2009-2021 Spartan Gladiator, MetroStar, & MetroStarX Emergency Vehicles Pump Shift Solenoid Valve

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August 10, 2021 NHTSA CAMPAIGN NUMBER: 21V628000

Solenoid Corrosion May Hinder Fire Fighting

A loss of power to the pump control module can cause a loss of water pressure for fighting fires, increasing the risk of injury.

 

NHTSA Campaign Number: 21V628

Manufacturer Custom Fire Apparatus, Inc.

Components EQUIPMENT, ELECTRICAL SYSTEM

Potential Number of Units Affected 12

 

Summary

Custom Fire Apparatus, Inc. is recalling certain 2009-2021 Spartan Gladiator, MetroStar, and MetroStarX emergency vehicles. The fire water pump solenoid may corrode internally, causing a loss of power to the pump control module.

 

Remedy

Dealers will remove and replace the pump shift solenoid, free of charge. Owner notification letters were mailed on July 12, 2021. Owners may contact Custom Fire’s customer service at 1-715-294-2555.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 


Recall Service Bulletin

RSB21-330-001

 

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
2 4135-GG5-001 Harn-Wabco ATC Valve Molded

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

 

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
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.

 

  1. Properly support chassis to gain access to work underneath.

 

  1. Locate air tanks and drain all air from tanks.

 

  1. Locate pump shift control solenoid and mounting bracket. Refer to Figure 5.1.

 

  1. Disconnect the air lines and the electrical harnesses from the solenoid.

 

  1. Remove the mounting bracket and solenoid from the chassis.

 

  1. 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.

 

Air Pump Shift Control Instructions (Nylon and Wire Braid)

  1. 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).

 

  1. 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.

 

  1. 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.

 

  1. Insert terminals from 4135-GG5-001 into a 12010973 connector. Refer to FIG 7.2.

 

  1. 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.

 

  1. 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.

 

  1. 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.

 

  1. 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).

 

  1. Install the air line to the pump shift control from the cab into the installed 45° elbow fitting.

 

  1. Install the air lines from the pump shift control to the solenoids.

 

  1. Install the air lines from the solenoids to the pump.

 

  1. 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.

 

  1. Check pump operation to ensure Road and Pump Modes.

 

Electric Pump Shift Control Instructions (nylon and wire braid)

  1. 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 0716MM5-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.

 

  1. 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.

 

  1. 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

 

  1. Insert terminals from 4135-GG5-001 into a 12010973 connector. Refer to FIG 11.1.

 

  1. 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.

 

  1. 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.

 

  1. 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.

 

  1. 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.

 

  1. 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.

 

  1. 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)

b. For wire braid air lines use fitting 0716-MM5-DD02 (Item 1)

 

  1. Install the air lines from the solenoids to the pump.

 

  1. 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.

 

  1. Check pump operation to ensure Road and Pump Modes operate correctly.

 


26 Affected Products

Vehicles

MAKE MODEL YEAR
CUSTOM FIRE SPARTAN GLADIATOR 2009-2021
CUSTOM FIRE SPARTAN METROSTAR 2009-2021

 


6 Associated Documents

Recall 573 Report – AMENDMENT 2

RCLRPT-21V628-2871.PDF 214.394KB

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Defect Notice 573 Report

RCLRPT-21V628-3806.PDF 214.08KB

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Recall Acknowledgement

RCAK-21V628-4459.pdf 647.186KB

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Remedy Instructions and TSB

RCRIT-21V628-0910.pdf 611.628KB

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Recall 573 Report- Amendment 1

RCLRPT-21V628-3046.PDF 214.336KB

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Recall Quarterly Report #1, 2021-3

RCLQRT-21V628-2664.PDF 211.129KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V628&docType=RCL

 


 

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