Krystal Enterprises 3200 International Chassis Bus Owner's Manual
広告
広告
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 International Chassis models, and is designed to be used in conjunction with the original chassis manufacturer’s owner’s literature, as well as all other component manufacturers literature.
IMPORTANT: PLEASE READ CAREFULLY
For your safety and the safety of others, we ask that you completely familiarize yourself with this manual, and all other operators manuals before you operate this vehicle for the first time.
KRYSTAL ENTERPRISES
2701 East Imperial Highway Brea, California 92821
(800) KRYSTAL (579-7825) (714) 986-1200
4
TA B L E O F C O N T E N T S
SAFETY
Pre-Trip Inspection (suggested minimum)
General Vehicle Safety Warnings
Vapor Door Operational Safety Check List
Air Door Emergency Release Valve
Electric Door Emergency Release Lever
Wheelchair Securement and Occupant Restraint Systems
Emergency Egress Window Operation
OPERATION
Controls and Accessory Functions
Blank Page
Load Shed & High Idle Charge Protection Operating Procedures
CLICK ON THE DESCRIPTION TO GO TO THAT PAGE
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11
12
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TA B L E O F C O N T E N T S
High Idle Charge Protection Operating Controls
Battery Location - Primary and Secondary
Window, Door, Mirror and Light Control Switches
Back-Up Camera Controls and Operation
Air Operated - Single Plug Door
Air Operated - Single Plug Door
Air Operated - Double Plug Door with Lower Air Step
Braun Rear Door Wheelchair Lift
Ricon Rear Door Wheelchair Lift
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48
35
36
38
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54
31
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34
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CLICK ON THE DESCRIPTION TO GO TO THAT PAGE
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TA B L E O F C O N T E N T S
SPECIFICATION
Standard Chassis Specifi cation for 31’ & 35’
Standard Equipment for 31’ & 35’
Standard Chassis Specifi cation for 38’
General Vehicle Dimensional Specifi cations-Body & Chassis by Model
General Body Material and Construction Measurements
Vehicle Manufacturers Identifi cation Label
PREVENTATIVE CARE & MAINTENANCE
Preventative Maintenance Schedule
TROUBLE SHOOTING
ASSEMBLIES & SCHEMATICS - AIR & ELECTRIC
INTERNATIONAL Diamond Logic Electrical System
Legend for Standard Fuse & Circuit Breaker Panel
CLICK ON THE DESCRIPTION TO GO TO THAT PAGE
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56
58
59
61
90
92
TA B L E O F C O N T E N T S
Legend for Optional Fuse & Circuit Breaker Panel
Carrier Rooftop Air Conditioning System Diagrams
Model 35 & 38 Accessory Harness-Front Portion
Model 35 & 38 Accessory Harness-Rear Portion
Model 35 & 38 Accessory Harness-Legend
Model 35 & 38 Accessory Harness-Body Wiring Diagram Part 1 & 2
Front/Rear A/C Module Wiring Diagram
Circuit Board Assembly Phase 1
Circuit Board Assembly Phase 2
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105
106
108
KRYSTAL ENTERPRISES VEHICLE WARRANTY
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120
CLICK ON THE DESCRIPTION TO GO TO THAT PAGE
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8
Pre-Trip Inspection (suggested minimum)
Any item not passing inspection, must be reported immediately, before operating vehicle
Item
FAILURE OF HIGHLIGHTED ITEM(S) TO PASS INSPECTION WILL CAUSE VEHICLE TO BE GROUNDED
Inspection Procedure
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
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 clear
13 Check interior lighting: for operation and damage
14 Check Side Passenger Entry Door - Emergency Exit Operation (see page 11,12,13)
Pass Fail
Pre-Trip Inspection (suggested minimum)
Any item not passing inspection, must be reported immediately, before operating vehicle
Item
FAILURE OF HIGHLIGHTED ITEM(S) TO PASS INSPECTION WILL CAUSE VEHICLE TO BE GROUNDED
Inspection Procedure
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 100 psi Frt/Rr for KK35, and 120 psi Frt & 100 psi Rr for KK38
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
Pass Fail
9
10
GENERAL VEHICLE SAFETY WARNINGS
CAUTION - VERY IMPORTANT
NO STANDEES ARE ALLOWED,
AT ANY TIME WHILE THE VEHICLE IS IN MOTION.
DISCONTINUE OPERATION OF THE VEHICLE, WHEN THE LOW AIR
WARNING LIGHT OR BUZZER ON INSTRUMENT CLUSTER ACTIVATE,
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 ARE RESOLVED.
AIR DOOR EMERGENCY RELEASE VALVE, MUST BE OPERATED
DAILY, PRIOR TO VEHICLE OPERATION
Caution!
UNDER EMERGENCY
SITUATIONS, (IF EQUIPPED) THE BOTTOM AIR STEP WILL NOT DEPLOY.
Vapor Air & Electric Door Operational Safety Check List
ATTENTION
WHEN OPERATING A VEHICLE WITH A VAPOR DOUBLE PANEL AIR OR ELECTRIC
ACTUATED PASSENGER ENTRANCE DOORS, THE FOLLOWING PRECAUTIONS
SHOULD BE TAKEN.
AIR DOORS - SINGLE or DOUBLE
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.
Caution!
UNDER EMERGENCY SITUATIONS, (IF EQUIPPED) THE BOTTOM
AIR STEP WILL NOT DEPLOY.
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 sensi-
ELECTRIC DOORS
The Emergency Release Lever System (must be checked on a daily basis)
Once the emergency release lever has been actuated (by pushing the red handle from right to left as indicated on the sticker), it should then be possible to open the doors by pushing the panels outward with your hand.
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12
Air Door Emergency Release Valve
EMERGENCY USE ONLY
CAUTION!
UNDER
EMERGENCY
SITUATIONS,
(IF EQUIPPED) THE
BOTTOM AIR STEP
WILL NOT DEPLOY.
C
OU
N
T ER
CLO C
K
WI
S
E
ACTION:
VALVE MUST BE OPERATED DAILY,
PRIOR TO VEHICLE OPERATION
EMERGENCY OPERATION
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.
Electric Door Emergency Release Lever
Electric Door Motor Cover
EMERGENCY EXIT
PUSH HANDLE LEFT
PUSH DOORS OUT
EMERGENCY EXIT
PUSH HANDLE LEFT
PUSH DOORS OUT
Emergency Exit Lever Decal
EMERGENCY EXIT
PUSH HANDLE LEFT
PUSH DOORS OUT
Emergency Exit Lever
ACTION:
LEVER MUST BE CHECKED DAILY,
PRIOR TO VEHICLE OPERATION
EMERGENCY USE ONLY
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14
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!
Front Strap Attachment
Typical Wheelchair Securement Methods
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 the power if motorized.
Rear Strap Attachment
Typical 4-Point Restraint with Lap & Shoulder Belt
For Specifi c Operating Instructions and System Care and Maintenance, refer to your Kinedyne Literature
Lap Belt Attachment
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16
Air Door Lock Pin Assembly
CAUTION!
UNDER EMERGENCY
SITUATIONS, (IF EQUIPPED)
THE BOTTOM AIR STEP WILL
NOT DEPLOY.
CAUTION!
Security Pin must be removed during bus operation.
Pin is only to be used for security, if bus is not in operation.
Dual Overhead Parcel Racks
Overhead Parcel Rack for models 31 & 35 only
(curb side shown)
Overhead Parcel Rack for models 35 & 38 only with Roof Top Ducted A/C
(street side shown)
CAUTION!
Do not overload Parcel Racks. Do not fasten parcels to retainer bars.
17
Emergency Egress Window Operation
18
Lift up on lever to disengage latch
Pull down on lever to disengage latch
GL20 Touring Window
Windows with Emergency Exit stickers are designated emergency exits. Follow the directions on the sticker.
Disengage latches and push windows out
Panoramic Frameless Window
Emergency Roof Hatch Exit
This is a Dual Purpose hatch used for
Emergency Egress and Ventilation purposes.
SUGGESTED MAINTENANCE
Periodically inspect attaching fasteners for evidence of loosening due to tampering, and regularly clean surface with a mild soap and water.
CAUTION: When removing 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
SEE MANUFACTURERS LITERATURE
FOR ADDITIONAL INFORMATION
For Emergency Exit
Turn Red Handle Clockwise,
Then Push Knob to Open
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20
G
F
H J K
In Dash Control Panel
Switches 1 - 6
A B
D
C
E
Switches 7 - 12
Switches 13 - 18
Component Legend
A Air Park Brake **
B Front Fan Switch Hi-Low-Off
C Rear Fan Switch Hi-Low-Off
D Climate Control Cool-Heat-Off
E Auxiliary
F AM/FM - CD
G Audio/Video PA
H Fan Control Speed
J Temp Control
K Front A/C Control
** Air Brake is Standard with LCT
Transmission and Optional with
WTEC Transmission
N
In Dash Control Panel Switches and Components
Carrier Sutrak Controls for Roof Mounted A/C
Component Legend (cont)
O
P
Q
R
L Fan Switch - Carrier Sutrak
M Temp Control - Carrier Sutrak
N 12 Volt Access
L
M
Dash Panel Switch Legend
1 Air Suspension Dump - DUMP/SUSP
2 Heated Mirror - ON/OFF
3 BLANK
4 BLANK
5 Luggage Door Ajar Warning Light
6 Passenger Door Ajar Warning Light
7 Cabin Light - ON/OFF
8 Map Light - ON/OFF
9 Bath Pump - ON/OFF
10 Floor Heater - ON/OFF
11 Floor Heater - HI/LO
12 Load Shed - ON/OFF
13 BLANK
14 BLANK
15 BLANK
16 BLANK
17 BLANK
18 BLANK
21
2 3 4 6 7 8 13
22
1 5 9 10
FRONT VIEW
11 12
REAR VIEW
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
4 Radio Mode - enables radio, indicator light will be on
10 VCP Stop stops tape
11 VCP Replay - rewinds and replays from start of tape
5 PA Mode - enables PA , indicator light will be on
6 VCP Mode - enables VCP, indicator light will be on
12 VCP Rewind - rewinds tape
13 Paging Mode - (Internal or External) press button once to engage system, press again to toggle between internal/external
7 VCP Power
SEE MANUFACTURERS LITERATURE FOR ADDITIONAL INFORMATION
THIS PAGE IS INTENTIONALLY BLANK
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Video Entertainment Center
24
Bulkhead Mounted LCD Monitor
Ceiling Mounted CRT Monitor
Basic Operating Instruction
LCD Monitor
[ The TV cannot be viewed without fi rst truning on the DVD]
For specifi c Operating Instructions, Check
Your Component information.Manual
Under Loft LCD Monitor
1. After truning on the DVD, turn on the TV using the power on the TV or the button on the
TV remote.
