Solenoid Corrosion may Hinder Fire Fighting – 2009-2021 Spartan Fire Gladiator & MetroStar Emergency Vehicles

SEOCONTENT-START        Recall Service Bulletin Recall Service Bulletin RSB21-330-001 Page 1 of 12 QUA-FR-0291 Rev: 4.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properly. DATE: 7/8/2021 APPLIES TO: This service bulletin applies to 2009 through 2021 model year, Gladiator, MetroStar and MetroStar X model emergency response chassis cabs built between June 4, 2009 and November 11, 2020. NHTSA/TC Id: 21V-329 CONDITION: Fire pump fails to shift into pump mode. CORRECTION: Replace pump shift solenoid valve. LABOR ALLOCATION: 2 hours CLASSIFICATION: E3 PARTS NEEDED: Pump Shift Solenoid, Hand Valve: Nylon QTY Part Number Description 2 0918-MM5-012 ATC Valve w/Bayonet Conn 1 5034-MM5-001 Brkt-Air Solenoid Pump Shift 1 5035-MM5 Dia-Plumb Pump Shift, Hand Valve 2 08130125FH8Y Bolt 1/2-13×1.25 Flg Gr8 Yel 2 0813FLN8Y Nut,1/2-13 Toplock Flng Gr8 Yel 4 05180225H8Y Bolt-5/16-18 x 2.25 In 8 05FWSAE8Y Wshr 5/16” SAE Hardened 4 0518LN8Y Nut-Lock 5/16-18 Yel 4 0716-MM5-B02 Fit Brss M 90D Elbow 4-4 1 0716-MM5-C02 Fit Brss M 45D Elbow 4-4 30ft 2517-MM5-003 Nylon Tube – 1/4″ Green 2 12010973 Conn M W/P 2 Way SHD 4 12124582 Term M Pin W/P 14-16 4 12010293 Cable Seal 14-16AWG Weath Recall Service Bulletin Recall Service Bulletin RSB21-330-001 Page 2 of 12 QUA-FR-0291 Rev: 4.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properly. 2 4135-GG5-001 Harn-Wabco ATC Valve Molded Connector Reference: S-2742-001 Pump Shift Solenoid, Hand Valve: Wire Braid QTY Part Number Description 2 0918-MM5-012 ATC Valve w/Bayonet Conn 1 5034-MM5-001 Brkt-Air Solenoid Pump Shift 1 5035-MM5 Dia-Plumb Pump Shift, Hand Valve 2 08130125FH8Y Bolt 1/2-13×1.25 Flg Gr8 Yel 2 0813FLN8Y Nut,1/2-13 Toplock Flng Gr8 Yel 4 05180225H8Y Bolt-5/16-18 x 2.25 In 8 05FWSAE8Y Wshr 5/16” SAE Hardened 4 0518LN8Y Nut-Lock 5/16-18 Yel 4 0716-MM5-BB03 Fit Brss M Elbow 4-4 1 0716-MM5-DD02 Fit Brss M Elbow 4-4 8 0722-MM5-L01 Fit Strt Reus Hse End 4-4 30ft 0724-MM5-G01 Hose 266 SAE J1402 -4 T/C 410 S/S 2 12010973 Conn M W/P 2 Way SHD 4 12124582 Term M Pin W/P 14-16 4 12010293 Cable Seal 14-16AWG Weath 2 4135-GG5-001 Harn-Wabco ATC Valve Molded Connector Reference: S-2742-002 Recall Service Bulletin Recall Service Bulletin RSB21-330-001 Page 3 of 12 QUA-FR-0291 Rev: 4.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properly. Pump Shift Solenoid: Electric – Nylon QTY Part Number Description 2 0918-MM5-012 ATC Valve w/Bayonet Conn 1 5034-MM5-001 Brkt-Air Solenoid Pump Shift 1 5036-MM5 Dia-Plumb Pump Shift, Electric 2 08130125FH8Y Bolt 1/2-13×1.25 Flg Gr8 Yel 2 0813FLN8Y Nut,1/2-13 Toplock Flng Gr8 Yel 4 05180225H8Y Bolt-5/16-18 x 2.25 In 8 05FWSAE8Y Wshr 5/16” SAE Hardened 4 0518LN8Y Nut-Lock 5/16-18 Yel 1 0716-MM5-A02 Conn Brss M 4-4 4 0716-MM5-B02 Fit Brss M 90D Elbow 4-4 1 0716-MM5-C02 Fit Brss M 45D Elbow 4-4 1 0716-MM5-J05 Fit Brss Bushing 8-4 1 0716-MM5-R02 Fit Brss Street Tee -4 30ft 2517-MM5-003 Nylon Tube – 1/4″ Green 2 12010973 Conn M W/P 2 Way SHD 4 12124582 Term M Pin W/P 14-16 4 12010293 Cable Seal 14-16AWG Weath 2 4135-GG5-001 Harn-Wabco ATC Valve Molded Connector Reference: S-2742-003 Pump Shift Solenoid: Electric – Wire Braid QTY Part Number Description 2 0918-MM5-012 ATC Valve w/Bayonet Conn 1 5034-MM5-001 Brkt-Air Solenoid Pump Shift 1 5036-MM5 Dia-Plumb Pump Shift, Electric 2 08130125FH8Y Bolt 1/2-13×1.25 Flg Gr8 Yel 2 0813FLN8Y Nut,1/2-13 Toplock Flng Gr8 Yel 4 05180225H8Y Bolt-5/16-18 x 2.25 In 8 05FWSAE8Y Wshr 5/16” SAE Hardened 4 0518LN8Y Nut-Lock 5/16-18 Yel 4 0716-MM5-BB03 Fit Brss M Elbow 4-4 1 0716-MM5-DD02 Fit Brss M Elbow 4-4 Recall Service Bulletin Recall Service Bulletin RSB21-330-001 Page 4 of 12 QUA-FR-0291 Rev: 4.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properly. 