Spartan Motors USA, Inc.

Technical Service Bulletin

DATE:

November 29, 2017

APPLIES TO:

This service bulletin applies to 2003-2013 model year Star Models built
between July 22, 2003 and November 22, 2013

CONDITION:

Sub-Frame of apparatus body may crack.

CORRECTION:

Replace original sub-frame with “heavy” sub-frame.

LABOR ALLOCATION: 60 Hrs.
CLASSIFICATION:

E

PARTS NEEDED:
QTY
Part Number
1
S-8085-001
Kit # S-8085-001 Contains:
QTY
1
1
1

Assembly Number
001-0000
001-0001
TSB17-ERV-004

QTY
Part Number
1
S-6043-001
Kit # S-6043-001 Contains:
QTY
1
1

Assembly Number
06043-102-03A-000
TSB17-ERV-004

Description
Kit-Heavy Fix Sub-Frame

Description
Heavy Sub-Frame
Sub-Frame Ladder Structure
Instruction Document

Description
Kit-Star Fix Sub-Frame

Description
Star Sub-Frame 12150
Instruction Document

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 should be appropriately trained on industry standards
and have the tools and equipment to perform procedures safely and properly.
17023

Page 1 of 18

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

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 Motors USA, Inc. Customer
& Product Support Group.
All applicable industry safety standards must be followed when performing work identified in
this procedure.
All repairs must be done by an authorized service center. Each repair will require its own unique
kit number. Please contact Customer & Product Support Group for kit and coordination of
repairs.
Steps outlined below represent the instructions of sub-frame repair for a specific configuration
of a Star Model. Certain variations will be required to complete the same end goal depending
on apparatus configuration.

STEP-BY-STEP INSTRUCTIONS:
1. Pump test unit. Fill out pump test form.
2. Check for water in tank and drain if necessary.
3. Bring vehicle into shop and put in a location with enough room to work around.
4. Secure a roll around cage for unit parts. Label cage with unit number and station name.
5. Drain both A and B foam tanks, where applicable. (A) foam with auto fill system foam. (B)
foam using drain port on driver’s side. Put each foam type in correctly marked containers
and put in correct storage locations.
6. Disconnect hose bed lid sensor, where applicable. Tape wiring out of way on the top of
truck.
7. Remove hose bed dividers. Mark location of front and rear mounting locations for each
divider on truck at connection points. Mark with driver, middle and officers labels on
correct divider.
8. Remove hose bed lid, where applicable. Retain parts for re-use.
9. Remove hose bed front wall. Retain parts for re-use.
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 should be appropriately trained on industry standards
and have the tools and equipment to perform procedures safely and properly.
17023

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QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

10. Remove hose bed floor. Retain parts for re-use.
11. Remove upper tank floor plate. Retain parts for re-use.
12. Put hose bed dividers, hose bed floors and walls on a pallet. Put all the hardware from
previous listed items in a container marked hose bed.
13. Unplug upper foam fill sender wiring, where applicable. Mark sender and connector with #1
label. Route loose wire over front of box rail & tape out of way.
14. Label and disconnect the three 3/8” lines from the water fill tower, where applicable. Label
each fitting and hose with # 2, 3 and 4 labels. Secure to top of front box wall
15. Install tank lifting fixture to tank, (unique to each truck). Do not remove at this step.
16. Remove discharge and intake adaptors from left side of pump putting them in container
marked left adaptors, where applicable.
17. Remove discharge and intake adaptors from right side of pump putting them in container
marked right adaptors, where applicable.
18. Remove right side ladders putting it on pallet, where applicable. Retain parts for re-use.
19. Remove ladder compartment stop inside fill panel putting it on pallet, where applicable.
Retain parts for re-use.
20. Remove muffler putting it on pallet. Retain parts for re-use.
21. Put following parts in pump container, where applicable.
a. Disconnect rear discharge lines (3) flex connections at Victaulic connection on front of
tanks and retain for re-use. Label Victaulic’s with red tag.
b. Remove “A” foam tank fittings (2) from the tank and retain for re-use. Loosen clamps
and use a heat gun to loosen the hoses on the fittings. Secure hoses out of way.
c. Disconnect wiring from “A” foam sender and label sender and connector with “A” foam
label. Remove “A” foam sender. Retain parts for re-use.
d. Disconnect wiring from water sender and label sender and connector with water label.
Remove water sender. Retain parts for re-use.