(Note: TV must be set to Video #1 for DVD to work)
2. To view TV, push the TV/Video button to switch between TV and DVD(Video).
3. To view movies select DVD, from the on screen menu.
4. The DVD buttons on the remote will now operate all the functions of the DVD.
Dash Mounted DVD Player
Components shown here may vary from what you have installed in your vehicle.
To view the TV, the DVD Player must be turned on.
Next set the DVD to TV by using the remote control.
See manufacturers literature for operating instructions on your specifi c component
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26
Load Shed & High Idle Charge Protection Operating Procedures
Load Shed System Reference Guide
The Load Shed portion of your vehicles Charge Protection System, is engaged by pressing the switch marked
“Load Shed” on the dash. Once engaged, this system monitors system voltage and automatically shuts down vehicle functions as necessary, to maintain the proper specifi ed voltage levels. This system is automatic and not adjustable. It is recommended that the Load Shed system be enabled at all times. NOTE: The light on this switch will only be illuminated if the system is actively monitoring and turning off systems to conserve voltage.
See your INTERNATIONAL manual for specifi c details.
ENABLING CONDITIONS:
Parking brake set
Gear shift lever in PARK
Foot off service brake
Foot off accelerator
Manual High Idle System Reference Guide
SPSC (Stationary Pre-Set Speed Controls)
T
HIS
S
YSTEM OFFERS
P
RE
-P
ROGRAMED SETTINGS FOR MANUAL
H
IGH
I
DLE
C
HARGE
P
ROTECTION
Note: This means, if all vehicle enabling conditions are met,
Manual High Idle Charge Protection mode can be engage.
This feature provides two different predetermined speeds which are selected with the SET/CRUISE or RESUME/ACCEL positions.
You need to know which position to use for your specifi c need.
Press the right side SET/CRUISE or RESUME/ACCEL switch for the desired pre-set speed
Press the switch that selects the desired speed.
To select the other speed, press the other switch. The engine will immediately return to idle.
You must press the switch a second time to go to the second speed. This is done to protect equipment from being inadvertently operated at the wrong speed.
Brake lights connected and functional
TO ACTIVATE HIGH IDLE CHARGE PROTECTION
Do the following:
Press the “ON” position on the left side CRUISE/THROTTLE
- ON/OFF switch.
TO DEACTIVATE HIGH IDLE CHARGE PROTECTION,
Do the following:
Press the “OFF” position on the left side CRUISE/THROTTLE
- ON/OFF switch.
(CONTINUES ON NEXT PAGE)
High Idle Charge Protection Operating Controls
See Section D of your INTERNATIONAL Operators Manual for specifi c information on the basic functions of your engine speed control system.
All speed control functions are activated by using
the switches on the steering wheel as shown below.
The switches on the steering wheel control fi ve (5) possible options;
1. Cruise Control. 2. Throttle. 3. Stationary Variable Speed.
4. Stationary Pre-Set Speed. 5 Mobile Variable Speed.
The Stationary Pre-Set Speed function is used to provide High Idle Charge Protection
Refer to your INTERNATIONAL Operators Manual - Chassis, for complete Speed Control System instructions
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28
Battery Compartment and Under Vehicle Storage
Battery Compartment Access
This tray contains three (3) in-line INTERNATIONAL batteries
See your INTERNATIONAL manual for specifi c details and specifi cations.
Under Vehicle Storage Bin
Standard on model 38
Optional on model 31 & 35
Window, Door , Mirror and Light Control Switches
Door Lock and Window Control Switch
If equipped, these switches allow the driver to lock/unlock doors and windows, and raise and lower windows. The passenger side may also be comparably equipped.
Mirror Control Switch
This rocker switch allows the operator to switch from right to left mirror. When either the right or left mirror is engaged, pressing the 4 arrow control, allows the mirror to move in 4 different directions for precise adjustment.
Leaving the heated mirror switch on in hot weather may cause the mirror to crack.
Door Switch
This switch opens and closes the passenger door.
Panel Dimmer Switch
This momentary rocker switch controls and adjusts the dash cluster lights up and down eight levels of brightness.
Park Light Switch
This three position switch activates dash lights and exterior running lights and headlights.
These 3 switches are located to the left of the steering wheel, below the dash cluster
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30
Back-Up Camera Controls and Operation
1
2
3
4
5
NOTE:
To reverse image on monitor, push button on back of camera
LCD Monitor
Location of the monitor may vary according to vehicle confi guration
Monitor Controls
1. Power Button, glows dimly when system is connected fully manual, becoming 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 indicate by a bar graph at bottom on screen.
5. Volume Button, controls +- output volume of built-in speaker, when feature is connected. Also used in Picture Adjustment Mode.
Back-Up Camera
(located on rear of vehicle)
System Operation
This system consists of two major components:
1. The Back-Up Camera 2. LCD Monitor
The system may be connected two ways:
1. Fully manual, requiring the power button on the LCD Monitor to be pushed to energize the system and activate the monitor.
2. Automatic, which activates the monitor whenever the ignition is turned to accessory or the engine is started.
SEE MANUFACTURERS LITERATURE
FOR ADDITIONAL INFORMATION
Rear Step Operation
Rear Step Switch Guard
SEE MANUFACTURERS LITERATURE
FOR ADDITIONAL INFORMATION
Rear Step
Operational Schematic
For the double rear step (shown above) and the single rear step, operation is the same.
The schematic (this page) explains the electrical operation of both steps. The power switch allows you to enable or disable step operation.
When the step is enabled, opening the rear door automatically extends the step.
Note: See Manufacturers literature regarding periodic lubrication requirements.
31
Rear Cargo Door Micro Switch
32
Rear Door and Hinge Assy
Cargo Door Micro Switch
The switch is located at the rear cargo door upper hinge, shown at left and above. 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.
Foldaway Seating
Fold
Forward
Lever “A”
Push/Release
Lever “B ”
Lift
Rearward
Lift
Pull Towards
Aisle Until
Down Lock
Engages
Push in
Lever “D”
Truss
Lock “C”
Rotate Clockwise
To Lock,
Counter-Clockwise to Unlock
Front
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.
To Raise
1. Push lever “A” forward, and fold the back cushion down against the seat cushion until lever has snapped back into locked position.
2. Push lever “B” upward, and lift the seat into the fold away position, and rotate the Truss Lock “C” to lock the assembly in place.
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34
Bus Passenger Seating
Bus seating is mounted into the fl oor of the vehicle as shown in the photos to the left and right
To move 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 horizontal with the track when the seat is re-attached to the seat track.
CAUTION: Bolts must be torqued to 35 ft... Lbs.
AMAYA seating installation, 38’ model only
Caution:
When Adding Seating, Do Not Exceed Weight Distribution/Payload Limitations
Standard seating installation,
31’ & 35’ models only
Optional Stainless Steel Wheel Liners
C A U T I O N !
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.
Lug
Wheel Liner Tool
Jam Nut
Cover Assy
Pop Out
Center
Hub Center
Emblem
Turn
Installation
Tool
INSTALLATION - REMOVAL INSTRUCTIONS
NOTE: When removing or installing, never remove the original equipment lug nuts.
1. TO REMOVE, simply place the Wheel Liner Tool over the Jam Nut Covers.
2. Remove Jam Nut Covers from each wheel and remove Liners
1. TO INSTALL, determine the correct placement of liners for proper 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
Jam Nut
Cover Assy
Hub Center
Emblem
Turn
Installation
Tool
Front Wheel Liner
Front
Wheel
Lug
Rear Wheel Liner
Rear
Wheel
35
Air Conditioning Assemblies for Models 31 & 35 ONLY
36
ACC Front Air Conditioning
This unit also provides heat when A/C is not required, by toggling switch on the dash panel
Both units are operated by the driver, using the controls on the
Dash Panel, see page 20 & 21.
Optional ACC Rear Air Conditioning
A/C only - No Heat
MODEL BY BTU’S
68,000 BTU Front with 40,000 BTU Rear using (Single Aux Compressor)
Model 38 Roof Top Carrier A/C (Single Aux Compressor)
FREON CHARGE
11.75 lbs.
11.75 lbs
68,000 BTU (Dual Aux Compressors)
40,000 BTU (Dual Aux Compressors)
Model 38 Roof Top Carrier A/C (Dual Aux Compressors)
5.50 lbs
6.0 lbs
7.0 lbs. per compressor
Air Conditioning System - Roof Mounted for Model 35 & 38 Only
Intake grille for roof mounted A/C
Removing intake grille for access to fi lter and electrical panel .
Intake grille fasteners are twist out to disengage and push in to engage.
Intake Filter should be cleaned often to insure proper fi ltration. Fuses and relays for the A/C system are located for easy access as shown on the right.
For schematics of wiring diagrams and fuse locations see pages 96-101
Roof mounted A/C electrical panel located behind forward intake grille
37
Floor Heater Assembly - Optional Rear
38
30,000 BTU Model 65,000 BTU Model
Both units are turned on when the heat mode is selected on the In Dash Control Panel (see page 20)
Movable Wall, Standard - Front View (models 31 & 35 only)
Caution:
When Adding Seating, Do Not Exceed Weight Distribution/Payload Limitations
Movable Wall shown above in the forward position
39
Movable Wall, Standard - Rear View (models 31 & 35 only)
40
The standard movable wall can be moved by doing the following:
1. Remove the seats from in front of the wall
2. From the baggage compartment side, remove the plastic track cover on both the side wall and fl oor to expose the 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 plastic track covers and engage top latches.
