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Ford Econline Super Duty Chassis 450 1998 Series, Owner'S Manual

The Ford Econoline Super Duty Chassis 450 1998 Series Owner's Manual is an essential guide for owners of this powerful vehicle. With detailed instructions and valuable insights, this manual equips users with the knowledge needed to maintain and operate their vehicle efficiently. Download it for free at manualshive.com.

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Krystal Enterprises

73

73

► inspect engine air fi lter

► replace engine and frame mounted fuel fi lters

► inspect steering linkage, suspension, ball joints, driveshafts, and driveshaft guards

► inspect engine cooling system and hoses

► inspect brake system

► inspect exhaust system and heat shields

► inspect automatic transmission fl uid and external fi lter element

► check wheels for end play and noise

► inspect and lubricate 4 x 2 ball joints (E-450 only)

► inspect and lubricate steering idler arms

► replace cabin air fi lter, if equipped

► inspect half shaft boots, if equipped

► re-inspect torque settings on Ridewell Suspension System

► clean air compressor intake fi lter

► 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 systems

AT 20,000 MILES/2400 HOURS DO THE FOLLOWING:

► change engine oil and replace oil fi lter

► inspect tires for wear and inspect tread depth

PREVENTIVE MAINTENANCE SCHEDULE

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Summary of Contents for Econline Super Duty Chassis 450 1998 Series

Page 1: ...F o r d C h a s s i s 4 5 0 5 5 0 S e r i e s F o r d C h a s s i s 4 5 0 5 5 0 S e r i e s ProCarManuals com ...

Page 2: ...ProCarManuals com ...

Page 3: ...ughout 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 ...

Page 4: ... Systems 14 Air Door Lock Pin Assembly 16 Dual Overhead Parcel Rack 17 Emergency Egress Window Operation 18 Emergency Roof Hatch Exit 19 OPERATION Overhead Control Panels 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 ...

Page 5: ... Micro Switch 33 Foldaway Seating 34 Bus Passenger Seating 35 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 Se...

Page 6: ... Equipment on F550 Shuttle Buses 63 General Vehicle Dimensional Specifications Body Chassis by Model 64 General Body Material and Construction Measurements 66 Air Conditioning Charging Chart 67 Vehicle Manufacturers Identification Label 68 Ridewell Air Suspension Chart 69 PREVENTATIVE CARE MAINTENANCE Preventative Maintenance Schedule 70 TROUBLE SHOOTING Basic Troubleshooting Guide 86 ProCarManuals ...

Page 7: ...le Bus Passenger Side Rear Wiring Diagram 94 F 550 Circuit Board Assembly Ver 1 96 F 550 Circuit Board Assembly Ver 2 98 E 450 F 550 Circuit Board Assembly Ver 3 100 F 550 Shuttle Bus Wiring Diagram 107 Misc Air Electrical Diagrams and Schematics 108 PARTS SERVICE WARRANTY 112 VENDOR REFERENCE LIST 116 INDEX 118 KRYSTAL ENTERPRISES VEHICLE WARRANTY 124 ProCarManuals com CLICK ON THE DESCRIPTION TO...

Page 8: ...eck operation of ventilation system heating defrosters fans and air conditioning 9 Check horn wipers washers and mirrors for cleanliness adjustment operation and damage 10 Check condition of fire extinguisher warning reflectors and first aid kit 11 Check all doors glass and windows for operation cleanliness and damage 12 Check all emergency exits for operation warning devices markings to be free and ...

Page 9: ...5 psi for F 550 20 Check oil level 21 Check transmission fluid level 22 Check engine coolant level 23 Check power steering fluid level 24 Check brake fluid level 25 Check belts for tension and wear 26 Check operation of cameras if applicable 27 Check operation of PA system if applicable 28 Check operation of audio and video system if applicable 29 Check wheelchair lift for proper function or damage a...

Page 10: ... OF THE VEHICLE IF ANY CRITICAL ITEM ON THE PRE TRIP INSPECTION LIST FAILS TO PASS OR UNTILALL PROBLEMS HAVE BEEN RESOLVED IF A DOOR AJAR WARNING LIGHT 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 GENERAL VEHICLE SAFETY ...

Page 11: ...hut 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 WHEN OPERATING A VEHICLE WITH A VAPOR DOUBLE PANELAIR OR ELECTRIC ACTUATED PASSENGER ENTRANCE DOORS THE FOLLOWING PRECAUTIONS SHOULD BE TAKEN ATTENTION The Emergency Release Lever System ...

