Ford Econline Super Duty Triton V10 Bus 1998 Owner's Manual
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.
2701 East Imperial Highway Brea, California 9282
(714) 986-1200
Krystal Enterprises
4
T A B L E O F C O N T E N T S
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 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 Controller Wiring Diagram - Gasoline 26
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Krystal Enterprises
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T A B L E O F C O N T E N T S
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 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 Series (Under Vehicle) Wheelchair Lift
56
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Krystal Enterprises
6
T A B L E O F C O N T E N T S
SPECIFICATION
Standard Chassis Specifi cation for E450 Super Duty RV Cutaway 58
Standard Equipment on E450 Shuttle Buses 60
Standard Chassis Specifi cation for F550 Super Duty Cab & Chassis 61
Standard Equipment on F550 Shuttle Buses 63
General Vehicle Dimensional Specifi cations-Body & Chassis by Model 64
General Body Material and Construction Measurements 66
Air Conditioning Charging Chart 67
Vehicle Manufacturers Identifi cation Label 68
Ridewell Air Suspension Chart 69
PREVENTATIVE CARE & MAINTENANCE
Preventative Maintenance Schedule 70
TROUBLE SHOOTING
Basic Troubleshooting Guide 86
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Krystal Enterprises
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T A B L E O F C O N T E N T S
ASSEMBLIES & SCHEMATICS - AIR & 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 & 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 - WARRANT
Y 112
VENDOR REFERENCE LIST 116
INDEX 118
KRYSTAL ENTERPRISES VEHICLE WARRANTY 124
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Krystal Enterprises
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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
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Item Inspection Procedure Pass Fail
1 Check preventative maintenance schedule: for services due at present mileage
2 Check operation of: drivers seat and seat belt
3 Check operation of: steering wheel and shift levers
4 Check operation of: turn indicators
5 Check operation of: foot pedals and parking brake
6 Check operation of: all gauges, for normal readings with engine running
7 Check operation of: dash indicator lights with key on, engine not started, then again with
engine started
8 Check 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: fi re extinguisher, warning refl ectors and fi rst aid kit
Check: all doors, glass and windows: for operation, cleanliness, and damage.
11
12 Check: all emergency exits for operation, warning devices, markings, to be free and clear
13 Check interior lighting: for operation and damage
14 Check Side Passenger Entry Door - Emergency Exit Operation & Sensitive Edge if equipped
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Pre-Trip Inspection (suggested minimum)
Item Inspection Procedure Pass Fail
15 Check Side Passenger Entry Door: for damage and proper closing operation
16 Check exterior lighting: for operation and damage
17 Check exterior: for cleanliness, markings and damage
18 Check fuel cap: in place and secure
19 Check all tires and wheels: for tread depth, cracks & bulges, missing lug nuts, and air
pressure 80 psi for E-450 and 95 psi for F-550
20 Check: oil level
21 Check: transmission fl uid level
22 Check: engine coolant level
23 Check: power steering fl uid level
24 Check: brake fl uid 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 and securement station equipment
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
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Krystal Enterprises
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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 UNTIL ALL PROBLEMS
HAVE 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 TRAILER
DO NOT ATTEMPT TO TOW OR PULL ANOTHER VEHICLE WITH THIS BUS.
GENERAL VEHICLE SAFETY WARNINGS
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Krystal Enterprises
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Vapor Air & Electric Door Operational Safety Check List
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 fi nal 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.
WHEN OPERATING A VEHICLE WITH A VAPOR DOUBLE PANEL AIR OR ELECTRIC
ACTUATED PASSENGER ENTRANCE DOORS, THE FOLLOWING PRECAUTIONS
SHOULD BE TAKEN.
ATTENTION
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.
AIR DOORS
ELECTRIC DOORS
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Krystal Enterprises
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Air Door Emergency Release Valve
C A U T I O N !
For 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
U
N
T
E
R
C
L
O
C
K
W
I
S
E
NOTE:
VALVE MUST BE CHECKED DAILY,
PRIOR TO VEHICLE OPERATION
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Krystal Enterprises
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Electric Door Emergency Release Lever
Emergency Exit Lever Decal
EMERGENCY 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
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Krystal Enterprises
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Wheelchair Securement and Occupant Restraint Systems
Pre-Trip Inspection
Is 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 replacement of the entire strap or belt assembly.
Are all fl oor anchorages, (i.e., tracks or plates), clear of dirt or debris to allow for proper system fi tting
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 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!
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Krystal Enterprises
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Typical Wheelchair Securement Methods
Rear Strap Attachment
Lap Belt Attachment
Front Strap Attachment
For Specifi c Operating Instructions and System Care
and Maintenance, Refer to Your Kinedyne Literature
With the wheelchair and occupant
facing toward the front of the vehicle,
center the wheelchair between the fl oor
tracks or plates. As you position
the wheelchair, remember that
the securement straps need to
have approximately a 45°
angle from the fl oor tracks
or plates to where they
attach to the frame. Also,
keep in mind the proper
extension and placement of the occupant
restraint shoulder
belt. Apply the
wheel locks
or turn off
Typical 4-Point Restraint with Lap & Shoulder Belt
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Krystal Enterprises
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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.