Movable Wall (E-Z Move) - Open Front
Caution:
When Adding Seating, Do Not Exceed Weight Distribution/Payload Limitations
E-Z Move Wall Operating Instructions
Movable Wall to the open position (with luggage compartment)
1) Release the top two clamps located on the ceiling.
2) Enter bus through the rear door and release bottom clamp
3) Push the movable wall at the upper most centrally located handle to the stop
4) Release the divider clamp and slide out each divider half. Rotate the clamp assembly into the seat track and engage clamps . SAFETY ALERT
5) Engage the top two clamps into the locked position SAFETY ALERT
SAFETY ALERT
Clamps must be locked down before operating vehicle
Movable Wall to the closed position (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 stop.
5) Engage the bottom clamp into the receiver located in the fl oor. SAFETY ALERT
6) Close the rear door. Enter the bus, walk to the rear and engage the top two clamps into the locked position. SAFETY ALERT
SAFETY ALERT
Clamps must be locked down before operating vehicle.
41
Movable Wall (E-Z Move) - Open Rear
42
To Open and Close E-Z Move Wall
Instructions for Opening and Closing the E-Z Move Wall shown on the previous page, may also be found mounted on the back of the Movable Wall. Follow the instructions for Open Position - (with luggage compartment) or Close Position - (no luggage compartment)
SAFETY ALERT: ALL CLAMPS MUST BE LOCKED DOWN BEFORE OPERATING VEHICLE
Movable Wall (E-Z Move) - 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
43
44
Single Plug Door - Air Operated
4-Way
Valve
Closing
Cushioning
Valve
Closing
Speed
Valve
Opening
Speed
Valve
Opening
Cushioning
Valve
CAUTION!
Never attempt adjustment of the Boomerang Arm, call KRYSTAL SERVICE
Air Door Speed Adjustment Procedure
Single Plug Door System
(door shown partially open)
Secondary Entry Door
Switch - used on air operated door systems, located on passenger door post
1. Remove the air motor cover located in the stepwell.
2. Using the photo on this page, identify the speed control valves. Using a 3/8” wrench, loosen the locknuts on both valves.
3. Operate the door and adjust both valves until the opening and closing speeds are equal and acceptable. Then tighten both locknuts.
4. Using a fl at blade screwdriver, adjust the opening and closing cushioning valves on the air motor, then replace cover.
Compressed Air Schematic - Single Plug Door
DETAIL FOR 2005 & NEWER MODELS
4 WAY SOLENOID VALVE
AIR PILOT
CLOSE VALVE (CUSHIONING)
BLUE
TEE
DOOR SWITCH ELECTRONIC PANEL
LOCATED AT STEPS
YELLOW
RED
CLOSE
OPEN
SPEED CONTROL VALVES
OPEN VALVE (CUSHIONING)
DOOR MOTOR
DETAIL FOR 2004 & OLDER MODELS
4 WAY SOLENOID VALVE
CLOSE VALVE (CUSHIONING)
DOOR SWITCH ELECTRONIC PANEL
LOCATED AT STEPS
YELLOW
RED
CLOSE
DOOR MOTOR
EMERGENCY RELEASE
IN OUT BLUE
OPEN
SPEED CONTROL VALVES
OPEN VALVE (CUSHIONING)
FROM INTERNATIONAL AIR TANK
45
46
Single Plug Door with Air Operated Lower Step
CAUTION!
Never attempt adjustment of the Boomerang Arm, call KRYSTAL SERVICE STEP
4-Way
Valve
DOOR
Closing
Speed
Valve DOOR
4-Way
Valve
DOOR
Closing
Cushioning
Valve
STEP
Air
Pressure
Regulator
DOOR
Opening
Speed
Valve
DOOR
Opening
Cushioning
Valve
Air Door Speed Adjustment Procedure
Single Plug Door System
With Extended Lower Step
Note!
Emergency override prevents door from opening if
Lower Step Fails To Deploy
Secondary Entry Door
Switch - used on air operated door systems, located on passenger door post
1. Remove the air motor cover located in the stepwell.
2. Using the photo on this page, identify the speed control valves. Using a 3/8” wrench, loosen the locknuts on both valves.
3. Operate the door and adjust both valves until the opening and closing speeds are equal and acceptable. Then tighten both locknuts.
4. Using a fl at blade screwdriver, adjust the opening and closing cushioning valves on the air motor, then replace cover.
Lower Step Adjustment Procedure and Door/Step Air Schematic
Air Operated Step Adjustment Procedure
1. Remove the air motor cover located in the stepwell, and remove air step cover from the underside of air step.
2. Locate the speed control valves on the cylinder located on the underside of the air step. Using a 3/8” wrench, loosen the locknuts on both valves.
3. Check air pressure on guage to verify operating pressure is between 60 psi minimum and 80 psi maximum.
4. Operate the door and adjust both speed control valves until the extension and retraction speeds are equal and acceptable.
Then tighten both locknuts, and replace both covers.
SINGLE PLUG DOOR AND LOWER STEP AIR SCHEMATIC
47
Double Plug Door - Air Operated
48
If adjustments become necessary, do not attempt adjustments.
Contact the Krystal Service Dept., at 1-800-Krystal (579-7825)
CAUTION!
The Emergency Release Valve System - (must be checked on a daily basis)
Once the 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.
Caution!
UNDER EMERGENCY SITUATIONS, (IF EQUIPPED) THE BOTTOM AIR STEP WILL NOT DEPLOY.
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 fi nal closing position. If the reversing process actuates too late, the sensitivity of the differential pressure switch would require re-adjustment. Do not attempt adjustment, call the KRYSTAL SERVICE DEPT.
Double Plug Door - Air Operated
Double Plug Door System
(doors shown partially open)
Secondary Entry Door Switch, used on air operated double plug door systems, is located on the indash control panel as shown on page 20-21
49
50
Electric Swing Door System
Electric door motor Cover
EMERGENCY EXIT
PUSH HANDLE LEFT
PUSH DOORS OUT
Electric door motor with control arm
For removal of door motor cover
1. Remove black rubber strip from molding channel
2. Remove exposed screws in aluminum channel
3. Remove screws from 3 corners of cover
EMERGENCY EXIT
PUSH HANDLE LEFT
PUSH DOORS OUT
NOTE:
Emergency Exit Lever Decal
LEVER MUST BE CHECKED DAILY,
PRIOR TO VEHICLE OPERATION
Electric Door Adjustment Procedure
Door Speed Is Factory Set
If adjustments become necessary, do not attempt adjustments. Contact the Krystal
Service Dept., at 1-800-Krystal (579-7825)
Electric Swing Door System
Any concerns regarding door operation, such as opening or closing speed, or nonoperation, should be directed to the Krystal Service Department. Never attempt any adjustments on any portion of this door assembly.
51
52
Lift Motor Assy
Back-up Pump
Wheelchair Lift - Rear Door, BRAUN
User Instructions
Passenger Loading and Unloading
Do not exceed the 800 pound load capacity of the lift. Prior to lift operation, the lift should be inspected for proper function. If any problems exist, DO NOT
USE LIFT. Contact Braun Corp. at 1-800-THE LIFT for repair.
Passengers loading from the ground level, should back onto the platform. All passengers loading onto the platform, should be positioned fully within the yellow boundaries, facing outward from the vehicle, with the wheelchair locks locked, gripping handrails if able. Electric wheelchairs should be turned off.
UNFOLD The UNFOLD function deploys the lift from the upright position,
FOLD The FOLD function raises the lift from the horizontal fl oor level position,
DOWN The DOWN function lowers the platform to the ground level, and ex-
UP The UP function raises the roll stop to full vertical position, before raising
Lift Control
Pump Handle
Release Valve
C A U T I O N !
Never raise or lower lift if roll stop is malfunctioning
C A U T I O N !
YOU MUST READ AND UNDERSTAND THE MANUFACTURERS
OPERATORS MANUAL BEFORE EVER OPERATING THIS LIFT
Wheelchair Lift - Rear Door, BRAUN
Lift Closed Lift Extended Lift Lowered
Emergency Back-Up Operation
In the event of an electrical system failure, this lift system provides for full manual operation. Locate the back-up pump release valve, and the hand pump handle on the motor housing.
To Unfold the Platform 1. Place the slotted end of the pump handle onto the back-up pump release valve, and turn counterclockwise until the platform reaches fl oor 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 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 fl oor level.
To Fold Platform Up
1. Repeat step 2 above until fully upright.
Note: Refer to Operator’s Manual for Detailed Operating & Maintenance Procedures
53
54
Lift Motor Assy
Back-up Pump
Pump Handle
(not shown)
Wheelchair Lift - Rear Door, RICON
ATTENTION!
Lift needs service, when green light is continuously lit,
Basic User Instructions
Passenger Loading and Unloading
Do not exceed the 800 pound load capacity of the lift. Prior to lift operation, the lift should be inspected for proper function. If any problems exist, DO NOT
USE LIFT. Contact Ricon Corp. at 1-818-322-2884 for repair.
Passengers loading from the ground level, should back onto the platform. All passengers loading onto the platform, should be positioned centrally on the platform, facing outward from the vehicle, with the wheelchair locks locked, and restraint belt fastened. Electric wheelchairs should be turned off.
Lift Control
Release Valve
UNFOLD The UNFOLD function deploys the lift from the upright position, with the platform extended fl at at fl oor level, with the roll stop vertical.
FOLD
The FOLD function raises the lift from the horizontal fl oor 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 fl at 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 fl oor level position for unloading.
C A U T I O N !
Never raise or lower lift if roll stop is malfunctioning
C A U T I O N !
YOU MUST READ AND UNDERSTAND THE MANUFACTURERS
OPERATORS MANUAL BEFORE EVER OPERATING THIS LIFT
Wheelchair Lift - Rear Door, RICON
Lift Closed Lift Extended
Emergency Back-Up Operation
Lift Lowered
In the event of an electrical system failure, this lift system provides for full manual operation. Locate the back-up pump release valve, and the hand pump handle on the motor housing.
To Deploy the Platform 1. Place the slotted end of the pump handle onto the back-up pump release valve, and turn counterclockwise ¼ turn until the platform reaches fl oor 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, and pump until platform reaches fl oor level.
