of an emergency evacuation?Are complete system operational instructions, in either printed or decal form, located within the vehiclecompartment 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!14Krystal EnterprisesRETURN TO MENU

Typical Wheelchair Securement MethodsFront Strap AttachmentWith the wheelchair and occupantfacing toward the front of the vehicle,center the wheelchair between the floortracks or plates. As you positionthe wheelchair, remember thatthe securement straps need tohave approximately a 45 angle from the floor tracksor plates to where theyattach to the frame. Also,keep in mind the properextension and placement of the occupantrestraint shoulderbelt. Apply thewheel locksor turn offRear Strap AttachmentTypical 4-Point Restraint with Lap & Shoulder BeltFor Specific Operating Instructions and System Careand Maintenance, Refer to Your Kinedyne LiteratureLap Belt AttachmentKrystal EnterprisesRETURN TO MENU15

Air Door Lock Pin AssemblyCAUTION!Security Pin must be removedduring bus operation.Pin is only to be used for security,if bus is not in operation.16Krystal EnterprisesRETURN TO MENU

Dual Overhead Parcel RackCAUTION!Do not overload Parcel Racks.Do not fasten parcels to retainerbars.Overhead Parcel Rack (right side shown)Krystal EnterprisesRETURN TO MENU17

Emergency Egress Window OperationLift up on lever todisengage latchWindows with Emergency Exit stickers are designatedemergency exits. Follow the directions on the sticker.Lift levers and push window out18Krystal EnterprisesRETURN TO MENU

Emergency Roof Hatch ExitThis is a Dual Purpose hatch used forEmergency Egress and Ventilation purposes.SUGGESTED MAINTENANCEPeriodically inspect attaching fasteners for evidence ofloosening due to tampering, and regularly clean surfacewith a mild soap and water.CAUTION: When removing graffiti, it is the customersresponsibility to ensure cleaning solutions are compatible with the materials used on Safety Vents. Solutionscontaining, acetone, ether, lacquer thinner, or other solvents can destroy the high strength properties of manyengineering plastics - AVOID these cleanersEMERGENCY EXIT1 PUSH BLACK TAB 2 PUSH HANDLE OUTFor Emergency ExitPUSH UPTO OPENSEE MANUFACTURERS LITERATUREFOR ADDITIONAL INFORMATION VENTDOWNHANDLE PullTO CLOSEFor VentilationKrystal EnterprisesRETURN TO MENU19

Overhead Control Panels AssembliesE-450 Overhead Control PanelF-550 Overhead Control Panel20Krystal EnterprisesRETURN TO MENUE-450 with PA in Console