2004 Orion VII: complaints, problems and recalls

Reported: 2004-08-30 (August 30, 2004)

ON CERTAIN BUSES, THE ASSEMBLY OF THE WALKING BEAM CONNECTION TO THE REAR SUSPENSION EXHIBITS LOOSE OR BREAKING OF BOLTS DUE TO MISALIGNED SPACERS.

Consequence: THE BOLTS ATTACHING THE REAR AXLE TO THE WALKING BEAM SUSPENSION CAN BREAK. THE AXLE MOVES UPWARD CAUSING THE TIRE TO CONTACT THE WHEELWELL. PARTIAL REAR WHEEL AXLE ALIGNMENT IS LOST. THE VEHICLE EXHIBITS A BRAKING EFFECT ON THE REAR WHEEL.

Remedy: DEALERS WILL INSPECT AND REPLACE THE SPACER WITH ONE THAT WILL PROVIDE PROPER ALIGNMENT WHERE NEEDED AND CONFIRM TORQUE. THE RECALL BEGAN JULY 14, 2005. OWNERS SHOULD CONTACT ORION AT 1-905-403-7832.

Reported: 2004-09-13 (September 13, 2004)

ON CERTAIN BUSES, THE BATTERY STORAGE SLIDING TRAY LOCKING TOGGLE WAS NOT TIGHTENED SUFFICIENTLY. THE BATTERY DOOR CAN OPEN ALLOWING THE BATTERY TRAY TO SLIDE OUT FROM THE STORED POSITION.

Consequence: THIS COULD CAUSE AN OBSTACLE, WHICH COULD RESULT IN A CRASH.

Remedy: DEALERS WILL INSPECT AND ADD A LOCKING PIN TO KEEP THE BATTERY TRAY FROM SLIDING. ORION HAS NOT YET PROVIDED AN OWNER NOTIFICATION SCHEDULE FOR THIS CAMPAIGN. CUSTOMERS MAY ALSO CONTACT ORION AT 1-905-403-7832.

Reported: 2005-02-16 (February 16, 2005)

ON CERTAIN TRANSIT BUSSES EQUIPPED WITH ARVINMERITOR URRESKO TIE ROD CLAMPS, HEAT TREATMENT OF CLAMPS CREATED A SURFACE HARDNESS THAT COULD LEAD TO A FRACTURE OF THE CLAMPS.

Consequence: IN THE EVENT OF A CRACK, THE CLAMPS COULD BREAK OFF AFFECTING TOE-IN AND ALIGNMENT. THE TIE ROD CAN COME LOOSE RESULTING IN STEERING LOSS AND A CRASH COULD OCCUR WITHOUT PRIOR WARNING.

Remedy: ARVINMERITOR IS CONDUCTING THE OWNER NOTIFICATION AND REMEDY FOR THIS CAMPAIGN. OWNERS MAY CONTACT ARVINMERITOR AT 1-866-668-7221 OR ORION BUS AT 905-403-7832.

Reported: 2005-03-02 (March 2, 2005)

ON CERTAIN TRANSIT BUSES, THE FUEL LIFT PUMP COULD FAIL IN A MANNER WHICH RESULTS IN ENGINE FUEL STARVATION, WHICH COULD RESULT IN A STALL CONDITION. POTENTIAL LIFT PUMP FAILURE MODES INCLUDE: BRUSH WEAR OUT, BUSHING FAILURE, ROTOR TAB INSERT FAILURE, OR ANY OTHER FAILURE MODE THAT WOULD CAUSE THE FUEL PUMPING ELEMENT TO STOP SPINNING.