Page 12: ...Emergency Door Opening turn the red valve counter clockwise this will release the door after about 5 seconds then the door can be pushed open EMERGENCY USE ONLY C O UNTER CLOCKW IS E NOTE VALVE MUST BE CHECKED DAILY PRIOR TO VEHICLE OPERATION ProCarManuals com RETURN TO MENU ...

Page 13: ...ENCY EXIT PUSH DOORS OUT PUSH HANDLE LEFT Electric Door Motor Cover EMERGENCY EXIT PUSH DOORS OUT PUSH HANDLE LEFT EMERGENCY EXIT PUSH DOORS OUT PUSH HANDLE LEFT Emergency Exit Lever EMERGENCY USE ONLY NOTE LEVER MUST BE CHECKED DAILY PRIOR TO VEHICLE OPERATION ProCarManuals com RETURN TO MENU ...

Page 14: ...e 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 event of an emergency evacuation Are complete system operational instructions in either printed or decal form located within the ...

Page 15: ... 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 Poi...

Page 16: ...rystal Enterprises 16 Air Door Lock Pin Assembly CAUTION Security Pin must be removed during bus operation Pin is only to be used for security if bus is not in operation ProCarManuals com RETURN TO MENU ...

Page 17: ...Krystal Enterprises 17 Dual Overhead Parcel Rack CAUTION Do not overload Parcel Racks Do not fasten parcels to retainer bars Overhead Parcel Rack right side shown ProCarManuals com RETURN TO MENU ...

Page 18: ...cy Egress Window Operation Windows with Emergency Exit stickers are designated emergency exits Follow the directions on the sticker Lift levers and push window out Lift up on lever to disengage latch ProCarManuals com RETURN TO MENU ...

Page 19: ...ty 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 SEE MANUFACTURERS LITERATURE EMERGENCY EXIT 1 2 PUSH BLACKTAB PUSH HANDLE OUT PUSH BLACKTAB PUSH BLACKTAB PUSH BLACKTAB PUSH BLACKTAB PUSH BLACKTAB PUS...

Page 20: ...Krystal Enterprises 20 Overhead Control Panels Assemblies E 450 Overhead Control Panel F 550 Overhead Control Panel E 450 with PA in Console ProCarManuals com RETURN TO MENU ...

Page 21: ...the number of hours your igni tion has been turned on The Low Battery Light indicates a low battery condition exists and the Charge Protect System needs to be engaged This switch must be on to power the optional Wheelchair Lift This switch turns on or off the optional ceiling lights This switch operates optional Destination Sign when equipped This switch operates the optional in step heater when e...

Page 22: ...trol Mode cool off heat 3 Door Switch open or close passenger door Note Cool mode A C on both front 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 9 Rear Door Ajar Light WARNING DEVICE 6 7 8 3 2 5 4 1 9 ProCarManuals com RETURN TO MENU ...

Page 23: ...ases treble 10 VCP Stop stops tape 4 Radio Mode enables radio indicator light will be on 11 VCP Replay rewinds and replays from start of tape 5 PA 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 7 VCP Power 11...

Page 24: ...is auto matically engaged 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...

Page 25: ...Yellow Orange DIESEL RPM GAS RPM PTO 12V GND PTO ENGAGE PTO GND Ground Ground Ignition Fused Hot in Run 12V 12V OUT Orange To Ground High Idle switch wire optional E Series F Series 12V IN Black HIGH IDLE N C N C RPM1 RPM2 RPM3 BVP VAR Ground 10K 10Turn Potentiometer To 12V fused ignition Hot in Run User Interface Ford Diesel Engine ProCarManuals com RETURN TO MENU ...

Page 26: ...ge DIESEL RPM GAS RPM PTO 12V GND PTO ENGAGE PTO GND Ground Ignition Fused Hot in Run 12V E Series F Series N C RPM1 RPM2 RPM3 BVP VAR Ground 10K 10Turn Potentiometer To 12V fused ignition Hot in Run User Interface Orange LtBlue Orange Yellow Orange Orange White Orange White PTO RPM Select PTO Mode PTOIndicator Ford Gasoline Engine ProCarManuals com RETURN TO MENU ...

Page 27: ...ngine compartment drivers side E 450 Charge System Fuse located behind panel Rear Ignition Power Fuse shown with kick panel removed F 550 Charge Isolator Solenoid located in engine compartment drivers side F 550 Charge System and Rear Power Fuse located behind panel under steering column F 550 Charge System F 550 Charge System and Rear Power Fuse and Rear Power Fuse located behind panel located be...

