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Krystal Enterprises
103103
E-450 & F-550 Front & Rear A/C Module
As used on 2004 & later models
ITEM NO
DESCRIPTION
COMMENT
7.5 amp Compressor Fuse
30 amp Condensor Fuse
35 amp High Side Fuse
20 amp Low Side Fuse
Compressor Relay
Condenser Relay
High Side Relay
Low Side Relay
These modules are used to control all A/C functions for the front and rear A/C units. Each A/C unit requires one (1) module each. These modules are mounted in the header above the driver, behind the driver’s control panel.
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Front/Rear A/C Module Wiring Diagram
REF: RELAYS
REF: FUSES
Detail of A/C Module wiring as shown in photos on pg. 104
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E-450 & F-550 RELAY BUSS VER D
HEATER FAN HIGH
HEATER FAN LOW
HIGH IDLE
SPARE
REAR CONDENSER
85
30
87a 87a 87
86
85
30
87a 87a 87
86
85
8530
87a 87a 87
86
85
30
87a 87
86
85
8530
87a 87a 87
86
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F-550 Shuttle Bus - Wiring Diagram
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Air and Electrical Diagrams & Schematics
Double Plug Air Door Schematic (ref. pg 49)
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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)
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Air and Electrical Diagrams & Schematics
E-450 Electrical Schematic for Swing Doors System (ref. pg. 51)
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Air and Electrical Diagrams & Schematics
F-550 Electrical Schematic for Swing Door System (ref. pg 51)
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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 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 fi rst, 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.
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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 fl at bed rig is preferred. UNDER NO CIRCUMSTANCES, should the bus be towed by lifting the rear end, serious frame damage can occur.
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PARTS - SERVICE - WARRANTY
WARRANTY VERSUS NON- WARRANTY
Whether a particular problem 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
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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- 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 manager at:
KRYSTAL ENTERPRISES Attn: Service Department Manager 2701 East Imperial Highway Brea, California 92821
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Vendor Reference Listing
Vendor
Warranty Period
AUTOMOTIVE CLIMATE CONTROL A/C 1-800-462-6322
AUDIOVOX TV & VCP 1-800-274-1886
CARRIER A/C 1-800-673-2431
FIRESTONE TIRES 1-800-356-4644
FORD HOTLINE 1-800-343-5338
FORD ROADSIDE ASSISTANCE 1-800-241-3673 (24 HOUR HOTLINE) FREEDMAN SEATING 1-713-929-6100
PHOENIX USA 1-931-561-6128
KRYSTAL SERVICE DEPT 1-800-579-7825
KWIKEE ELECTRIC STEPS 1-800-736-7366
MICHELIN TIRES 1-800-847-8475
PENNTEX ALTERNATORS 1-800-590-2818
ROSEN 1-866-467-6736
PANASONIC 1-949-251-1851
SHURFLOW WATER PUMPS 1-800-854-3218
SONY STEREO 1-800-282-28482 Years, Unlimited Miles 1 Year, Unlimited Miles 2 Years, Unlimited Miles 1 Year Replacement, No Charge 3 Years, 36,000 Miles Bumper to Bumper 3 Years, 100,000 Miles on Diesel Engine
See FORD Manual
2 Years or 20,000 Miles, Whichever Comes First 3 Years See Copy of Krystal Warranty 1 Year or 12,000 Miles, Whichever Comes First 1 Year Replacement, No Charge 18 Months, or 75,000 Miles, Whichever Comes First 1 Year, Unlimited Miles 1 Year, Unlimited Miles 2 Years, Unlimited Miles 1 Year, Unlimited Miles
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Vendor Reference Listing
Warranty Period
Vendor
TRANSPEC WORLDWIDE 1-810-274-9400
VELVAC MIRRORS 1-800-783-8871
VOYAGER PA SYSTEM 1-800-274-1886
INTERMOTIVE VEHICLE CONTROLS 1-530-823-23321 Year, Unlimited Miles 1 Year, Unlimited Miles 1 Year, Unlimited Miles 2 Years or 24,000 Miles
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INDEX
A/C Module-Frt & Rear 2004 104
Accessory Switches 21
Air and Electrical Diagrams & Schematics 108
Air Conditioning 37
Air Conditioning Charging Chart 67
Air Door Lock Pin 16
Air Schematic, Single & Double Plug Doors 47, 49
Audio/Video. PA Control 23
Back-Up Camera 31
Battery Location 28
Body Materials & 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 & 2 96, 98118
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INDEX
Circuit Board Assembly Ver. 3 100
Compressed Air Supply & Schematic, single & double plug door 45, 47, 49
Construction Materials & Measurements 66
Dimensional Specifi cations, Boby & Chassis 64
Double Plug Door System 48, 49
E-450 & F-550 Modular Circuit Board Assembly Ver. 3 100
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
Emergency Release Valve 8, 11, 12, 48
Emergency Roof Hatch 19Krystal Enterprises
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INDEX
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
GENERAL VEHICLE SAFETY WARNINGS 10
Heated Mirror Switch 29
High Idle Controller 24, 25, 26
Hour Meter 21
Identifi cation Label, Vehicle Manufacturers 68
Idle Controller 24, 25, 26
LCD Monitor, ref back-up camera 31
Low Air warning light 21
Low Battery Light 21120
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INDEX
Micro Switch 33
Mirror Control Switch 29
Mirror Switch 29
Movable Wall 40, 42
Obstruction Sensing System, Sensative Edge 11
Occupant Restraint Systems, ADA 14
Overhead Control Panel 20, 22
Overhead Parcel Rack 17
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
Rear Step 32
Ricon Rear Door Wheelchair Lift 54Krystal Enterprises
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INDEX
Ridewell Air Suspension Chart 69
Safety Check List, Vapor Air & Elect Door 11
Seating, Std. Passenger & Foldaway 34, 35
SERVICE, Warranty 112, 113, 114, 115, 116
Single Plug Door System 46, 47
Specifi cation for E450, Std Chassis 58, 59
Specifi cation 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
TOWING 113
Troubleshooting Guide 86
Vapor Air & Electric Door Safety Alerts 11
VEHICLE SAFETY WARNINGS 10
Vendor Reference Listing 116122
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INDEX
Video Entertainment Center 30
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 & 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 107Krystal Enterprises
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KRYSTAL ENTERPRISES
LIMITED WARRANTY
Krystal Enterprises (hereinafter referred to as Krystal Enterprises and Krystal) is the fi nal 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 specifi cally 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 defi ned as the cage, skin, front and rear caps, and fl oor structure to be free from defects, in material and workmanship under normal use and service for fi ve (5) years or 100,000 miles, whichever comes fi rst, 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 KRYSTAL 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
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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.
If 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 infl uences, 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 replacement 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
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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
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