To Stow Platform Up
1. Repeat step 2 above until fully upright.
Note: Refer to Operator’s Manual for Detailed Operating & Maintenance Procedures
55
56
Chassis Specifi cation - Standard 3200 for Model 31 & 35
Chassis
GVWR - Total
Front Axle Capacity
Front Springs Capacity
Rear Suspension
Rear Axle Capacity
Rear Axle Ratio
Shock Absorbers
Engines
Fast Idle Controller
Transmission
Alternator
Batteries - Chassis
Steering
Steering Column
Brakes
Fuel Tank
International 3200
23,880 lbs
8,000 lbs
8,000 lbs
INTERNATIONAL AIR RIDE - 20,000 lbs
17,500 lbs
4.63
Gas Filled
DT466 Turbo Diesel - 210HP
Standard INTERNATIONAL
Allison 2200 PTS Series Electronic 5-Speed Automatic
270 Amp Leece-Neville
3 - 12 Volt, 1950 CCA
Power Assisted
Locking, Energy Absorbing, Tilt w/ Cruise Control
4 Wheel ABS Power Disc Brakes w/Air Actuated Parking Brake
65 Gallon
Cab Paint
Glass
Doors
Lights
Air Conditioner
Heater/Defroster
Safety
Air Bags
Windshield Wipers
Gauges/Instrumentation
Mirrors
Tires
Wheels
Wheelbase
Chassis Specifi cation - Standard 3200 for Model 31 & 35
9219 White
Tinted All Windows
Power Door Locks - Power Windows
Halogen Sealed Beam Headlights
Cab 23,000 BTU INTERNATIONAL with R-134a
4-Speed Fan
3-Point Shoulder/ Lap Belts
Driver Safety Restraint System
Intermittent
Voltmeter, Oil Pressure, Temperature, Fuel Gauge,
Speedometer, Tachometer, Air Pressure Gauges
Power Remote with Heated Element
245/70R19.5F 12Ply All-Season Radial
19.5” x 7.5”, 8 - Hole, Stamped Steel
31= 218” 35= 254”
57
58
Standard Equipment on 3200 Model 31 & 35
• DT466 Turbo Diesel Engine 210HP
• Power Steering
• 4-Wheel ABS Power Disc Brakes
• Heavy Duty Dual Batteries
• Allison 5-Speed Auto Transmission
• International Air Ride Rear Suspension
• 245/70R19.5F All Season Radial Tires
• 50 States Emissions
• 65 Gallon Fuel Tank
• Adjustable Tilt Steering Wheel
• Cruise Control
• Engine Oil Cooler
• Transmission Oil Cooler
• Automatic High Idle Controller
• Drive Shaft Guards
• .063 Aluminum Exterior Side Walls
• Welded Steel Cage Frame
• Cab Running Boards
• Air Ride Drivers Seat
• Captains Chairs - Co-Pilot
• 3/4” Resin Laminated Floor
• 2” 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 - In Dash
• Power Cab Door Locks
• Power Cab Windows
• Back-up Alarm
• Valance Lighting
• Single Plug Air Actuated Sedan Entry Door
• Full Body Undercoating
• Base White Body Color
• Power Remote/Heated Mirrors
• GL20 80% Tinted Windows w/UV Protection
• 270 Amp Leece-Neville Alternator
• Movable Luggage Partition
• Rear Luggage Door w/Electric Step
Chassis Specifi cation - Standard 3200 for Model 38
GVWR - Total
Front Axle Capacity
Front Springs Capacity
Rear Suspension
Rear Axle Capacity
Rear Axle Ratio
Shock Absorbers
Engines
Fast Idle Controller
Transmission
Alternator
Batteries - Chassis
Steering
Steering Column
Brakes
Fuel Tank
27,500 lbs
10,000 lbs
10,000 lbs
INTERNATIONAL AIR RIDE - 20,000 lbs
17,500 lbs
4.11 with DT466 Engine
Gas Filled
DT466 In-Line 6 cylinder Turbo Diesel - 245HP
Standard INTERNATIONAL
Allison 3000 PTS Series Electronic 5-Speed Automatic
270 Amp Leece-Neville
3 - 12 Volt, 1950 CCA
Power Assisted
Locking, Energy Absorbing, Tilt w/ Cruise Control
S-Cam Air Brake System with ABS
65 Gallon
MODEL 38 SPECICICATIONS CONTINUED ON PAGE 58
59
60
Cab Paint
Glass
Lights
Doors
Air Conditioner
Heater/Defroster
Safety
Air Bags
Windshield Wipers
Gauges/Instrumentation
Mirrors
Tires
Wheels
Wheelbase
Chassis Specifi cation - Standard 3200 for Model 38
9219 White
Tinted All Windows, Power Assisted Door
Halogen Sealed Beam Headlights
Power Door Locks - Power Windows
Cab - 23,000 BTU INTERNATIONAL
4-Speed Fan
3-Point Shoulder/ Lap Belts
Driver Safety Restraint System
Intermittent
Voltmeter, Oil Pressure, Temperature, Fuel Gauge,
Speedometer, Tachometer, Air Pressure Gauges
Power Remote with Heated Element
245/70R19.5F 16 PLY All Season Radial
19.5” 8 - Hole, 8-Lug Steel
K38 - 291”
Standard Equipment on 3200 Model 38
• DT466 6cyl. Turbo Diesel Engine 245HP
• Power Steering
• Full Air Brake System w/ABS
• 3 Heavy Duty INTERNATIONAL Batteries
• Allison 5-Speed Auto Transmission
• International Air Ride Rear Suspension
• 245/70R19.5F All Season Radial Tires
• 50 States Emissions
• 65 Gallon Fuel Tank
• Adjustable Tilt Steering Wheel
• Cruise Control
• Engine Oil Cooler
• Transmission Oil Cooler
• Automatic High Idle Controller
• Drive Shaft Guards
• .063 Aluminum Exterior Side Walls
• Welded Steel Cage Frame
• Cab Running Boards
• Air Ride Drivers Seat
• Captains Chairs - Co-Pilot
• 3/4” Resin Laminated Floor
• 2” Fiberglass Insulation
• Dual Overhead Racks w/Reading Lamps
• Smooth Rubber Flooring w/Ribbed Center Aisle
• Amaya Coach Seating
• 165,000 BTU Ducted Roof A/C System
• AM/FM Stereo w/CD Player - In Dash
• TV VCP Package
• Power Cab Door Locks
• Power Cab Windows
• Back-up Alarm
• Paging System
• Single Plug Air Actuated Sedan Entry Door
• Full Body Undercoating
• Base White Body Color
• Power Remote/Heated Mirrors
• Frameless Panoramic View Windows
• 270 Amp Leece-Neville Alternator
• S/S Wheel Inserts
• Rear Luggage Partition-Permanent
• Rear Luggage Door w/Electric Step
• Under Vehicle Storage Bins
61
62
General Vehicle Dimensional Specifi cations-Body & Chassis by Model
Features Models
GVWR
Wheelbase
Overall Length
Turning Radius
Interior Height
Interior Body Length (without Luggage)
Interior Body Length (with Luggage)
Depth of Luggage Compartment
Clear Door Opening - Luggage Door
Clear Door Opening - Single Plug
Clear Door Opening - Double Plug
Clear Door Opening - Swing Doors
Clear Door Opening - Wheelchair Lift Door
Exterior Height
Exterior Width (excluding Mirrors)
Exterior Width (including Mirrors)
31 31W 35 35W 38
25,500 lbs 25,500 lbs 25,500 lbs 25,500 lbs 27,500 lbs
218” 218” 254” 254” 291”
30’ 10”
29’ 1”
76.5”
262”
224”
38”
30’ 10”
29’ 1”
76.5”
262”
224”
38”
34’ 4”
33’ 2”
76.5”
302”
258”
44”
34’ 4”
33’ 2”
76.5”
302”
258”
44”
38’
37’ 6”
75”
330”
286”
44”
30½” x 64½” 30½” x 64½” 30½” x 64½” 30½” x 64½” 30½” x 64½”
32½” x 81” 32½” x 81” 32½” x 81” 32½” x 81” 32½” x 81”
40½”
42”
N/A
124”
102”
120”
40½”
42”
42” x 73¾”
124”
102”
120”
40½”
42”
N/A
124”
102”
120”
40½”
42”
42” x 73¾”
124”
102”
120”
40½”
42”
N/A
124”
102”
120”
General Vehicle Dimensional Specifi cations-Body & Chassis by Model (cont)
Features Models
Interior Width - at Floor
Interior Width - at Shoulder
Aisle Width
Hip to Knee
Seat Cushion Length
Front of Seat Cushion to Seat Back
Floor Height from Ground at Rear
1st Step from Ground
Riser Height
Step Height
31
89½”
94 ½ ”
18”
26 ½ ”
18”
27 ½ ”
37 ½ ”
14”
11”
11 ½ ”
31W
89½”
94 ½ ”
18”
36 ½ ”
18”
27 ½ ”
37 ½ ”
14”
11”
11 ½ ”
35
89½”
94 ½ ”
18”
26 ½ ”
18”
27 ½ ”
37 ½ ”
14”
11”
11 ½ ”
35W
89½”
94 ½ ”
18”
26 ½ :
18”
27 ½ ”
37 ½ ”
14”
11”
11 ½ ”
38
89½”
96”
18”
27 ½ ”
18”
27 ½ ”
37 ½ ”
14”
11”
11 ½ ”
63
64
General Body Materials and Construction Measurements
Size of Steel Tubing used in Body Sidewall & Roof Structure
Center line Spacing of Tubing used in Body Sidewall & Roof Structure
Wall Thickness of Steel Tubing used in Body Sidewall & Roof Structure
Thickness of Aluminum Sidewall & One Piece Aluminum Roof
Size of Steel Tubing used in Main Floor Structure
Center line Spacing of Tubing used in Floor Structure
Wall Thickness of Steel Tubing used in Floor Structure
Thickness of Double Backed Insulated Fiberglass Batting Insulation
Window Size - KK31 & KK35
Window Size - KK38
1” x 1½”
30”
.095
.063
2” x 4”
24”
.120
2”
32” x 40”
45” x 41”
Vehicle Manufacturers Identifi cation Label
Model 31 & 35
K
25500
8000
245/70R19.5F
19.5x7.5
17500
245/70R19.5F
19.5x7.5
100
100
11567
3629
7938
690
DUAL
690
Model 38
K
27500
10000
245/70R19.5 F
120 19.5x7.5
175000
245/70R19.5F
19.5X7.5
100
12474
4536
7938
830
DUAL
690
INTERNATIONAL
INTERNATIONAL
LABEL EXPLANATION
K # - This is your permanent Krystal Vehicle
Identifi cation number.