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Krystal Enterprises
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Dual Overhead Parcel Rack
CAUTION!
Do not overload Parcel Racks.
Do not fasten parcels to retainer
bars.
Overhead Parcel Rack (right side shown)
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Krystal Enterprises
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Emergency 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
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Krystal Enterprises
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Emergency Roof Hatch Exit
This is a Dual Purpose hatch used for
Emergency Egress and Ventilation purposes.
SEE MANUFACTURERS LITERATURE
FOR ADDITIONAL INFORMATION
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 graffi ti, it is the customers
responsibility to ensure cleaning solutions are compatible with the materials used on Safety Vents. Solutions
containing, acetone, ether, lacquer thinner, or other solvents can destroy the high strength properties of many
engineering plastics - AVOID these cleaners
EM ERGENCY E XI T
1
2
PUSH BLACK TAB
PUSH HANDLE OUT
For Emergency Exit
VENT HANDLE
PUSH UP
TO OPEN
Pull DOWN
TO CLOSE
For Ventilation
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Krystal Enterprises
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Overhead Control Panels Assemblies
E-450 Overhead Control Panel
F-550 Overhead Control Panel
E-450 with PA in Console
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Krystal Enterprises
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Controls - Indicator and Accessory Switches
When the Low Air warning light
is lit, this indicates the normal
operating air supply has fallen
below safe operating levels
Discontinue Operation
The Hour Meter accumulates
the number of hours your ignition 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 equipped.
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Krystal Enterprises
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Drivers Overhead Control Panel
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 & 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 7 832 541 9
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Krystal Enterprises
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Audio/Video PA Control
SEE MANUFACTURERS LITERATURE FOR ADDITIONAL INFORMATION
1 On/Off Volume Control - controls power and volume 8 VCP Play - starts the tape playing
2 Bass Control - increases or decreases bass 9 VCP Fast Forward - fast forwards tape
3 Treble Control - increases or decreases 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
9
5
1
10
12
13
3
6
7
8
4
2
FRONT VIEW
REAR VIEW
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Krystal Enterprises
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HIC900 Throttle Controller Operating Procedures
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 (speed=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˚ F.
Engine Coolant Temperature below 230˚ F.
Brake Lights Functional
Foot Off Accelerator Pedal
AUTOMATIC BATTERY CHARGE PROTECTION
Any time your vehicle is Powered-up”, Charge Protection is automatically 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 PROTECTION” OR “FAST IDLE” Do the following:
Press the Manual Engage button on the DRIVERS OVERHEAD
CONTROL PANEL and release.
Fast Idle system will only be turned off when the button is released.
To exit “AUTOMATIC CHARGE PROTECTION Mode”, simply
depress the service brake pedal. See the Off Road Engineering
literature for specifi c details regarding other operating parameters.
Quick Reference Guide
Fast Idle Switch is shown as mounted
on Driver’s Overhead Control Panel (ref. page 20)
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Krystal Enterprises
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HIC900 Throttle Controller Wiring Diagram - DIESEL
Vehicle SEIC Wiring
Diesel Engine SEIC Wires
Orange/Yellow
PTO_RPM
PTO
Purple/Lt Blue
Orange/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
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Krystal Enterprises
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HIC900 Throttle Controller Wiring Diagram - GASOLINE
Vehicle SEIC Wiring
Gasoline Engine SEIC Wires
Orange/Yellow
PTO
Engage
Orange/Lt Blue
Orange
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/Lt Blue Orange/Yellow Orange
Orange/White
Orange/White
PTO RPM
Select
PTO ModePTO Indicator
Ford Gasoline Engine
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Krystal Enterprises
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Charge Protection System Components
E-450 Charge Isolator
Solenoid located in
engine compartment
-drivers side.
(diesel version shown)
Gas version is located
below primary battery.
F-550 Charge Isolator
Solenoid (located in engine
compartment-drivers side)
E-450 Charge System Fuse,
located behind panel & Rear
Ignition Power Fuse (shown
with kick panel removed)
Solenoid (located in engine
compartment-drivers side)
F-550 Charge System
and Rear Power Fuse
(located behind panel
under steering column)
and Rear Power Fuse
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Krystal Enterprises
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Battery Location - Primary and Secondary
F-550 Primary Battery LocationF-550 Primary Battery Location F-550 Diesel Engine Compartment
E-450 Diesel Engine Compartment
E-450 2004 and Older Models
E-450 Diesel Primary
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
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Krystal Enterprises
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E-450 Heated Mirror Switch and Mirror Control Switch
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 position 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.
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Krystal Enterprises
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Video Entertainment Center
Bulkhead Mounted TV and DVD
Basic Operating Instruction
Bulkhead mounted TV and DVD
[The TV may be viewed with
or without using the DVD]
For specifi c 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(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
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