Consequence: IF THE FUEL LIFT PUMP PUMPING ELEMENT STOPS SPINNING AND THE FUEL PUMPING VANES STOP IN A LOCATION WHICH BLOCKS FUEL FLOW THROUGH THE LIFT PUMP, THE ENGINE WILL BE STARVED OF FUEL. FUEL STARVATION COULD CAUSE LOW ENGINE POWER, ENGINE MISFIRE, OR ENGINE STALL. PRIOR TO THE ENGINE STALLING, THE OPERATOR COULD EXPERIENCE LOW ENGINE POWER, ENGINE MISFIRE, AND/OR DASH-MOUNTED FAULT LAMP ILLUMINATION.

Remedy: CUMMINS IS CONDUCTING THE OWNER NOTIFICATION AND REMEDY FOR THIS CAMPAIGN. OWNERS MAY CONTACT CUMMINS AT 1-800-343-7357 OR ORION BUS AT 905-403-7807.

Reported: 2005-06-14 (June 14, 2005)

ON CERTAIN COMMERCIAL BUSES EQUIPPED WITH VAPOR DOOR ASSEMBLIES, THE TWO PIECE CURVED CONNECTING RODS WHEN USED AS AN ELEMENT OF THE DOOR ACTUATION LINKAGE IN CONJUNCTION WITH A VAPOR MEDIUM PNEUMATIC DIFFERENTIAL ENGINE, MAY BE SUBJECT TO FATIGUE FAILURE RESULTING IN BENDING OR BREAKING OF THE CONNECTING ROD.

Consequence: A BROKEN CONNECTING ROD CAN ALLOW THE DOOR PANEL TO MOVE FREELY IN AN UNCONTROLLED MANNER, LEAVING PASSENGERS INSIDE THE VEHICLE UNPROTECTED BY THE DOOR PANEL AND ENABLING A PROTRUDING DOOR PANEL TO STRIKE PERSONS OR OBJECTS OUTSIDE THE VEHICLE.

Remedy: ORION IS WORKING WITH VAPOR BUS INTERNATIONAL TO NOTIFY OWNERS AND HAVE THE REPAIR PERFORMED ON THEIR VEHICLES. THE REMEDY CONSISTS OF REPLACING THE TWO PIECE CONNECTING ROD WITH A ONE PIECE CONNECTING ROD. OWNERS MAY CONTACT ORION BUS AT 905-403-7832 OR VAPOR AT 847-777-6400.

Reported: 2005-09-13 (September 13, 2005)

ON CERTAIN TRANSIT BUSES EQUIPPED WITH CUMMINS ISB-02 DIESEL ENGINES BUILT WITH EMC CONTROLLED FUEL LIFT PUMPS. ERRATIC VOLTAGE SUPPLY TO THE FUEL LIFT PUMP CAUSES PREMATURE ELECTRIC BRUSH WEAR INTERNAL TO THE FUEL LIFT PUMP. THIS PREMATURE WEAR COULD RESULT IN FUEL LIFT PUMP FAILURE AND IN SOME CASES MAY CAUSE AN ENGINE STALL CONDITION.

Consequence: SHOULD THE ENGINE STALL, A VEHICLE CRASH COULD OCCUR.

Remedy: CUMMINS, IN CONJUNCTION WITH ORION, WILL NOTIFY OWNERS AND REPAIR THE ENGINES BY EMC RECALIBRATION AND REPLACEMENT OF THE FUEL LIFT PUMP AT NO CHARGE TO THE CUSTOMER. OWNERS MAY CONTACT CUMMINS ASSISTANCE CENTER AT 1-800-DIESELS OR ORION AT 1-315-223-5100.

Reported: 2006-12-22 (December 22, 2006)

ON CERTAIN BUSES EQUIPPED WITH A GRAHAM WHITE BRAKE AIR DRYER MODEL QBA15, THE BRAKE AIR DRYER TIMER DOES NOT FUNCTION PROPERLY. THE AIR ENTERING INTO THE BRAKE SYSTEM MAY NOT HAVE THE MOISTURE REMOVED. IF NOT PROPERLY DRAINED, SMALL ICE CRYSTALS MAY FORM IN THE BRAKE SYSTEM PREVENTING THE SYSTEM TO OPERATE THE BRAKES PROPERLY.