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 should be appropriately trained on industry standards
and have the tools and equipment to perform procedures safely and properly.
17023

Page 3 of 18

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

e. Disconnect wiring from “B” foam sender and label sender and connector with “B” foam
label. Remove “B” foam sender. Retain parts for re-use.
f. Disconnect front tank fill hose from tank nipple. Remove the tank fill nipple. Retain parts
for re-use.
g. Remove 6” intake pipe Victaulic couplings in pump housing. Retain parts for re-use.
Remove the Victaulic and tag with red label.
h. Remove 4” tank to pump hump hose from tank and nipple. Retain parts for re-use. If
necessary cut hose and mark hose that it is cut.
i.

Disconnect the “B” foam hose. Remove the “B” foam pipe from the tank. Retain parts
for re-use.

22. Put following mounting hardware and parts in rear compartment container, where
applicable.
a. Remove 3 screws on brass reducers from rear discharge pipe. Remove rear discharge
pipe mounting plate. Retain parts for re-use.
b. Remove 3 rear discharge pipes and label each one with correct location labels (Drivers,
Middle, and Officer with an arrow pointing out orientation).
23. Disconnect and label auto tank fill valve wiring using labels 5,6,7,8 and 9, where applicable.
24. Disconnect lube lines from auto fill assembly, where applicable.
25. Remove auto tank fill valve, where applicable. Retain parts for re-use. Remove Victaulic’s
and red tag them.
26. Remove drain valve (remove drain pipe, valve and linkage). Retain parts for re-use.
27. Remove dump valve and bezel assembly, where applicable. Retain parts for re-use.
28. Remove rear MIV assembly, where applicable. Retain for re-use. Remove Victaulic’s and red
tag them. Retain parts for re-use.
29. Remove tank fill nipple on tank and body cover plate from rear of body. Retain parts for reuse.

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 should be appropriately trained on industry standards
and have the tools and equipment to perform procedures safely and properly.
17023

Page 4 of 18

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

30. Remove tank. Retain parts for re-use. Put tank on roll around dolly’s and put in storage
location. Cover foam holes to prevent continued drainage.
31. Set vehicle in a spot that it can be lifted without overhead obstruction.
32. Disconnect batteries and label front cab doors that batteries are disconnected.
33. Cut U-bolts from 6” intake pipe and properly dispose of, where applicable.
34. Remove 6” intake pipe through top opening on body, where applicable. Retain parts for reuse.
35. Remove P clamps holding priming hoses, sensing hoses and rear wiring harness, where
applicable. Lay hoses and wiring over front edge of box and secure.
36. Set lifts and raise vehicles.
37. Remove exhaust elbow and place on pallet. Retain parts for re-use.
38. Install body holding fixture.
a. Front at point just in front of wheel well opening. Refer to FIG. 5-1.

FIG. 5-1
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 should be appropriately trained on industry standards
and have the tools and equipment to perform procedures safely and properly.
17023

Page 5 of 18

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

b. Rear behind fuel tank. Necessary to remove P clamps holding wiring to bottom of frame
rails for fixture clearance. Refer to FIG. 6-1.

FIG. 6-1

39. Lower vehicle.
40. Secure welding blanket over opening into pump area inside tank area.
41. Remove rubber tank spacers from the top of sub frame area and properly dispose of.
42. Remove sub frame bolt heads and washers. Use a torch to remove and properly dispose of.
43. Remove per reference pictures:

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 should be appropriately trained on industry standards
and have the tools and equipment to perform procedures safely and properly.
17023

Page 6 of 18

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

a. Sub Frame. Refer to FIG. 7-1.

FIG. 7-1

b. Diagonal Supports (4)
c. Lower Gussets (4)
44. Remove & clean per reference pictures:
a. Welds. Refer to FIG. 7-2.

