Calspan On-Site Motorcoach Fire Investigation; Vehicle: 1999 MCI Model 102-EL3 56-Passenger Motorcoach; Location: State of Texas

NHTSA · 2010 · ROSA P / Calspan Corp.

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Summary

This report details an on-site investigation conducted by the Crash Data Research Center (Calspan Corporation) for the National Highway Traffic Safety Administration (NHTSA) regarding a fire incident involving a 1999 MCI Model 102-EL3 motorcoach. The incident occurred in May 2009 in Texas while the vehicle was traveling at highway speed on a divided roadway. The motorcoach was transporting 53 passengers, including 38 students and 15 adult chaperones, along with the driver. The investigation was motivated by the need to determine the origin and cause of the fire, which resulted in the vehicle being declared a total loss, although all occupants evacuated safely without injury. The methodology involved a comprehensive on-site inspection of the motorcoach and the incident location, conducted in July 2009. Investigators performed a thorough visual examination and documentation of the vehicle’s exterior, interior, driveline, fuel system, and engine compartment, supported by digital imaging. The investigation also included an assessment of the incident site conditions, such as road surface and weather, and a review of driver and passenger accounts. Additionally, a fire expert reviewed the collected documentation and images to provide an independent opinion on the fire’s origin and cause, adhering to NFPA 921 guidelines for fire and explosion investigations. The findings revealed that the fire originated in the rear engine compartment and was confined primarily to the rear exterior and engine areas, with minimal heat and smoke damage to the passenger interior. The driver had detected smoke emanating from the right rear area and executed a controlled stop, initiating evacuation procedures. Detailed inspection of the engine compartment identified significant high-heat damage around the starter and fuel filter assembly. Specifically, investigators found evidence of electrical arcing between a heavy-gauge battery cable and a steel mounting bracket for the fuel filter. The cable’s insulation had likely abraded due to vibration, causing the exposed energized wire to contact the bracket. This arcing melted the cable and eroded the bracket, igniting accumulated oil and grease in the area. The fire subsequently consumed the fuel filter canisters, starter components, and surrounding fiberglass panels, leading to the extensive rear-end damage observed. The significance of this investigation lies in the identification of a specific mechanical failure as the primary cause of the fire. The report concludes that the arcing of the starter cable against the fuel filter bracket was the ignition source. This finding highlights the potential risks associated with electrical component wear and vibration in heavy-duty vehicles, particularly regarding the proximity of high-current cables to metal structures. The successful evacuation and lack of injuries underscore the effectiveness of the driver’s response and the vehicle’s safety features, such as the onboard fire extinguisher and emergency exits, despite the total loss of the vehicle.

Key finding

The fire originated in the engine compartment, likely caused by electrical arcing from a starter cable contacting a grounded bracket, and was successfully contained without passenger injury.

Methodology

other

Provenance

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• bus coach