Page 28: ...Diesel Engine Compartment E 450 2004 and Older Models E 450 Diesel Primary Battery Location Battery Location Under Floor Auxiliary Battery curb side for E 450 F 550 E 450 diesel shown E 450 2004 and Older Models 2005 E 450 Primary Secondary Slide Out Battery Compartment Located on Curb Side of Vehicle E 450 2005 and Newer Models ProCarManuals com RETURN TO MENU ...

Page 29: ...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 C A U T I O N Leaving the heated mirror switch on in hot weather may cause mirror to crack ProCarManuals com...

Page 30: ...tions 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 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 INFOR...

Page 31: ...anual be coming bright upon activation 2 A B 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 indica...

Page 32: ...h 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 SEE MANUFACTURERS LITERATURE FOR ADDITIONAL INFORMATION Rear Step Operational Schematic Operational Schematic Rear Step Switch Guard ProCarManuals com RETURN TO MENU ...

Page 33: ...e It operates the rear interior lights and also activates the door ajar light on the front overhead control panel This switch works in conjunction with the rear step allowing the power switch shown on previous page to enable or disable step operation Cargo Door Micro Switch Rear Door and Hinge Assy ProCarManuals com RETURN TO MENU ...

Page 34: ...lace To Lower 1 Rotate the Truss Lock C 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 A forward and lift the back cushion until the lever A has snapped back into the locked position Lift Rearward Lift Lever B Lever A Push Release Pull Towards Aisle Until Down Lock Engages Truss Lock C Rotate Clockwise To ...

Page 35: ...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 Do Not Exceed Weight Distribution Payload Limitations ProCarManuals com RETURN TO MENU ...

Page 36: ...er hand hole alignment 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 SEE MANUFACTURERS LITERATURE FOR ADDITIONAL INFORMATION 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 Wheel liners should only be removed using...

Page 37: ... 22 For information on A C charging specifications see the A C Charging Chart on page 67 Optional ACC Rear Air Conditioning This unit only operates when the dash A C is turned on A C only No Heat ACC Front Air Conditioning These units also provide heat when A C is not required by toggling switch on the overhead control panel ProCarManuals com RETURN TO MENU ...

Page 38: ...ses 38 Rear Floor Heater Assembly E 450 F 550 30 000 BTU Model 65 000 BTU Model Both units are turned on when the heat mode is selected on the Drivers Overhead Control Panel see page 22 ProCarManuals com RETURN TO MENU ...

Page 39: ...Krystal Enterprises 39 THIS PAGE IS INTENTIONALLY BLANK ProCarManuals com RETURN TO MENU ...

Page 40: ...nterprises 40 Standard Movable Wall Front View Movable Wall shown above in the forward position Caution When Adding Seating Do Not Ex ceed Weight Distribution Payload Limitations ProCarManuals com RETURN TO MENU ...

Page 41: ...he track 3 Disengage the top latches at the outside corners of the wall 4 From the front side of the wall loosen the bolts 5 With assistance on both sides of the wall push evenly on both sides and slowly move the wall to the desired position 6 When securing wall make sure to re torque all bolts to 35 ft lbs Note if seats are installed seat bolts must also be torqued to 35 ft lbs 7 Replace all plas...

Page 42: ...fore operating vehicle Movable Wall to the closed position no 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 sto...

Page 43: ... 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 To Open and Close E Z Move Wall ProCarManuals com RETURN TO MENU ...

Page 44: ...ove Wall Clamp Assemblies LH RH Lower Clamp Assembly LH shown Center Lower Clamp Assembly LH RH Ceiling Clamp Assembly RH shown SAFETY ALERT ALL CLAMPS MUST BE LOCKED DOWN BEFORE OPERATING VEHICLE ProCarManuals com RETURN TO MENU ...

Page 45: ...or hatch between the passenger seats midway back on the right side of the vehicle On the E 450 the air supply com pressor is located beneath the first right hand side passenger seat 1 Pre Filter 2 Air Dryer 3 Compressor 4 Check Valve 5 Pressure Switch 6 Over Temperature Sensor 7 Solenoid Switch 1 7 5 6 3 2 4 ProCarManuals com RETURN TO MENU ...

Page 46: ...re 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 Single Plug Door System door shown partially open Secondary Entry Door Switch used on air operated door systems located on passenger door post Closing Speed Valve Opening Speed Valve 4 Way Valve Closing Cushioning Valve Opening Cush...