VIN # - This is your DMV Vehicle Identifi cation
Number.
GVWR -This is the gross rated capacity of your vehicle
GAWR Front -This is the rated capacity of the front axle
GAWR Rear -This is the rated capacity of the rear axle
Date Incomplete Vehicle Manufactured -
This is the date the chassis was produced by
INTERNATIONAL
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 cation and color used on your vehicle.
Tires, Rims - This indicates the required tire and rim sizes, and air capacities for your specifi c vehicle.
65
66
GENERAL PREVENTATIVE MAINTENANCE INFORMATION
Please familiarize yourself with all INTERNATIONAL Manuals that have been provided with your new vehicle. They detail specifi c components, and specify how they are to be properly maintained. Both IN-
TERNATIONAL and Krystal recommend that you study your manuals carefully before ever attempting to operate this vehicle for the fi rst time.
IMPORTANT
The information contained in this section of your Krystal Owners Manual does not supersede any information that relates to a specifi c component of the INTERNATIONAL portion of your vehicle.
REGARDING THE INTERNATIONAL PORTION OF YOUR VEHICLE:
ANY PROCEDURE REFERENCED IN THE FOLLOWING PREVENTATIVE MAINTENANCE
SECTION OF THIS MANUAL, SHOULD ALWAYS BE REFERENCED TO THAT SPECIFIC PORTION
OF YOUR INTERNATIONAL CHASSIS OPERATORS MANUALS, SEE MAINTENANCE & SPECIFI-
CATIONS - SECTION “E” OF YOUR INTERNATIONAL CHASSIS MANUAL.
LUBRICATION AND MAINTENANCE INTERVALS
After a vehicle is placed in operation, Regular Lubrication and Maintenance Intervals should be established, based upon the type of service and road conditions that the vehicle will be subjected to, such as; ON HIGHWAY, CITY, OR SEVERE SERVICE.
PREVENTATIVE MAINTENANCE SCHEDULE
The following Maintenance Schedules are provided as a convenient reference for the specifi ed systems and components which require periodic service.
These schedules are not intended to be a complete list of all possible services to be performed on a regular basis, nor is it suggested that more frequent services not be considered.
Because of the different types of operations coaches are subjected to, the severity of service must be considered when establishing maintenance intervals. Therefore, any such intervals given in the following schedule must be adjusted according to the specifi c type of operation in which your particular vehicle will be used.
The intervals given include those recommended by Krystal Enterprises, Inc., and those recommended by INTERNATIONAL Truck and Engine Corporation. The recommendations should be considered as maximum intervals. It should be noted that maintenance inspection and service operations of shorter intervals are always preferable to longer intervals. Check your INTERNATIONAL Engine and Chassis Operation and Maintenance Manual for additional specifi c information not covered in this section of your Krystal Operators Manual.
67
68
MAINTENANCE OPERATIONS FOR THE DT466 ENGINES
OP
NO.
Maintenance
Operation y l i
D a
Every 21.100 km(15,000 miles), 550 hours, 6 months
Every 43,000 km, 30,000 miles, 1100 hours, 12 months
Inspection Intervals (whichever Miles, Kilometers, Hours, Months occurs First)
Every 24 months
Every
193,100 km,
120,000 miles, or
5000 hours
Every
290,000 km,
180-200,000 miles, or
6700 - 7500 hours
Annually Every
322,000 km,
200,000 miles, or
3800 hours or
2 years
Every
241,000 km,
150,000 miles, or
6000 hours, or 2 ½ years
Every
500,000 km,
300,000 miles, or
12,000 hours, or 5 years
7
8
1
2
3
4
5
6
9
10 check oil level 1 check coolant level 1 drain water separator(fuel system) 1,2 inspect air to air cooler 1 inspect for external leakage1 inspect air restriction indicator 3 inspect belt 1 change engine oil & fi lter 4 check coolant
SCA concentration
(conventional coolant only) 1 inspect air intake piping and clamps 1
■
■
■
■
■
■
■
Refer to Op 8 page 81
■
■
See page 68 for specifi c explanation of Notes
MAINTENANCE OPERATIONS FOR THE DT466 ENGINES
OP
NO.
Maintenance
Operation
16
17
18
19
14
15
11
12
13
20
21 measure air intake restriction 1,3,5 change fuel fi lters 6 change coolant fi lter
(if equipped) 7,9 pressurize induction system 1,5 inspect vibration damper 1,8 adjust valve lash 5,8 measure crankcase pressure 5 inspect turbo 1 inspect electrical system 1 service cooling system 7 extended life coolant 9 l i
D a y
Every 21.100 km(15,000 miles), 550 hours, 6 months
Every 43,000 km, 30,000 miles, 1100 hours, 12 months
Inspection Intervals (whichever Miles, Kilometers, Hours, Months occurs First)
Every 24 months
Every
193,100 km,
120,000 miles, or
5000 hours
Every
290,000 km,
180-200,000 miles, or
6700 - 7500 hours
Annually Every
322,000 km,
200,000 miles, or
3800 hours or
2 years
Every
241,000 km,
150,000 miles, or
6000 hours, or 2 ½ years
Every
500,000 km,
300,000 miles, or
12,000 hours, or 5 years
■
■
■ ■ ■
■
■
■
■
■
■
■ (green) ■ (red)
■
See page 68 for specifi c explanation of Notes
69
70
5.
6.
1.
2.
3.
4.
7.
8.
9.
DETAILED MAINTENANCE NOTES FOR THE DT466 ENGINES
PLEASE REFER AS NECESSARY OR AS REQUIRED TO YOUR
INTERNATIONAL Engine Operation and Maintenance Manual for detailed explanations
Correct if necessary
If equipped
Service Air Cleaner elements as required
If fuel contains more than 0.05% sulfur, reduce oil change intervals, see page 81 of your INTERNATIONAL Engine Operation and Maintenance Manual
Refer to current Engine Diagnostic Manual sections in your INTERNATIONAL Engine Operation and Maintenance Manual
Change according to transfer pump minimum specifi cations
Refer to appropriate manual charts in Section 6 of your INTERNATIONAL Engine Operation and Maintenance Manual for cooling system maintenance schedules
Refer to EGES-210, DT466 and DT530 Diesel Engine Service Manual - Latest Revision
Extended life coolant does not require a fi lter. If a fi lter is installed, only a blank fi lter containing no supplemental coolant should be used.
THIS PAGE IS INTENTIONALLY BLANK
71
72
PREVENTIVE MAINTENANCE SCHEDULE
SPECIAL INSTRUCTIONS/SUGGESTIONS
It is strongly suggested that the following items always be observed or acted upon at every established maintenance interval or as otherwise specifi ed by
INTERNATIONAL and/or Krystal Enterprises.
