NHTSA Investigation PE09042

ALTERNATOR CABLE CHAFING

THIS INVESTIGATION WAS PROMPTED BY A REVIEW OF SERVICE BULLETINS PROVIDED BYMCI TO THE AGENCY. MOTOR COACH INDUSTRIES (MCI) SUBMITTED A SERVICE BULLETIN/PRODUCT IMPROVEMENT CAMPAIGN (#3016) IN THEIR 579.5 MONTHLY SUBMISSION REGARDING AN ALTERNATOR CABLE CHAFING ISSUE ON D SERIES COACHES EQUIPPED WITH A CATERPILLAR C13 ENGINE AND A 50DN DELCO ALTERNATOR. THE BULLETIN REPORTED THE CABLE CAN CHAFE AGAINST AN ENGINE BRACKET OR AS A RESULT OF MOVEMENT WITHIN THE CABLE CLAMPS.THE CORRECTIVE ACTION IS TO INSTALL A NEW CABLE AND SUPPORT BRACKETS.ODI BELIEVES THAT THERE IS A HIGH RISK FOR A THERMAL EVENT RESULTING FROM ALTERNATOR CABLES CHAFING WITHIN THE ENGINE COMPARTMENT.ODI PLACES INCREASED EMPHASIS ON PREVENTING POTENTIAL FIRES INVOLVING MOTOR COACHES AND OTHER VEHICLES WHICH CARRY LARGE NUMBERS OF PASSENGERS.IN NOVEMBER2009, MCI FILED A SAFETY RECALL (09V-346) OUTLINING THEIRREMEDY PROGRAM TO RESOLVE THIS ISSUE. MCI WILL INSTALL A NEW CABLE WITH A HEAVY DUTY TERMINAL THAT DOES NOT HAVE A SPIRAL LOOM OVER THE CABLE PASSING THROUGH THE CABLE CLAMPS.ALSO, THE NEW CLAMP AND MOUNTING BRACKET WERE CHANGED TO BETTER ALIGN THE CABLE AS IT PASSES THROUGH THE CABLE CLAMP THUS PREVENTING A CHAFING CONDITION. THE ACTION TAKEN BY MCI RESOLVES THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.

An investigation is a separate record from a recall and from a manufacturer communication. A manufacturer campaign to repair a safety defect or a failure to meet a federal safety standard.