1995 Neoplan AN440: complaints, problems and recalls

EXTREME EXOTHERMIC REACTION IN EXHAUST CATALYST GENERATED SUFFICIENT LOCALIZED TEMPERATURES TO IGNITE SURROUNDING MATERIAL, RESULTING IN FIRE AND DAMAGE TO REAR PORTION OF TRANSIT BUS.

Owner-reported narrative. Look up ODI 542112 at NHTSA ↗

EXTREME EXOTHERMIC REACTION IN EXHAUST CATALYST GENERATED SUFFICIENT LOCALIZED TEMPERATURES TO IGNITE SURROUNDING MATERIAL, RESULTING IN FIRE AND DAMAGE TO REAR PORTION OF TRANSIT BUS.

Owner-reported narrative. Look up ODI 542113 at NHTSA ↗

EXTREME EXOTHERMIC REACTION IN EXHAUST CATALYST GENERATED SUFICIENT LACALIZED TEMPERATURES TO IGNITE SURROUNDING MATERIAL, RESULTING IN FIRE AND DAMAGE TO REAR PORTION OF TRANSIT BUS.

Owner-reported narrative. Look up ODI 542114 at NHTSA ↗

Reported: 1995-08-30 (August 30, 1995)

SOME TEMPERATURE SENSITIVE TRIGGERS WERE NOT X-RAYED. THESE TRIGGERS COULD CONTAIN INTERNAL VOIDS THAT WOULD MAKE THE TRIGGERS SUSCEPTIBLE TO ADVANCED CREEP CAUSING FALSE ACTIVATION AND VENTING OF THE CNG.

Consequence: VENTING OF THE CNG COULD RESULT IN A FIRE.

Remedy: NEOPLAN WILL REPLACE THE PRD WITH THE NEWER DESIGN "GENERATION 2.5" PRESSURE RELIEF DEVICE.

Reported: 1996-09-23 (September 23, 1996)

THESE BUSES ARE EQUIPPED WITH COMPRESSED NATURAL GAS FUEL TANKS SUPPLIED BY EDO CANADA. THE FUEL CYLINDER STRAPS EXPAND WHEN TANKS ARE PRESSURIZED CAUSING BRACKETS TO BREAK THE MOUNTING HARDWARE.

Consequence: THIS CONDITION CAN CAUSE THE CYLINDER TO FALL INCREASING THE RISK OF EXPLOSION OR FIRE.

Remedy: A NEW STRAP WITH ELASTOMERIC SPRINGS THAT WILL ALLOW THE STRAP TO EXPAND WITH THE TANK HAS BEEN DESIGNED AND WILL BE INSTALLED ON THESE BUSES.

Reported: 1996-09-23 (September 23, 1996)

THE TYPE 4 COMPRESSED NATURAL GAS (CNG) FUEL TANK SUPPLIED BY EDO CANADA CAN RUPTURE DURING FUELING.

Consequence: RUPTURE OF A CNG FUEL TANK CAN CAUSE CNG LEAKAGE INCREASING THE RISK OF A FIRE OR EXPLOSION.

Remedy: EACH TANK IS BEING VISUALLY INSPECTED, ASSISTED BY DYE PENETRANT AND RESONANCE TESTED. A DETECTION SHIELD IS PLACED UNDER EACH PAIR OF TANKS, UNDER THE BUS, TO PROVIDE EASE OF INSPECTION FOR ANY DAMAGE. ANY DAMAGED TANK WILL BE REPLACED.

Reported: 1998-11-19 (November 19, 1998)

VEHICLE DESCRIPTION: TRANSIT COACHES EQUIPPED WITH CUMMINS L-10 ENGINES AND NELSON CATALYSTS AND SOLD TO LOS ANGELES, CALIFORNIA TRANSIT AUTHORITY. THE CATALYST CAN EXPERIENCE HIGH TEMPERATURES, WHICH COULD BE CAUSED FROM UNBURNED METHANE IGNITING INSIDE THE CATALYST BRICK.

Consequence: THIS CONDITION CAN RESULT IN EXTREME OVERHEATING OF THE CATALYST AND COULD CAUSE IGNITION OF SURROUNDING COMBUSTIBLES IN CLOSE PROXIMITY TO THE CATALYST.

Remedy: DEALERS WILL INSPECT THE VEHICLES FOR PROPER INSTALLATION AND POSITIONING; INCREASE THE SIZE OF THE FIBERGLASS HOLE SURROUNDING THE TAIL PIPE, REMOVE A RUBBER AIR INLET BOOT THAT WAS TOO CLOSE TO THE CATALYST; REPLACE THE FLEX PIPE IN THE EXHAUST SYSTEM; AND ADD A BLANKET AROUND THE CATALYST TO PROVIDE ADDED INSULATION.