Page 47: ...ompressed Air Schematic Single Plug Door CLOSE DOOR MOTOR OPEN OPEN VALVE CUSHIONING SPEED CONTROL VALVES BLUE AIR PILOT TEE YELLOW DOOR SWITCH ELECTRONIC PANEL 4 WAY SOLENOID VALVE CLOSE VALVE CUSHIONING DETAIL FOR 2005 NEWER MODELS FOR 2004 OLDER MODELS ProCarManuals com RETURN TO MENU ...

Page 48: ...he emergency release valve has been actuated by turning 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 about 10 to 30 mm before the final closing position If t...

Page 49: ... Plug Door System w Sensitive Edge doors shown partially open Electrical Schematic for Doors with Sensitive Edge For Larger Schematics See Electrical Section pg 108 109 Air Schematic for Double Plug Doors Air Schematic for Double Plug Doors ProCarManuals com RETURN TO MENU ...

Page 50: ...Service Dept at 1 800 Krystal 579 7825 Electric door motor with control arm Emergency Exit Lever Decal 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 Electric door motor Cover EMERGENCY EXIT PUSH DOORS OUT PUSH HANDLE LEFT NOTE LEVER MUST BE CHECKED DAILY PRIOR TO VEHICLE OPERATION...

Page 51: ...Krystal Enterprises 51 Swing Door System Electrical Schematic Swing Door System For Larger Schematics See Electrical Section pg110 111 F 550 Schematic E 450 Schematic ProCarManuals com RETURN TO MENU ...

Page 52: ...oor 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 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 g...

Page 53: ...wise to stop the platform make sure valve is tight but not over tight To Lower Platform and Roll Stop 1 Repeat step 1 in the previous procedure to lower the lift to the ground level To Fold Roll Stop and Raise Platform 1 Place the slotted 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 flo...

Page 54: ...x tends 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 C A U T I O N Never raise or lower lift if roll stop is malfunctioning Do not exceed the 800 pound load capacity of the lift Prior to lift operation the lift should be inspected for pro...

Page 55: ... level 2 Turn the release valve clockwise to stop the platform make sure valve is tight but not over tight To Lower Platform and Roll Stop 1 Repeat step 1 in the previous procedure to lower the lift to ground level To Fold Roll Stop and Raise Platform 1 Place the slotted 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 a...

Page 56: ...g and Unloading 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 Optio...

Page 57: ...ach the desired platform height To lower the platform turn the manual down valve SLOWLY counter clockwise to lower the platform To lower the front 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 Pus...

Page 58: ...xle Ratio Gas 4 63 Diesel 4 10 Rear Springs Leaf Shock Absorbers Gas Pressurized Engines 6 8 Liter Triton EFE V 10 Gas 6 0 Liter Power Stroke V 8 Diesel Fast Idle Controller Gas Penntex Diesel Ford or InterMotive Transmission Torque Shift 5 Speed Automatic w Tow Haul Mode Alternator Gas Pentex 200 Amp Diesel Ford Dual 110 Amp Batteries Chassis Dual 84 63 AMP HR 1400 CCA Batteries Coach Single 112 ...

Page 59: ...adlights Air Conditioner 8 000 BTU Cab with R 134a Heater Defroster 4 Speed Fan Safety 3 Point Shoulder Lap Belts Air Bags Dual Safety Restraint System Windshield Wipers Intermittent Gauges Instrumentation Voltmeter Oil Pressure Temperature Fuel Gauge Mirrors Heated Power Remote 10 x 7 Tires LT225 75R16 Wheels 16 5 8 Hole Stamped Steel Wheelbase KK22 158 KK24 176 KK28 209 Standard Chassis Specifica...

Page 60: ...Boards Captains Chairs Driver Co Pilot 3 4 Resin Laminated Floor 2 Fiberglass Insulation Commercial Grade Carpet Ribbed Rubber Aisle Mid High Seats with Level 3 Fabric 53 000 BTU A C System AM FM Stereo Cassette w CD Clock Power Cab Door Locks Power Cab Windows Back up Alarm Valance Lighting Air Actuated Sedan Entry Door Full Body Undercoating Base White Body Color Power Remote Heated Mirrors 80 T...