1 0716-MM5-J05 Fit Brss Bushing 8-4 1 0716-MM5-R02 Fit Brss Street Tee -4 1 0716-MM5-Y03 Conn Brss M 4-4 8 0722-MM5-L01 Fit Strt Reus Hse End 4-4 30ft 0724-MM5-G01 Hose 266 SAE J1402 -4 T/C 410 S/S 2 12010973 Conn M W/P 2 Way SHD 4 12124582 Term M Pin W/P 14-16 4 12010293 Cable Seal 14-16AWG Weath 2 4135-GG5-001 Harn-Wabco ATC Valve Molded Connector Reference: S-2742-004 GENERAL INSTRUCTIONS: Thoroughly review entire service bulletin before starting work. If there are questions or concerns with steps defined in this service bulletin, contact Spartan Fire, LLC. Customer & Product Support Group. All applicable industry safety standards must be followed when performing work identified in this procedure. STEP-BY-STEP INSTRUCTIONS: 1. Identify the pump shift control type (air or electric) and the air supply line type (nylon or wire braid). • S-2742-001 is required for air pump shift control with nylon air supply lines. • S-2742-002 is required for air pump shift control with wire braid air supply lines. • S-2742-003 is required for electric pump shift control with nylon air supply lines. • S-2742-004 is required for electric pump shift control with wire braid air supply lines. Recall Service Bulletin Recall Service Bulletin RSB21-330-001 Page 5 of 12 QUA-FR-0291 Rev: 4.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properly. 2. Properly support chassis to gain access to work underneath. 3. Locate air tanks and drain all air from tanks. 4. Locate pump shift control solenoid and mounting bracket. Refer to Figure 5.1. FIG 5.1 5. Disconnect the air lines and the electrical harnesses from the solenoid. 6. Remove the mounting bracket and solenoid from the chassis. 7. For air pump shift control (nylon or wire braid) continue to step 8. For electric pump shift control (nylon or wire braid) skip to step 22. Recall Service Bulletin Recall Service Bulletin RSB21-330-001 Page 6 of 12 QUA-FR-0291 Rev: 4.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properly. Air Pump Shift Control Instructions (Nylon and Wire Braid) 8. Assemble the solenoid valve assemblies by using solenoid part number 0918-MM5-012 (Item 2). Install 90° degree elbows in the supply and delivery ports of the solenoid valve. Refer to Fig 6.1. a. For nylon air lines, use fitting 0716-MM5-B02 (Item 3 in left assembly). b. For wire braid air lines, use fitting 0716-MM5-BB0 (Item 3 in right assembly). FIG 6.1 9. Refer to FIG 6.2, Inspect to assure crimp barrels are straight to wire. If barrels are removed, ensure wire stranding is twisted and straight to wire insulation. Ensure all conductor areas are kept clean and free of contamination. FIG 6.2 Recall Service Bulletin Recall Service Bulletin RSB21-330-001 Page 7 of 12 QUA-FR-0291 Rev: 4.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properly. 10. Insert 12010293 cable seal on to all wires during the crimping of 12124582 terminal pin on all wires. Inspect to ensure terminal is straight and not bent. Ensure the wire’s conductors are crimped to the conductor grip of the terminal while the cable seal is crimped along with the wire’s insulation grip. Refer to FIG. 7.1. FIG 7.1 11. Insert terminals from 4135-GG5-001 into a 12010973 connector. Refer to FIG 7.2. 12. Refer to FIG 7.2, ensure terminals are fully seated and locked into the connector and are straight. Close secondary locking back shell and do a slight pull test to ensure wires remain in terminal and connector. FIG 7.2 Insulation Grip Conductor Grip Recall Service Bulletin Recall Service Bulletin RSB21-330-001 Page 8 of 12 QUA-FR-0291 Rev: 4.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properly. 13. Attach the solenoids to the bracket using 05180225H8Y (Item 4), 05FWSAE8Y (Item 5) and 0518LN8Y (Item 6). Torque bolts to 21 lb-ft. Refer to Fig 6.1. 14. Install the bracket and solenoids on the chassis using 08130125FH8Y and 0813FLN8Y in the original mounting location of the bracket. Torque bolts to 93 lb-ft. 15. Locate the primary air tank. Identify the pressure protection valve with the air lines that route to the pump shift hand valve in the cab and the solenoid supply port. Remove the branch tee and fittings from the end of the pressure protection valve and replace it with 45° elbow fitting. Refer to Fig 8.1. a. For nylon air lines use fitting 0716-MM5-C02 (Item 1). b. For wire braid air lines use fitting 0716-MM5-DD02 (Item 1). FIG 8.1 16. Install the air line to the pump shift control from the cab into the installed 45° elbow fitting. Recall Service Bulletin Recall Service Bulletin RSB21-330-001 Page 9 of 12 QUA-FR-0291 Rev: 4.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properly. 17. Install the air lines from the pump shift control to the solenoids. 