Air Conditioning - serviced each spring
Front Axle - complete inspection, lubrication and adjustments
Rear Axle - complete inspection, re-torquing, replace worn parts
Air Brakes System - inspect, clean, lubricate and adjust all components
Desiccant Air Dryer - replace every 12 months
Hydraulic Brakes - inspect, clean, lubricate, replace fl uid, shoes, linings
Catalytic Converter - check for proper function
Air Induction System - inspect complete system every 12 months
Chassis Mounted Charge Air Cooler - inspect daily
Cooling System - inspect coolant level daily, Note special instructions for Extended Life Coolant
Fan Clutch - inspect every spring
Fuel System - inspect accelerator and system components frequently
Propeller Shaft - at regular lubrication intervals, all components should be inspected
KRYSTAL RECOMMENDED PREVENTIVE MAINTENANCE SCHEDULE
THE FOLLOWING PAGES SPECIFY THE MINIMUM REQUIREMENTS NECESSARY
TO PROPERLY MAINTAIN YOUR VEHICLES SYSTEMS AND COMPONENTS
CHECK EVERY DAY:
all items on Pre-Trip inspection (see page 8 & 9)
side passenger door emergency release valve operation
side passenger entry door, operation, locking, damage, and adjustment
emergency roof hatch
emergency egress window latches
function of all interior and exterior lights
check all seat belts for proper operation
tire pressure, Model 31 & 35 - 100 psi Frt/Rr, Model 38 - 120 psi Frt & 100 psi Rr
fl uid leaks from, transmission, engine, power steering, engine coolant, gear oil, fuel
drain fuel fi lter/water separator
CHECK EVERY MONTH:
windshield washer fl uid level
door linkage and pivot arm lubrication
lube rear Kwikee step, (if equipped)
clean air intake fi lter for A/C system
tires for wear, and tread depth
73
74
KRYSTAL RECOMMENDED PREVENTIVE MAINTENANCE SCHEDULE
AT 5,000 MILES/600 HOURS DO THE FOLLOWING:
inspect tires for wear and inspect tread depth
rotate tires
re-inspect torque settings on International Air Ride Suspension System
lube door seals with silicon spray, check for proper sealing
lube Vapor door rotary drive mechanism
check the torque of all door hardware on Vapor door systems
AT 10,000 MILES/1200 HOURS DO THE FOLLOWING:
inspect tires for wear and inspect tread depth
rotate tires
clean battery terminals
check the torque of all door hardware on Vapor door systems
AT 15,000 MILES/1800 HOURS DO THE FOLLOWING:
inspect tires for wear and inspect tread depth
rotate tires
inspect steering linkage, suspension, ball joints, drive shafts, and drive shaft 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
KRYSTAL RECOMMENDED PREVENTIVE MAINTENANCE SCHEDULE
inspect and lubricate steering idler arms
replace cabin air fi lter, if equipped
inspect half shaft boots, if equipped
re-inspect torque settings on International Air Ride 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:
inspect tires for wear and inspect tread depth
rotate tires
clean battery terminals
check the torque of all door hardware on Vapor door systems
AT 25,000 MILES/3000 HOURS DO THE FOLLOWING:
inspect tires for wear and inspect tread depth
rotate tires
check the torque of all door hardware on Vapor door systems
clean condenser coils
75
76
KRYSTAL RECOMMENDED PREVENTIVE MAINTENANCE SCHEDULE
AT 30,000 MILES/3600 HOURS DO THE FOLLOWING:
inspect tires for wear and inspect tread depth
rotate tires
inspect steering linkage, suspension, ball joints, drive shafts, and drive shaft guards
inspect engine cooling system and hoses
inspect brake system
inspect exhaust system and heat shields
change automatic transmission fl uid and external fi lter element
check wheels for end play and noise
inspect and lubricate 4 x 2 ball joints
inspect and lubricate steering idler arms
replace cabin air fi lter, if equipped
inspect half shaft boots, if equipped
clean air compressor intake fi lter
clean battery terminals
lube door seals with silicon spray, check for proper sealing
re-inspect torque specifi cations on INTERNATIONAL 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
KRYSTAL RECOMMENDED PREVENTIVE MAINTENANCE SCHEDULE
AT 35,000 MILES/4200 HOURS DO THE FOLLOWING:
inspect tires for wear and inspect tread depth
rotate tires
check the torque of all door hardware on Vapor door systems
AT 40,000 MILES/4800 HOURS DO THE FOLLOWING:
inspect tires for wear and inspect tread depth
rotate tires
clean battery terminals
check the torque of all door hardware on Vapor door systems
AT 45,000 MILES/5400 HOURS DO THE FOLLOWING:
inspect tires for wear and inspect tread depth
rotate tires
inspect steering linkage, suspension, ball joints, drive shafts, and drive shaft 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 steering idler arms
replace cabin air fi lter, if equipped
inspect half shaft boots, if equipped
77
78
KRYSTAL RECOMMENDED PREVENTIVE MAINTENANCE SCHEDULE
clean air compressor intake fi lter
lube door seals with silicon spray, check for proper sealing
re-inspect torque specifi cations on INTERNATIONAL Suspension System
check air system for leaks, and electrical connections
lube Vapor door rotary drive mechanism
check the torque of all door hardware on Vapor door systems
AT 50,000 MILES/6000 HOURS DO THE FOLLOWING:
inspect tires for wear and inspect tread depth
rotate tires
clean battery terminals
check the torque of all door hardware on Vapor door systems
clean condenser coils
AT 55,000 MILES/6600 HOURS DO THE FOLLOWING:
inspect tires for wear and inspect tread depth
rotate tires
check the torque of all door hardware on Vapor door systems
AT 60,000 MILES/7200 HOURS DO THE FOLLOWING:
inspect tires for wear and inspect tread depth
rotate tires
inspect steering linkage, suspension, ball joints, drive shafts, and drive shaft guards
KRYSTAL RECOMMENDED PREVENTIVE MAINTENANCE SCHEDULE
inspect engine cooling system and hoses
inspect brake system
inspect exhaust system and heat shields
change automatic transmission fl uid and external fi lter element
check wheels for end play and noise
replace wheel bearing grease seal
inspect and lubricate steering idler arms
replace cabin air fi lter, if equipped
inspect half shaft boots, if equipped
clean air compressor intake fi lter
clean battery terminals
lube door seals with silicon spray, check for proper sealing
re-inspect torque specifi cations on INTERNATIONAL 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 65,000 MILES/7800 HOURS DO THE FOLLOWING:
inspect tires for wear and inspect tread depth
rotate tires
check the torque of all door hardware on Vapor door systems
79
80
KRYSTAL RECOMMENDED PREVENTIVE MAINTENANCE SCHEDULE
AT 70,000 MILES/8400 HOURS DO THE FOLLOWING:
inspect tires for wear and inspect tread depth
rotate tires
clean battery terminals
check the torque of all door hardware on Vapor door systems
AT 75,000 MILES/9000 HOURS DO THE FOLLOWING:
inspect tires for wear and inspect tread depth
rotate tires
inspect steering linkage, suspension, ball joints, drive shafts, and drive shaft 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 steering idler arms
replace cabin air fi lter, if equipped
inspect half shaft boots, if equipped clean air compressor intake fi lter
lube door seals with silicon spray, check for proper sealing
re-inspect torque specifi cations on INTERNATIONAL Suspension System
lube Vapor door rotary drive mechanism
check the torque of all door hardware on Vapor door systems
clean condenser coils
KRYSTAL RECOMMENDED PREVENTIVE MAINTENANCE SCHEDULE
AT 80,000 MILES/9600 HOURS DO THE FOLLOWING:
inspect tires for wear and inspect tread depth
rotate tires
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:
inspect tires for wear and inspect tread depth
rotate tires
check the torque of all door hardware on Vapor door systems
AT 90,000 MILES/10800 HOURS DO THE FOLLOWING:
inspect tires for wear and inspect tread depth
rotate tires
replace engine and frame mounted fuel fi lters
inspect steering linkage, suspension, ball joints, drive shafts, and drive shaft 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
81
82
KRYSTAL RECOMMENDED PREVENTIVE MAINTENANCE SCHEDULE
inspect and lubricate steering idler arms
replace cabin air fi lter, if equipped
inspect half shaft boots, if equipped clean air compressor intake fi lter
clean battery terminals
lube door seals with silicon spray, check for proper sealing
re-inspect torque specifi cations on INTERNATIONAL 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 95,000 MILES/11400 HOURS DO THE FOLLOWING:
inspect tires for wear and inspect tread depth
rotate tires
check the torque of all door hardware on Vapor door systems
AT100,000 MILES/12000 HOURS DO THE FOLLOWING:
inspect tires for wear and inspect tread depth
rotate tires
clean condenser coils
clean battery terminals
check the torque of all door hardware on Vapor door systems
SUPPLEMENTARY PREVENTIVE MAINTENANCE INFORMATION
In addition to the required Preventative Maintenance information included in the previous schedule, the following specifi c exceptions should be noted.
Extended Life Coolant
Extended Life Coolant must have ELC extender added at 150,000 miles in order to extend the life of the coolant to 300,000 miles, 5 years, or 12,000 hours of operation.
Rear Axle Lubricant:
Must be changed every 18 months or 90,000 miles.
Change Rear Axle Lubricant:
On Dana axles using synthetic fl uid, fl uid must be changed every 3 years or 250,000 miles.
Check your INTERNATIONAL Engine Operation and Maintenance Manual, for special operating condition maintenance requirements, that may be applicable due to your specifi c vehicle operating profi le.
83
User Notes - Preventive Maintenance
Additional User Notes Additional User Notes
84
Basic Troubleshooting Guide
The following section details basic troubleshooting techniques that will help you to understand and determine the best course of action regarding some commonly encountered problems.
PROBLEM POSSIBLE SOLUTIONS
VIBRATION: Noises or Vibration at high speeds only, or in a certain range of speeds:
A certain range of speeds indicates a damaged or otherwise out-of-balance drive line, Contact your nearest INTERNATIONAL DEALER. The
Krystal Service Dept. can recommend one near you.
REAR A/C BLOWER INOPERATIVE Check to make sure the INTERNATIONAL front A/C unit is on. Check fuses on the A/C control relay board in ceiling. If the rear A/C is still not working, call the Krystal Service Dept.
MOVING CARGO PARTITION TO
ADD ADDITIONAL SEATING
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 fl oor, 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 LIGHTING
SLIDER WINDOWS HARD TO
OPEN AND CLOSED
One or all exterior clearance lights inoperative, please refer to the
INTERNATIONAL wiring schematic in the Krystal Electrical Schematic
Manual. Exterior running lights work off of the Krystal relay board.
If any of the windows start to stick during opening or closing, simply spray both side tracks with silicone spray and work the windows a few times to lubricate the tracks. This should be done approximately every three months.
85
86
Basic Troubleshooting Guide
PROBLEM POSSIBLE SOLUTIONS
PAGING SYSTEM INOPERATIVE
NO TELEVISION RECEPTION
REAR VCP & TV INOPERATIVE
EXTERIOR SEALANTS CRACKING
OR LIFTING
Check the 15 amp fuse, on the fuse panel behind the dash cover, on the passenger side. See page 92-93 for fuse legend & location. See instructions for the paging system located on page 22.
If the TV has power, but you cannot pickup any stations, make sure
VCP mode button on the P.A. System is engaged and the VCP power button is engaged.
Check to make sure all connections on the back of both units are tight.
Check the fuse located at the front face of the TV, and on the backside of the VCP.
If the exterior seams of the bus ever crack or start lifting, simply 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 fi nger for a smooth appearance.
REAR ELECTRIC STEP INOPERATIVE Check to make sure the step switch is turned on. This switch is located inside the cargo area on the right hand sidewall. If this will not power up the step, call the Krystal Service Dept. The rear step should be lubricated every 30 days to ensure proper operation of the step.
REAR STEREO/CD INOPERATIVE Check to make sure all connections are tight. Also remove the stereo and check the fuse located on the backside of the stereo.
Basic Troubleshooting Guide
PROBLEM POSSIBLE SOLUTIONS
CANNOT REMOVE WATER FROM
LAVATORY
Make sure fresh water tank has water in it and the water pump switch is in the on position. NOTE: Always be sure to turn the water pump switch off when not in use. Failure to do so could cause a steady drain on the auxiliary battery or could cause damage to the water pump. The fresh water fi ll 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. Check the fuse located on the INTERNATIONAL fuse panels behind the dash cover. (Ref. diagram on pages 92-93)
BACK-UP ALARM INOPERATIVE Check to make sure reverse lights are coming on, if not, check the fuse located on the INTERNATIONAL fuse panels behind the dash cover.
(Ref. diagram on pages 92-93)
87
PROBLEM
Troubleshooting Notes
POSSIBLE SOLUTIONS
88
PROBLEM
Troubleshooting Notes
POSSIBLE SOLUTIONS
89
90
INTERNATIONAL’S Diamond Logic Electrical System
This vehicle is equipped with the Diamond Logic Electrical System. This system is self diagnosing, and self monitoring, making troubleshooting and repairs quicker and faster than conventional systems.