Page 61: ...age Constant Rate Auxiliary Shock Absorbers HD Gas Pressurized Engines 6 8 Liter Fuel Injected V 10 Gas Engine 6 0 Liter Power Stroke V 8 Diesel Fast Idle Controller Gas Penntex Diesel Ford or InterMotive Transmission Torque Shift 5 Speed Automatic w Tow Haul Mode Alternator Gas Pentex 200 Amp Diesel Ford Dual 110 Amp Batteries Chassis Dual Maintenance Free 78 Amp Hr 1300 CCA Batteries Coach Singl...

Page 62: ...isted Door Lights Halogen Sealed Beam Headlights Air Conditioner 8 000 BTU Cab with R 134a Heater Defroster 4 Speed Fan Safety 3 Point Shoulder Lap Belts w Adjustable D Rings Air Bags Dual Safety Restraint System Windshield Wipers Intermittent Gauges Instrumentation Tachometer Trip Odometer Voltmeter Oil Pressure Coolant Temperature Fuel Gage Indicator Lights Mirrors Heated Power Remote 10 x 7 Tir...

Page 63: ... Frame Cab Running Boards Captains Chair Driver Co Pilot 3 4 Resin Laminated Floor 2 Batted Fiberglass Insulation Commercial Grade Carpet Ribbed Rubber Center Aisle Mid High Seats with Level 3 Fabric 68 000 BTU A C System w Dual Compressors AM FM Stereo Cassette Power Cab Door Locks Power Cab Windows Back up Alarm Valance Lighting Air Actuated Sedan Style Entry Door Full Body Undercoating Base Whi...

Page 64: ...oor 30 x 64 30 x 64 30 x 64 30 x 64 30 x 64 Clear Door Opening Single Plug 29 x 81 29 x 81 29 x 81 29 x 81 29 x 81 Clear Door Opening Double Plug 40 40 40 40 40 Clear Door Opening Swing Doors 42 42 42 42 42 Clear Door Opening Wheelchair Lift Door 42 x 73 42 x 73 42 x 73 42 x 73 42 x 73 Exterior Height 112 112 112 114 114 Exterior Width excluding Mirrors 96 96 96 96 96 Exterior Width including Mirr...

Page 65: ...ngth 18 18 18 18 18 Floor Height from Ground at Rear 31 31 31 33 33 1st Step from Ground 11 11 11 12 12 Riser Height 6 6 6 9 9 Step Height 10 10 10 12 12 Movable Wall Depths approx E 450 36 40 30 32 28 36 N A N A Movable Wall Depths approx F 550 N A N A N A 29 63 30 54 UVL Wheelchair Lift Door Opening N A N A N A 42 42 ProCarManuals com RETURN TO MENU ...

Page 66: ...e 16 Aluminum Sidewall Material 063 One Piece Aluminum Roofing Material 040 Size of Steel Tubing used in Main Floor Structure 2 x 4 Center line Spacing of Tubing used in Floor Structure 32 max Gauge of Steel Tubing used in Floor Structure 12 Thickness of Double Backed Insulated Fiberglass Batting Insulation 2 Window Size 32 x 40 General Body Materials and Construction Measurements ProCarManuals com...

Page 67: ...000 BTU w FACTORY TIE IN w factory tie in 11 50 lbs 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 lbs E450 2000 with Carrier A C 68 000 BTU add on unit 5 00 lbs 40 000 BTU w FACTORY TIE IN w factory tie in 5 50 lbs Roof Top Carrier A C Ducted 7 0 lbs per compressor E450 w ACC 2004 2005 Models 68 000 BTU 4 vents 5 25 lbs 40 000 BTU w...

Page 68: ...he 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 specifi...

Page 69: ...LB 70 N m 25 FT LB 35 N m AIR SPRING CONNECTION ONLY 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 Note All bolt nut assemblies join ing the Ridewell hangers to the FORD frame must be torqued to 120 ft lbs dry or 90 ft lbs lubricated If any bolts are fo...

Page 70: ...ons 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 shoul...

Page 71: ...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 windshield washer fluid level and drain fuel filter water separator door linkage and pivot arm lubrication and lube rear Kwikee step i...

Page 72: ...e mechanism check the torque of all door hardware on Vapor door systems AT 10 000 MILES 1200 HOURS DO THE FOLLOWING change engine oil and replace oil filter 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 15 000 MILES 1800 HOURS DO THE FOLLOWING change engine oil and replace o...

Page 73: ...50 only inspect and lubricate steering idler arms replace cabin air filter if equipped inspect half shaft boots if equipped 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 hard...

Page 74: ...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 inspect tires for wear and inspect tread depth rotate tires replace engine air filter replace engine and frame mounted fuel filters inspect steering linkage suspension ball joints driveshafts and driveshaft guards inspe...