18. Install the air lines from the solenoids to the pump. 19. Check installed air lines per plumbing diagram 5035-MM5. Fill air system and check for air leaks. Tie wrap all loose air lines and cables to existing cable runs. 20. Check pump operation to ensure Road and Pump Modes. Electric Pump Shift Control Instructions (nylon and wire braid) 21. Assemble the solenoid valve assemblies by using solenoid part number 0918-MM5-012 (Item 2). Install 90° degree elbows in the delivery ports of the solenoid valve. Install street tee 0716- MM5-R02 (Item 5) into supply port of the one solenoid. Install a 90° elbow into the top port of the street tee and a straight fitting into to other port of the street tee. Install a 90° elbow into the supply port of the other solenoid. Refer to Fig 9.1. a. For nylon air lines use fitting 0716-MM5-B02 (Item 4) and 0716-MM-A02 (Item 3), referenced in the left assembly. b. For wire braid air lines use fitting 0716-MM5-BB03 (Item 4) and 0716-MM5-Y03 (Item 3) referenced in the right assembly. FIG 9.1 Recall Service Bulletin Recall Service Bulletin RSB21-330-001 Page 10 of 12 QUA-FR-0291 Rev: 4.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properly. 22. Refer to FIG 10.1, Inspect to assure crimp barrels are straight to wire. If barrels are removed ensure wire stranding is twisted and straight to wire insulation. Ensure all conductor areas are kept clean and free of contamination. FIG 10.1 23. Insert 12010293 cable seal on to all wires during the crimping of 12124582 terminal pin on all wires. Inspect to ensure terminal is straight and not bent. Ensure the wire’s conductors are crimped to the conductor grip of the terminal while the cable seal is crimped along with the wire’s insulation grip. Refer to FIG. 10.2 FIG 10.2 24. Insert terminals from 4135-GG5-001 into a 12010973 connector. Refer to FIG 11.1. 25. Refer to FIG 11.1 ensure terminals are fully seated and locked into the connector and are straight. Close secondary locking back shell and do a slight pull test to ensure wires remain in terminal and connector. Insulation Grip Conductor Grip Recall Service Bulletin Recall Service Bulletin RSB21-330-001 Page 11 of 12 QUA-FR-0291 Rev: 4.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properly. FIG 11.1 26. Attach the solenoids to the bracket using 05180225H8Y (Item 6), 05FWSAE8Y (Item 7) and 0518LN8Y (Item 8). Torque bolts to 21 lb-ft. Refer to Fig 9.1. 27. Install the bracket and solenoids on the chassis using 08130125FH8Y and 0813FLN8Y in the original mounting location of the bracket. Torque bolts to 93 lb-ft. 28. Locate the air tank supplying air pressure to the pump shift solenoid. The solenoid may be supplied from the primary air tank or an auxiliary air tank. Proceed to Step 31 if the pump shift solenoid is supplied from the primary air tank. Proceed to Step 32 if the pump shift solenoid is supplied from an auxiliary air tank. 29. If the pump shift solenoid is supplied from the primary tank install an airline from the air tank to the straight fitting on the supply port of the new solenoid. Run an air line between the supply port fittings. Refer to Fig 9.1. 30. If the pump shift solenoid is supplied from an auxiliary air tank, remove the fitting, check valve and nipple fittings from the air tank. Install 0716-MM5-J05 bushing (Item 2) into the elbow on the air tank. Install a 45° elbow fitting into the bushing. Refer to FIG 11.1. Install an air line from the air tank to the straight fitting on the supply port of the new solenoid. Run an air line between the supply port fittings. Refer to Fig 9.1. a. For nylon air lines use fitting 0716-MM5-C02 (Item 1) Recall Service Bulletin Recall Service Bulletin RSB21-330-001 Page 12 of 12 QUA-FR-0291 Rev: 4.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properly. b. For wire braid air lines use fitting 0716-MM5-DD02 (Item 1) FIG 11.1 31. Install the air lines from the solenoids to the pump. 32. Check installed air lines per plumbing diagram 5036-MM5. Fill air system and check for air leaks. Tie wrap all loose air lines and cables to existing cable runs. 33. Check pump operation to ensure Road and Pump Modes operate correctly. ********************************************************************************************************************** Recall Service Bulletin Recall Service Bulletin RSB21-330-004A Page 1 of 7 CPS-FR-0008 Rev: 1.