This system should only be diagnosed and repaired by authorized service centers. Any attempt by unauthorized personnel may damage your system and/or jeopardize your warranty.
Your new Diamond Logic Electrical System and all component interfaces are covered by INTERNA-
TIONAL and Krystal to provide you with seamless coverage for your electrical system.
When problems arise, simply follow the procedures as outlined in the Parts-Service-Warranty section in this manual.
The following pages will provide you with schematics and diagrams that can help you understand the general concept of your buses electrical components and how they are connected. These schematics and diagrams will prove helpful when trying to determine which connection is faulty and where it is located. The following pages will also provide some basic general information about your buses possible confi guration, including some information which is provided in greater detail in your INTER-
NATIONAL product manuals.
INTERNATIONAL’S Diamond Logic Electrical System
STANDARD PANEL OPTIONAL PANEL
Fuses and Circuit Breakers are located behind the dash cover on the passenger side, See page 92-93 for diagrams & legends.
91
92
Legend for Standard Fuse & Circuit Breaker Panel
30A
F4
15A
F3
15A
F2
10A
F1
F8
15A
F7
5A
F6
5A
F5
10A
F12
F11
5A
F10
5A
F9
F10
F11
F12
F13
F14
F15
F16
F5
F6
F7
F8
F9
F1
F2
F3
F4
ACC
BAT
BAT
BAT
ACC
BAT
BAT
BAT
BAT
*
BAT
BAT
BAT
OPT
STD
STD
OPT
OPT
OPT
OPT
STD
STD
STD
STD
STD
OPT
CB/RADIO
INST CLUSTER
OWNER/OPERATOR
HEATER - A/C BLOWER
SYS CONTROLLER / 6 SWITCH PACK
KEY SWITCH / DIAG CONN
CIGAR LIGHTER
NOT AVAIL
OPT PANEL LIGHT
HEATER - A /C CONTROL
NOT AVAIL
DOME LIGHTS / MAP LIGHT / RADIO
RIGHT MIRROR HEAT
AUX POWER SOURCE
PWR WINDOW / LOCKS DRIVER DOOR
PWR WINDOW / LOCKS PASS DOOR
30A
F16
30A
F15
20A
F14
10A
F13
ACC
RELAY
10A
F18
10A
F17
5A
F20
5A
F19
IGN
RELAY
5A
F22
5A
F21
AUTO
SHIFT
RELAY
5A
F24
5A
F23
F17
F18
F19
F20
F21
F22
F23
F24
IGN
IGN
IGN
IGN
IGN
IGN
IGN
OPT
OPT
STD
STD
STD
OPT
OPT
**
ALLISON - LCT/EATON
AUTOSHIFT - AUTOCLUTCH
LEFT MIRROR HEAT
INST CLUSTER / HTR -A/C CONTROLS
SYSTEM CONTROLLER / NTR - A/C BLOW
OWNER / OPERATOR
DRIVERS INFO CENTER
COMPASS / TEMP
ACCELERATOR CLUTCH SW
PLEASE NOTE:
The legend shown on this page refl ects all available standard confi gurations and may include items not ordered with your vehicle.
Legend for Optional Fuse & Circuit Breaker Panel
F31
F32
F33
F34
F27
F28
F29
F30
F35
F36
IGN
IGN
IGN
IGN
IGN
IGN
IGN
ACC
ACC
STD
STD
STD
STD
STD
OPT
OPT
OPT
STD
IGN
RELAY
F28
F27
F30
F29
F32
7.5A
F31
REAR CAMERA
P.A. / DVD
A/C IGNITION TRIGGER
IGNITION / RADIO
F36
7.5A
F35
15A
F34
15A
F33
F38
F37
F41
F42
F43
F44
F37
F38
F39
F40
F45
F46 ACC
BAT
BAT
BAT
BAT
BAT
BAT
BAT
BAT
OPT
OPT
OPT
OPT
OPT
OPT
OPT
OPT
OPT
OPT
F40
F39
PLEASE NOTE:
The legend shown above refl ects all available options and may include options not ordered with your vehicle.
F42
20A
F41
F46
F45
F44
10A
F43
REAR STEP
RADIO MEMORY
93
Carrier Rooftop Air Conditioning System Diagram
Evaporator
Control Panel
Condenser
Shielded
Cable
94
+ -
12V Battery
Fan Temp
In Dash Control Panel
High
Pressure
Switch
Alternator
Waterpump
Heating
Heating
Valve
Low
Pressure
Switch
Compressor
Clutch
High
Pressure
Switch
Low
Pressure
Switch
Compressor
Clutch
B+
U4
U2
U3
F1A
OGRD
15A
BKYE
BKBU
Carrier Control Panel-Thermostat Schematic
1 8 10
Thermostat
Sensor
9
Poti
7 1 6
REL 1
Heating
2 4
Cooling
3 5
11
REL 2
K1A
X3
11 pol.
WH
All wires
1.5mm
2
85 30
86 87a 87
1
87a
87
87 87
K4A
87
2
V2
V1
V3
3 4 5
WHBU
7 1
S1A
Climate
S2A
D+61
Alternator
Control Panel
B1N Inside
Sensor
V5
V4
9 10 11
1 2
R1N
Temperature
Setting
Control Panel
X20
Y1A
Liquid Line Valve
Y2A
BKGY
OGRD
B+
UH
UK
95
96
B+
K2A
86 30
85 87a 87
Compressor - Heatpump Schematic
K3A
F2A 15A
86 30
85 87a 87
B10F
P>
B11F
P<
4
Y7M
2
1
2.5mm
2
1
2
4
B20F
P>
B21F
P<
4
Y8M
2
1
2.5mm
1
2
2
4
UH
UK
BLUE
BKGY
OGRD F3A 10A F4A 10A
6
B10F
P>
B11F
P<
2
1
4
Y7M
2.5mm
2
1
2
4
7
B20F
P>
B21F
P<
4
Y8M
2
1
2.5mm
2
1
2
4
Compressor
Clutch
Compressor
Clutch
8
2.5mm
2
Compressor
Clutch
Compressor
Clutch
DETAIL OF COMPRESSOR CLUTCH SECTION
Y31A M
Heating
Valve
Waterpump
Heating
B+
Condenser Blowers Schematic
30
87
86
K14M
85
30
87
87
K15M
87
BKBU
BKYE
OGRD
B+
U2
U4
U3
X1 white
F13M
15A
F14M
15A
F15M
15A
F16M
15A
M M M M
M21M M22M
Condenser
Blowers
M23M M24M
97
Evaporator Blowers Schematic
F1M
15A
F15M
85
86
F2M
15A
30
87
F3M
15A
F16M
85
86
F4M
15A
30
87
B+
U2
U4
98
X2 black
1
85
86
F1M
2
87 85
30 86
F3M
87
30
3
F01M 180A
Battery
12V
M
M1M
85
86
K4M
87 85
30 86
K6M
87
30
4 5 6
M
M2M
Evaporator
Blowers
M
M3M
M
M4M
Evaporator Blowers Schematic
B+
U2
F5M
15A
K8M
85
86
F6M
15A
30
87
U4
X2
85
86
K7M
87 85
30 86
K9M
87
30
10 11 12
B+
F7M
15A
K11M
85
86
F8M
15A
U2
30
87
87a 87
30
85
86
K13M
U4
85
86
K10M
87 85
30 86
K12M
87
30
13 14 15
M
M5M
M
M6M
Evaporator
Blowers
M
M7M
M
M8M
99
100
Model 35 & 38 Accessory Harness-Front Portion
FRONT OF VEHICLE
(D) DOOR AJAR LED
160"-LEG
16AWG BLACK/YELLOW
(C) SPEAKERS
17"-LEG
16AWG WHITE/BLACK
16AWG PINK
16AWG RED/YELLOW (LOOP)
16AWG BLACK/WHITE (LOOP)
SEE ACCESSORY HARNESS
LEGEND ON PAGE 102
(F) GROUND
32"-LEG
16AWG WHITE #5
16AWG WHITE #2
16AWG WHITE #3
16AWG WHITE #4
16AWG WHITE #1 (LOOP)
(K) INTERIOR LIGHTS
12"-LEG
16AWG YELLOW (CABIN)
14AWG ORANGE (MAP)
16AWG WHITE #4
(A) RF SPEAKER
150"-LEG
16AWG RED/YELLOW
16AWG BLACK/WHITE
INTERIOR LIGHT
14AWG ORANGE (MAP)
16AWG YELLOW (CABIN)
16AWG WHITE #2
67
10
59 15
(G) LF SPEAKER
44"-LEG
16AWG PINK (LOOP)
16AWG WHITE/BLACK
(LOOP)
7 4 155
(N) LR SPEAKER
48"-LEG
16AWG PINK
16AWG WHITE/BLACK
(M) EXTERIOR LIGHTS
11"-LEG
16AWG BROWN (LOOP)
16AWG WHITE #1 (LOOP)
168 6
(B) ENTRY DOOR LIGHT
127"-LEG
16AWG BLUE/WHITE
16AWG WHITE #3
(I) EXTERIOR LIGHTS
16"-LEG
16AWG BROWN
(LOOP)
16AWG WHITE #1
(LOOP)
(J) EXTERIOR LIGHTS
10"-LEG
16AWG BROWN (LOOP)
16AWG WHITE #1 (LOOP)
(P) EXTERIOR LIGHTS
45"-LEG
16AWG BROWN
(LOOP)
16AWG WHITE #1
(LOOP)
(E) RELAY BOARD
34"-LEG
14AWG PINK
16AWG RED
16AWG BLUE/WHITE
16AWG PURPLE
16AWG YELLOW (LOOP)
14AWG ORANGE (LOOP)
(H) EXTERIOR LIGHTS
166"-LEG
16AWG BROWN
16AWG WHITE #1
(L) EXTERIOR LIGHTS
14"-LEG
16AWG BROWN (LOOP)
16AWG WHITE #1 (LOOP)
(Q) EXTERIOR LIGHTS
66"-LEG
14AWG PINK
16AWG PURPLE
16AWG BROWN/WHITE
5
Model 35 & 38 Accessory Harness-Rear Portion
SEE ACCESSORY HARNESS
LEGEND ON PAGE 102
(U) EXTERIOR LIGHTS
13"-LEG
16AWG BROWN (LOOP)
16AWG WHITE #1 (LOOP)
REAR OF VEHICLE
(AA) RR SPEAKER
48"-LEG
16AWG RED/YELLOW
16AWG BLACK/WHITE
(O) EXTERIOR LIGHTS
15"-LEG
16AWG BROWN (LOOP)
16AWG WHITE #1 (LOOP)
(V) EXTERIOR LIGHTS
13"-LEG
16AWG BROWN (LOOP)
16AWG WHITE #1 (LOOP)
(T) MICRO SWITCH
60"-LEG
16AWG BLACK/YELLOW (LOOP)
16AWG WHITE #5
(Z) EXTERIOR LIGHTS
84"-LEG
16AWG BROWN (LOOP)
16AWG WHITE #1 (LOOP)
(CC) EXTERIOR LIGHTS
18"-LEG
16AWG BROWN (LOOP)
16AWG WHITE #1 (LOOP)
(EE) EXTERIOR LIGHTS
174"-LEG
16AWG BROWN