Page 75: ...ressor intake filter clean battery terminals lube door seals with silicon spray check for proper sealing 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 inspect drive belts and replace if necessary AT 35 000 MILES 4200 HOURS DO THE FOLLOWI...

Page 76: ...r hardware on Vapor door systems AT 45 000 MILES 5400 HOURS DO THE FOLLOWING change engine oil and replace oil filter inspect tires for wear and inspect tread depth rotate tires inspect engine air filter replace engine and frame mounted fuel filters inspect steering linkage suspension ball joints driveshafts and driveshaft guards inspect engine cooling system and hoses inspect brake system inspect ex...

Page 77: ... 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 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 cond...

Page 78: ...place engine and frame mounted fuel filters inspect steering linkage suspension ball joints driveshafts and driveshaft guards inspect engine cooling system and hoses 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 w...

Page 79: ...d electrical connections lube Vapor door rotary drive mechanism check the torque of all door hardware on Vapor door systems inspect drive belts and replace if necessary AT 65 000 MILES 7800 HOURS DO THE FOLLOWING change engine oil and replace oil filter 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...

Page 80: ...engine air filter replace engine and frame mounted fuel filters inspect steering linkage suspension ball joints driveshafts and driveshaft guards inspect engine cooling system and hoses inspect brake system inspect exhaust system and heat shields check wheels for end play and noise inspect and lubricate 4 x 2 ball joints E 450 only inspect and lubricate steering idler arms replace cabin air filter if...

Page 81: ...place oil filter inspect tires for wear and inspect tread depth rotate tires 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 inspect tires for wear and inspect tread depth rotate tires inspect engine a...

Page 82: ... heat shields check wheels for end play and noise inspect and lubricate 4 x 2 ball joints E 450 only inspect and lubricate steering idler arms replace cabin air filter if equipped inspect half shaft boots if equipped clean air compressor intake filter clean battery terminals lube door seals with silicon spray check for proper sealing re inspect torque settings on Ridewell Suspension System check air...

Page 83: ...ect 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 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 PREVENTIVE MAINTENANCE SCHEDULE ProCarManua...

Page 84: ...er 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 Check your FORD Owner s Guide Supplement for special operating condition mainte nance requirements that may ...

Page 85: ...Krystal Enterprises 85 85 Additional User Notes Additional User Notes User Notes Preventive Maintenance ProCarManuals com RETURN TO MENU ...

Page 86: ... Dept MOVING CARGO PARTITION TO ADD ADDITIONAL SEATING Caution Do Not Exceed Weight Distribution Payload Limitations Remove seats in front of the Partition Wall and loosen all four bolts securing the wall Then go behind the wall and remove the channel nut on the floor this will allow the wall to be move back and then additional seating can be installed Note torque Seat Bolts to 35 ft lbs EXTERIOR L...

Page 87: ... clean 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 apply 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...

Page 88: ... 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 INOPERAT...

Page 89: ...Krystal Enterprises 89 89 Troubleshooting Notes PROBLEM POSSIBLE SOLUTIONS ProCarManuals com RETURN TO MENU ...

Page 90: ...Krystal Enterprises 90 E 450 Circuit Board Assembly See fuse relay legend on next page Circuit Board located in compartment above driver ProCarManuals com RETURN TO MENU ...

Page 91: ...w 15A 3 A C Compressor 10A 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 30A Module 4 from left to right 1 Rear Condenser 20A 2 Front A C Mode 15A Relay Module Legend all amperage are maximum Relay Fuses Relay Fuses Power Solenoid Module 1 Module 2 Module 3 Module 4 Low Side Switching Controller High Side Switchin...

Page 92: ...Krystal Enterprises 92 E 450 Shuttle Bus Wiring Diagram Krystal Enterprises Ref Drwg 300 042 ProCarManuals com RETURN TO MENU ...

Page 93: ...n customer request Reference Table 1 Running Light 2 Running Light 3 Running Light 4 Side Marker Light 5 Running Light 6 Left Rear Cabin Speaker 7 Microswitch 8 Rear A C 9 Luggage Compart ment Light 10 Step Switch 11 Right Rear Cabin Speaker 12 Running Light 13 Running Light A C Tie In pass through harness to factory plug Rear Door Ajar warning light Charge Solenoid pass through leed Ref Drwg 300 ...