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properly. DATE: 7/8/2021 APPLIES TO: This Recall service bulletin applies to 2016 through 2021 model year, Metro Star model and Commercial emergency response chassis cabs built between November 2016 and February 2021. NHTSA/TC Id: 21V-329 CONDITION: Solenoids may be subject to internal corrosion. CORRECTION: Remove and replace solenoids with those that are appropriately rated for their environment. LABOR ALLOCATION: 2 hrs. CLASSIFICATION: E3 PARTS NEEDED: QTY Part Number Description 2 0918-MM5-012 ATC Valve 2 4135-GG5-001 Connector, Pigtail, for ATC Valve 1 5034-MM5-001 Bracket, Pump Shift, for ATC Valve 4 3092-MM5-A02 .25″ 90° Push-Lock Air Line Fitting GENERAL INSTRUCTIONS: Thoroughly review entire service bulletin before starting work. If there are questions or concerns with steps defined in this service bulletin, contact Spartan Fire, LCC. Customer & Product Support Group. All applicable industry safety standards must be followed when performing work identified in this procedure. Recall Service Bulletin Recall Service Bulletin RSB21-330-004A Page 2 of 7 CPS-FR-0008 Rev: 1.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properly. STEP-BY-STEP INSTRUCTIONS: 1. Properly support chassis to gain access to work underneath. 2. Locate air tanks and drain all air from tanks. 3. Locate pump shift control solenoid and mounting bracket. Reference Figure 2.1. Use masking tape to temporarily label the harness drops and pneumatic lines for Road and Pump modes to the appropriate valve. Figure 2.1 4. Disconnect pneumatic lines and electrical connections from the solenoids. Recall Service Bulletin Recall Service Bulletin RSB21-330-004A Page 3 of 7 CPS-FR-0008 Rev: 1.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properly. 5. Remove mounting bracket with solenoids from the chassis. 6. Remove solenoids from the mounting bracket. 7. Assemble solenoid valve assembly using solenoid part number 0918-MM5-012. Install 90° fittings part number 3092-MM5-A02 to the solenoids. Mount solenoids to the bracket part number 5034-MM5-001. Reference Figure 3.1 Figure 3.1 8. Install new mounting bracket with ATC solenoids to the chassis. 9. Reinstall previously labeled pneumatic lines to appropriate solenoid valve. 10. Using the connection pigtails part number 4135-GG5-001, make appropriate connections to previously marked harnessing connections, and then connect to the solenoids. 11. Verify installation and then fill pneumatic system and check for leaks. Tie wrap all loose pneumatic lines and wiring. 12. Verify proper operation in both Road and Pump modes. Recall Service Bulletin Recall Service Bulletin RSB21-330-004A Page 4 of 7 CPS-FR-0008 Rev: 1.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properly. a. Turn on the master battery and ignition switches. b. Ensure the park brake is set. c. Start the truck. d. Engage the water pump using the switch in the cab. Make sure to follow all operational and safety placards in the cab relating to engaging the pump. i. Do not run the water pump for more than 30 seconds without opening the tank to pump valve to recirculate tank water through the pump. e. Verify the “Pump Engaged” indicator light in the cab is illuminated. f. Disengage the water pump using the switch in the cab. g. Verify the “Pump Engaged” indicator light in the cab is no longer illuminated. h. Turn off the ignition and master battery switch. Recall Service Bulletin Recall Service Bulletin RSB21-330-004A Page 5 of 7 CPS-FR-0008 Rev: 1.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properly. Reference Materials Recall Service Bulletin Recall Service Bulletin RSB21-330-004A Page 6 of 7 CPS-FR-0008 Rev: 1.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properly. Recall Service Bulletin Recall Service Bulletin RSB21-330-004A Page 7 of 7 CPS-FR-0008 Rev: 1.0 21008 Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to vehicles of specific nature in conjunction with industry standards. Professional Technicians are appropriately trained on industry standards and have the tools and equipment to perform procedures safely and properlySEOCONTENT-END