16AWG WHITE #1
74
14 16 17 6 7 15 15 17 6 168
5
(S) LUGGAGE LIGHTS
62"-LEG
16AWG RED (LOOP)
16AWG BLACK/YELLOW
(LOOP)
(W) EXTERIOR LIGHTS
13"-LEG
16AWG BROWN
(LOOP)
16AWG WHITE #1
(LOOP)
(BB) EXTERIOR LIGHTS
18"-LEG
16AWG BROWN (LOOP)
16AWG WHITE #1 (LOOP)
(DD) EXTERIOR LIGHTS
24"-LEG
16AWG BROWN (LOOP)
16AWG WHITE #1 (LOOP)
(R) EXTERIOR LIGHTS
24"-LEG
16AWG BROWN (LOOP)
16AWG WHITE #1 (LOOP)
(X) REAR STEP SWITCH
57"-LEG
16AWG BLACK/YELLOW (LOOP)
16AWG BROWN/WHITE
(Y) LUGGAGE LIGHTS
84"-LEG
16AWG RED
16AWG BLACK/YELLOW
101
102
Model 35 & 38 Accessory Harness Legend
AWG
16
16
16
16
16
16
14
16
16
16
14
16
16
16
16
16
16
16
AWG
COLOR
BROWN/WHITE
WHITE #1
FROM LOCATION
H
Q
BROWN H
WHITE #4
WHITE #5
PURPLE
RED
PINK
BLACK/YELLOW
PINK
WHITE/BLACK
WHITE #3
BLUE/WHITE
ORANGE
WHITE #2
YELLOW
BLACK/WHITE
RED/YELLOW
COLOR
C
B
B
A
A
A
A
E
D
C
F
F
E
E
A
FROM LOCATION
TO DESTINATION
X
LOOP @ I, J, L, M, O, P, R, U, V, W,
Z, BB, CC, DD, ending @ EE
LOOP @ I, J, L, M, O, P, R, U, V, W,
Z, BB, CC, DD, ending @ EE
K
T
Q
LOOP @ S, ending @ Y
Q
LOOP @ S, T, X, ending @ Y
LOOP @ G, ending @ N
LOOP @ G, ending @ N
F
E
LOOP @ E, ending @ K
F
LOOP @ E ending @ K
LOOP @ C ending @ AA
LOOP @ C ending @ AA
TO DESTINATION
WIRE LIST
DESCRIPTION
REAR STEP SWITCH
EXTERIOR LIGHTS GROUND
EXTERIOR LIGHTS GROUND
EXTERIOR LIGHTS POWER
EXTERIOR LIGHTS POWER
INTERIOR LIGHT GROUND
MICRO SWITCH GROUND
RELAY BOARD TO REAR STEP
RELAY BOARD TO LUG. LIGHTS
RELAY BOARD TO REAR STEP
DOOR AJAR LED
SPEAKERS
SPEAKERS
ENTRY DOOR LIGHT GROUND
ENTRY DOOR LIGHT
INTERIOR (MAP) LIGHTS
INTERIOR LIGHTS GROUND
INTERIOR (CABIN) LIGHTS
SPEAKER
SPEAKER
DESCRIPTION
NOTES
NOTES
Model 35 & 38 Accessory Harness Wiring Diagram- Part 1
103
104
Model 35 & 38 Accessory Harness Wiring Diagram- Part 2
TURN SIGNAL HARNESS
(ROUTED ALONG FLOOR)
LEFT MID TURN SIGNAL
GREEN/YELLOW
RIGHT MID TURN SIGNAL
GREEN
TURN SIGNALS
GREEN/YELLOW
GREEN
A/C Module Wiring Diagram - Front/Rear
REF: RELAYS
REF: FUSES
Details of A/C Modules as shown in Diagrams on pg. 107 &109
105
Circuit Board Assembly Phase 1
106
Circuit board located in compartment above driver
Circuit Board Phase 1 - Electrical Diagram
1
This board confi guration was last used through Feb. ‘04
2
Front A/C
Module
3 4 5
Rear A/C
Module
6 7 8 9
107
108
Circuit Board Assembly Phase 2
Circuit Board Assembly located on divider panel behind driver’s seat.
Circuit Board Phase 2 - Electrical Diagram
4
Front A/C Module Rear A/C Module
3
2
1
109
110
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.
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 contacting 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.
111
112
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 facility.
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 appointment 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
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 authorization 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
113
114
Vendor Reference Listing
Vendor Warranty Period
ALLISON TRANSMISSION 1-800-252-5283 3 Years, Unlimited Miles
AUTOMOTIVE CLIMATE CONTROL A/C 1-800-462-6322 2 Years, Unlimited Miles
AUDIOVOX TV & VCP 1-800-274-1886
CARRIER A/C 1-800-673-2431
1 Year, Unlimited Miles
2 Years, Unlimited Miles
FREEDMAN SEATING 1-713-929-6100
GOODYEAR TIRES 1-800-466-3982
2 Years or 20,000 Miles, Whichever Comes First
Free Replacement 1st year or up to 3/32” tread ware, then pro-rated thereafter
PHOENIX USA 1-931-561-6128
INTERNATIONAL ROAD SERVICE 1-800-448-7825
KRYSTAL SERVICE DEPT 1-800-845-4883
KWIKEE ELECTRIC STEPS 1-800-736-7366
ROSEN 1-866-467-6736
PANASONIC 1-949-251-1851
SHURFLOW WATER PUMPS 1-800-854-3218
SONY STEREO 1-800-282-2848
TRANSPEC WORLDWIDE 1-810-274-9400
VOYAGER PA SYSTEM 1-800-274-1886
3 Years
1 Year Towing
See Copy of Krystal Warranty
1 Year or 12,000 Miles, Whichever Comes First
1 Year, Unlimited Miles
1 Year, Unlimited Miles
2 Years, Unlimited Miles
1 Year, Unlimited Miles
1 Year, Unlimited Miles
1 Year, Unlimited Miles
Vendor
Vendor Reference Listing
Warranty Period
115
116
INDEX
A
Air and Electrical Diagrams & Schematics 105
Air Conditioning 36, 37
Air Door Lock Pin 16
Air Schematic, Single & Double Plug Doors 45
Audio/Video. PA Control 22
B
Back-Up Camera 30
Battery Location 28
Body Materials & Construction Measurements 64
Braun Rear Door Wheelchair Lift 50, 51, 52, 53
C
Cargo Door Micro Switch 32
Caution!, Safety Alerts 14, 16, 17, 44
Charge Protection 26
Circuit Board Assembly, F-550 Ver 1 & 2 106, 108
Compressed Air Supply & Schematic, single 45
Construction Materials & Measurements 64
D
Dimensional Specifi cations, Boby & Chassis 62
INDEX
Double Plug Door System 47
E
Electrical Diagrams & Schematics, misc, enlargements 105
Emergency Egress Window 18
Emergency Release Lever 11, 13
Emergency Release Valve 8, 11, 12, 48
Emergency Roof Hatch 19
F
Foldaway Seating 33
H
Heated Mirror Switch 29
I
Identifi cation Label, Vehicle Manufacturers 65
Idle Controller, Ford & Penntex 26, 27
L
LCD Monitor, ref back-up camera 30
M
Micro Switch 32
Mirror Control Switch 29
117
118
INDEX
Movable Wall 39, 40, 41
O
Obstruction Sensing System, Sensative Edge 11
Occupant Restraint Systems, ADA 14
Overhead Parcel Rack 17
P
PARTS 110, 111, 112, 113
Passenger Seating 34
PA Control, Audio/Video 22
Pre-Trip Inspection 8
PREVENTATIVE MAINTENANCE SCHEDULE 66
Processing Warranty Claims 112, 113
R
Rear Step 31
Ricon Rear Door Wheelchair Lift 54
S
Safety Check List, Vapor Air & Elect Door 11
Seating, Std. Passenger & Foldaway 33, 34
SERVICE, Warranty 110, 111, 112, 113, 114
Single Plug Door System 44, 46
INDEX
Swing Door System 50
Switches, mirror, micro, pressure, door, step 32, 46, 49
T
TOWING 111
Troubleshooting Guide 85
V
Vapor Air & Electric Door Safety Alerts 11
VEHICLE SAFETY WARNINGS 10
Vendor Reference Listing 114
Video Entertainment Center 24
W
WARRANTY 110, 111, 112, 113
WARRANTY POLICY 110
WARRANTY REPAIRS 112, 113
WARRANTY SERVICE 111
Wheelchair Lift, Braun & Ricon 52, 54
Wheelchair Securement, ADA 14, 15
Wheel Liners, Stainless Steel 35
Wiring Diagrams, 100 - 105
119
120
KRYSTAL ENTERPRISES
LIMITED WARRANTY
Krystal Enterprises (hereinafter referred to as Krystal Enterprises and Krystal) is the fi nal stage manufacturer 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 (except 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 situation, the original retail customer should contact the Warranty Department of Krystal Enterprises. If the selling
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
121
122
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 INTERNATIONAL models and explains standard equipment as well as many options, and may include equipment not presently installed on your vehicle.
KRYSTAL ENTERPRISES
Copyright © 2005 Ver-2
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