Page 94: ...ght Tail Lights Power Step License Plate Light Running Light Left Tail Light Back up Alarm DETAIL D Ground Wires Trailer Plug Connection attach harness to factory plug routed along chassis Rear Harness Configuration Ref Drwg 300 042 ProCarManuals com RETURN TO MENU ...

Page 95: ...Krystal Enterprises 95 95 THIS PAGE IS INTENTIONALLY BLANK ProCarManuals com RETURN TO MENU ...

Page 96: ...50 Circuit Board Assembly Ver 1 F 550 circuit board located above driver F 550 circuit board located above driver 13 14 15 16 17 18 19 20 21 22 23 24 25 26 IRD IRD 12 1 2 3 4 5 6 7 8 9 10 11 IRD ProCarManuals com RETURN TO MENU ...

Page 97: ...Krystal Enterprises 97 97 F 550 Circuit Board Ver 1 Electrical Diagram Relays Circuit Breakers Front A C Board ProCarManuals com RETURN TO MENU ...

Page 98: ...Krystal Enterprises 98 23 24 25 26 27 28 29 30 13 14 15 16 17 18 19 20 21 22 12 F 550 circuit board located above driver F 550 Circuit Board Assembly Ver 2 ProCarManuals com RETURN TO MENU ...

Page 99: ...Krystal Enterprises 99 99 F 550 Circuit Board Ver 2 Electrical Diagram Front A C Board Rear A C Board Circuit Breakers Relays ProCarManuals com RETURN TO MENU ...

Page 100: ...Krystal Enterprises 100 E 450 F 550 Modular Circuit Board Assembly Ver 3 1 12 14 15 16 13 10 7 8 9 11 17 18 2 4 5 6 3 33 34 30 31 32 29 21 22 23 20 19 25 26 27 24 28 ProCarManuals com RETURN TO MENU ...

Page 101: ... Heater Fan HIGH 15 amp fuse max 14 ga Red Blk 10 Door Interlock Relay 27 Heater Fan LOW 10 amp fuse max 14 ga Yell Red 11 Rear Condenser Relay 28 Heater Relay Coil 3 amp fuse max 18 ga Red 12 Reading Lights 15 amp fuse max 29 Ignition Fuse Block Module 13 Reading Lights 15 amp fuse max 30 High Idle 7 5 amp fuse max 14 ga Org Blk 14 Clearance Lights 10 amp fuse max 31 Television 10 amp fuse max 14...

Page 102: ...itch 18 Ga Wht to 5 min timer 18 ga Wht Blk 2 To Door 16 Ga Blu Wht 420C 3 Heat Valve Trigger 18 Ga Grn Blk 4 Heat Valve 14 Ga Grn 400 5 Coil 3 Not Used 6 Output 3 Not Used PIN 5 P I N C O N N E C TO R 1 To Interior Light Switch 18 Ga Yel to 5 min timer side 18 Ga Yel Blk with Diode 2 Interior Lights 14 Ga Yel 350 B 3 To Interior Light Switch 18 Ga Yel 4 Interior LIghts 14 Ga Yel 350 A 5 Coil Comm...

Page 103: ...5 6 1 2 3 5 B PIN 6 P I N C O N N E C TO R 1 From Reading Light 18 Ga Wht Pupl 2 To Reading Lights D 16 Ga Org 700 3 Jumper from Pin 1 18 Ga Wht Pupl 4 To Reading Lights E 14 Ga Org 700 5 Clearance Lights F 16 Ga Brn Wht 230 6 Clearance Lights G 14 ga Brn 230 PIN 5 P I N C O N N E C TO R 1 Clearance Lights Jumper 16 Ga Brn Wht 230 2 Clearance Lights H 14 Ga Brn 230 3 Not Used 4 Not Used 5 Coil Com...

Page 104: ... A C unit requires one 1 module each These modules are mounted in the header above the driver behind the driver s control panel ITEM NO DESCRIPTION COMMENT 1 7 5 amp Compressor Fuse 2 30 amp Condensor Fuse 3 35 amp High Side Fuse 4 20 amp Low Side Fuse 5 Compressor Relay 6 Condenser Relay 7 High Side Relay 8 Low Side Relay As used on 2004 later models ProCarManuals com RETURN TO MENU ...

Page 105: ...Krystal Enterprises 105 105 Detail of A C Module wiring as shown in photos on pg 104 REF RELAYS REF FUSES Front Rear A C Module Wiring Diagram ProCarManuals com RETURN TO MENU ...