FIG. 7-2
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 should be appropriately trained on industry standards
and have the tools and equipment to perform procedures safely and properly.
17023

Page 7 of 18

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

Body Caulk. Refer to FIG. 8-1.

FIG. 8-1

b. Undercoating.
45. Repair damage to body if any. Welding cracks and holes shut. Consult Customer & Product
Support for questions.
46. Drive out sub frame bolts from the top and properly dispose of.
47. Remove vibra torque bushings. Retain for use.
48. Weld 4 corner gussets to sub frame.
49. Install plug spacer in middle, left, and right mounts.
50. Install new “Heavy Sub-frame” assembly. Trim and fit as necessary stop short of flush install
¼” aluminum spacers and bolts. Ensure bottom of new sub frame is 20.5” from bottom
tubes of truck, front and rear. Refer to FIG 9-1, and applicable prints.

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 should be appropriately trained on industry standards
and have the tools and equipment to perform procedures safely and properly.
17023

Page 8 of 18

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

FIG. 9-1

51. Raise vehicle.
52. Assemble retained vibra torque mounts. Install vibra torque spacers to ensure bottom of
body matches pump house running boards in height.

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 should be appropriately trained on industry standards
and have the tools and equipment to perform procedures safely and properly.
17023

Page 9 of 18

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

a. Front 4: Install springs. Tighten until 3 threads showing. Refer to FIG. 10-1.

FIG. 10-1

b. Rear 4: tighten to 225 lbf-ft. Refer to FIG. 10-2.

FIG. 10-2

53. Lower vehicle.
54. Weld sub frame at:

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 should be appropriately trained on industry standards
and have the tools and equipment to perform procedures safely and properly.
17023

Page 10 of 18

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

a. Front cross bream joints.
b. Compartment corners to sub frame. Refer to FIG. 11-1 and print 001-0000 sheet 4 detail
AB

FIG. 11-1

c. Rear body uprights.
55. Install small channel gussets (2) at rear body up rights. Refer to FIG. 11-2. Refer to
applicable prints.

FIG. 11-2

56. Install 1 corner gusset at right front frame to body connection point.
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 should be appropriately trained on industry standards
and have the tools and equipment to perform procedures safely and properly.
17023

Page 11 of 18

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

57. Install (4) 1” x 2.5” tubes on a diagonal from top of compartments to new sub frame and
weld inside of tank area. Refer to applicable prints.
58. Install (2) front 1/4” reinforcement plates. Clean caulk and metal as necessary. Trim to fit
and weld in. Refer to FIG. 12-1. Refer to applicable prints.

FIG. 12-1

59. Install (2) rear 1/4” reinforcement plates (Size may vary). Clean caulk and metal as
necessary. Trim to fit and weld in. Refer to applicable prints.
60. Install (2) vertical support tubes at rear of sub frame. Clean metal and weld in. Refer Fig. 122 and applicable prints.

FIG. 12-2

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 should be appropriately trained on industry standards
and have the tools and equipment to perform procedures safely and properly.
17023

Page 12 of 18

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

61. Install (2), 6” intake pipe supports on top of sub frame, where applicable. Clean metal and
weld in. Refer to Fig. 13-1.

FIG. 13-1

62. Touch up compartment interiors from welding heat.
63. Raise vehicle.
64. Remove body locating fixtures. Retain for re-use.
65. Loosen rear most vibra torque mounting bolts.
66. Remove rear front mounting bolts. Retain for re-use.
67. Set jacks at rear of body and raise body for clearance and remove rear front mounts. Retain
for re-use.
68. Weld all lower sub frame corner gussets to compartments.
69. Re-install retained front vibra torque mount at rear of truck.
70. Lower body and install bolts for the removed mounts.
71. Torque all 4 rear mounts to 225 lbf-ft.
72. Remove jacks and lower vehicle. Remove all 4 lifts.
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 should be appropriately trained on industry standards
and have the tools and equipment to perform procedures safely and properly.
17023

Page 13 of 18

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

73. Caulk inside tank area around all 1/4” reinforcements.
74. Install rear suction pipe, where applicable. Measure gap between pipe and mounting
bracket.
75. Remove rear suction pipe.
76. Install correct thickness rubber (1/4” or 1/2") on top of suction pipe brackets based on
measurement of gaps, where applicable. Refer to FIG. 14-1.