Page 106: ...4 GA RED BLK TO IGNITION FUSE 16 GA RED BLK TO LOAD L 18 GA RED BLK TO SWITCH PANEL 16 GA RED IGNITION FUSE BLOCK 14 GA YELL RED TO IGNITION FUSE 14 GA YELL RED TO LOAD M 18 GA YELL RED TO SWITCH PANEL 16 GA RED IGNITION FUSE BLOCK 16 GA ORG BLK TO IGNITION FUSE 16 GA ORG BLK TO MAIN PLUG U 18 GA ORG BLK TO A C MODE SWITCH 16 GA WHT GROUND 16 GA ORG BLU TO A C MODULES 16 GA WHT GROUND 16 GA GRN WH...

Page 107: ...Krystal Enterprises 107 107 F 550 Shuttle Bus Wiring Diagram ProCarManuals com RETURN TO MENU ...

Page 108: ...Krystal Enterprises 108 Air and Electrical Diagrams Schematics Double Plug Air Door Schematic ref pg 49 ProCarManuals com RETURN TO MENU ...

Page 109: ...terprises 109 109 Air and Electrical Diagrams Schematics Electrical Schematic for Doors with Sensitive Edge ref pg 51 Electrical Schematic for Doors with Sensitive Edge ref pg 53 ProCarManuals com RETURN TO MENU ...

Page 110: ...Krystal Enterprises 110 Air and Electrical Diagrams Schematics E 450 Electrical Schematic for Swing Doors System ref pg 51 ProCarManuals com RETURN TO MENU ...

Page 111: ...Krystal Enterprises 111 111 F 550 Electrical Schematic for Swing Door System ref pg 51 Air and Electrical Diagrams Schematics ProCarManuals com RETURN TO MENU ...

Page 112: ...NTERPRISES serial number which starts with K 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 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 i...

Page 113: ...nversion 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 bu...

Page 114: ... 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 ser...

Page 115: ... KRYSTAL SERVICE DEPARTMENT at 1 800 845 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 the 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 manag...

Page 116: ...l FREEDMAN SEATING 1 713 929 6100 2 Years or 20 000 Miles Whichever Comes First PHOENIX USA 1 931 561 6128 3 Years KRYSTAL SERVICE DEPT 1 800 579 7825 See Copy of Krystal Warranty KWIKEE ELECTRIC STEPS 1 800 736 7366 1 Year or 12 000 Miles Whichever Comes First MICHELIN TIRES 1 800 847 8475 1 Year Replacement No Charge PENNTEX ALTERNATORS 1 800 590 2818 18 Months or 75 000 Miles Whichever Comes Fi...

Page 117: ...E 1 810 274 9400 1 Year Unlimited Miles VELVAC MIRRORS 1 800 783 8871 1 Year Unlimited Miles VOYAGER PA SYSTEM 1 800 274 1886 1 Year Unlimited Miles INTERMOTIVE VEHICLE CONTROLS 1 530 823 2332 2 Years or 24 000 Miles Vendor Warranty Period ProCarManuals com RETURN TO MENU ...

Page 118: ...ir Schematic Single Double Plug Doors 47 49 Audio Video PA Control 23 B Back Up Camera 31 Battery Location 28 Body Materials Construction Measurements 66 Braun Rear Door Wheelchair Lift 52 C 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 2 96 98 INDEX ProCarManuals com RETURN TO MENU ...

Page 119: ... 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 Schematics misc enlargements 107 111 Electrical Schematic sensative edge swing door 49 108 109 Emergency Egress Window 18 Emergency Release Lever 11 13 Emergen...

Page 120: ...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 I 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 INDEX ProCarManuals com RETURN TO MENU ...

Page 121: ...Edge 11 Occupant Restraint Systems ADA 14 Overhead Control Panel 20 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 INDEX ProCarManuals com RETURN TO MENU ...

Page 122: ...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 Swing Door System 50 Switches mirror micro pressure door step 22 29 33 45 46 48 T TOWING 113 Troubleshooting Guide 86 V Vapor Air Electric Door Safety Alerts 11 VEHICLE SAFETY WARNINGS 10 Vendor Reference Listing 116 INDEX ProCarManuals...

Page 123: ...ery door open 21 WARRANTY 112 113 114 115 WARRANTY POLICY 112 WARRANTY REPAIRS 114 115 WARRANTY SERVICE 113 Wheelchair Lift Braun 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 INDEX ProCarManuals com RETURN TO MENU ...

Page 124: ...he 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 purcha...

Page 125: ...ke 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 infl...

Page 126: ...eviously 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 ...

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