FIG. 14-1

77. Drill and tap holes for rubber on suction support brackets, where applicable.
78. Drill and tap holes in sub frame for wire routing.

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 should be appropriately trained on industry standards
and have the tools and equipment to perform procedures safely and properly.
17023

Page 14 of 18

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

79. Install retained wiring, priming hoses and sensing hoses on sub frame and rear suction pipe
mounts using P clamps, where applicable. Refer to FIG. 15-1.

FIG. 15-1

80. Install retained rear intake pipe, where applicable. Connect retained front Victaulic to rear
intake in pump panel. Refer to FIG. 15-2.

FIG. 15-2

81. Install (5), 1” rubber spacers on sub frame assembly using 3 zip ties per spacer. Cut 2 1/2"
strips 32” long and glue together to make each 1” spacer.
82. Reconnect batteries.
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 should be appropriately trained on industry standards
and have the tools and equipment to perform procedures safely and properly.
17023

Page 15 of 18

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

83. Install retained tank. Making sure it is as far to the rear in vehicle as possible.
84. Install retained rear MIV assembly, where applicable. Refer to FIG. 16-1.

FIG. 16-1

85. Install retained rear tank fill nipple and cover plate, where applicable. Refer to FIG. 16-2.

FIG. 16-2

86. Install retained dump valve and bezel assembly, where applicable.
87. Install retained drain valve, where applicable.
88. Install retained auto tank fill valve, where applicable.
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 should be appropriately trained on industry standards
and have the tools and equipment to perform procedures safely and properly.
17023

Page 16 of 18

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

89. Connect auto tank fill wiring, where applicable.
90. Connect priming and sensing lines at rear vehicle.
91. Install (3) retained rear discharge pipes through tank, where applicable. Secure front
Victaulic’s loosely.
92. Install retained rear bracket for discharge pipes, where applicable.
93. Install (3) retained rear discharge pipe brass adaptors, where applicable. Use pipe dope on
all threads.
94. Tighten all rear discharge pipe connections in pump panel.
95. Install retained tank to pump hump hose and nipple. Replace with new hose if it was cut
during removal. Use pipe dope on connections.
96. Install retained foam tank senders and connect wiring, where applicable. A foam, B foam
and water. A foam sensor with arrow pointing up. Using pipe dope on all threads.
97. Install retained tank fill nipple using pipe dope. Connect tank fill hose to nipple.
98. Install retained “B” foam pipe into tank using pipe dope, where applicable.
99. Connect retained “B” foam hose.
100. Install retained foam tank fittings and hoses.
101. Connect the retained 3/8” lines to fill tower.
102. Connect retained upper foam level sender connector. Check that sender has arrow
pointing down.
103. Install retained “A” foam, where applicable.
104. Install retained “B” foam, where applicable.
105. Install retained intake and discharge fittings at right pump panel.
106. Install retained intake and discharge fittings at left pump panel.

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 should be appropriately trained on industry standards
and have the tools and equipment to perform procedures safely and properly.
17023

Page 17 of 18

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

107. Pump test vehicle. Record all deficiency’s on the pump test form and work order.
108. Inspect for tank water and foam leaks.
109. Repair problems found as directed.
110. Install retained right side ladder compartment stop bracket.
111. Install retained right side ladder.
112. Install retained hose bed floor.
113. Install retained tank upper floor plate.
114. Install retained hose bed front wall.
115. Install retained hose bed dividers using marked locations.
116. Install retained hose bed lid, where applicable.
117. Connect hose bed lid sensor wiring.
118. Check over vehicle using check list.
119. Road test vehicle.

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 should be appropriately trained on industry standards
and have the tools and equipment to perform procedures safely and properly.
17023

Page 18 of 18

QUA-FR-0290
Rev: 3.0