Consequence: THE BUS MAY NOT PERFORM AS EXPECTED WHEN STOPPING, INCREASING THE RISK OF A CRASH.

Remedy: DAIMLERCHRYSLER IS WORKING WITH GRAHAM WHITE TO DEVELOP A REMEDY. OWNERS ARE BEING ASKED TO INSPECT THE WET BRAKE AIR TANK FOR MOISTURE BY USING A MANUAL DRAIN. ONLY TWO CUSTOMERS ARE INVOLVED AND HAVE BEEN CONTACTED.

Reported: 2007-07-26 (July 26, 2007)

ON CERTAIN TRANSIT BUSES BUILT WITH CUMMINS ISL ENGINES, THE EXHAUST ELBOW WAS INCORRECTLY ASSEMBLED AND WELDED DURING PRODUCTION. THE UPPER FLANGE HAS A BUTT TYPE WELD INSTEAD OF A FILLET TYPE WELD.

Consequence: AN EXHAUST SYSTEM THAT IS NOT MAINTAINED TO ENSURE THAT THERE ARE NO LEAKING SECTIONS CAN CAUSE HEAT DAMAGE TO SURROUNDING COMPONENTS INCREASING THE RISK OF A FIRE.

Remedy: OWNERS WILL BE REIMBURSED FOR THE REPLACEMENT OF THE EXHAUST ELBOW. THE RECALL BEGAN DURING SEPTEMBER 2007. OWNERS MAY CONTACT ORION AT 1-800-716-7466.

Reported: 2007-08-28 (August 28, 2007)

ON CERTAIN TRANSIT BUSES EQUIPPED WITH CUMMINS ENGINES CONFIGURED WITH DIESEL PARTICULATE FILTERS (DPF) AND ULTRA COMPACT MODULES (UCM), THE UCM MAY FAIL. THE UCM IS LOCATED IN A WIRING HARNESS INSIDE THE ENGINE COMPARTMENT ON THE CURB SIDE.

Consequence: THE ENGINE MAY STALL AND THE UCM MAY FAIL CAUSING A FIRE.

Remedy: OWNERS WILL BE PROVIDED WITH INSTRUCTIONS AND PARTS TO REPLACE THE 5 AMP CIRCUIT BREAKER WITH A 2 AMP FUSE TO MITIGATE THE FAILURE OF THE UCM FROM SUBSEQUENTLY CAUSING A FIRE. THE RECALL BEGAN ON JANUARY 25, 2008. OWNERS MAY CONTACT DCBUSNA/ORION BUS AT 905-403-7832.

Reported: 2008-09-29 (September 29, 2008)

DAIMLER BUSES IS RECALLING 175 MY 2004-2008 ORION V AND VII BUSES EQUIPPED WITH A CUMMINS ISL DIESEL ENGINES. DUE TO VARIOUS ALTERNATOR CABLE ROUTING CONFIGURATIONS, IT MAY BE POSSIBLE FOR THE CABLE TO RUB ON ENGINE COMPONENTS.

Consequence: WHEN THE CABLE RUBBING IS NOT DETECTED DURING REGULAR MAINTENANCE INSPECTIONS, THE INSULATION CAN RUB TO EXPOSE THE ELECTRIFIED CABLE. ARCING CAN CAUSE A FIRE TO OCCUR.

Remedy: DAIMLER BUSES WILL REROUTE THE ALTERNATOR CABLE TO ENSURE THAT THE CABLE DOES NOT CONTACT ENGINE COMPONENTS. THE RECALL IS EXPECTED TO BEGIN ON OR BEFORE JANUARY 2009. OWNERS MAY CONTACT DAIMLER BUSES AT 1-800-716-7466.

Reported: 2009-10-20 (October 20, 2009)

DAIMLER BUSES OF NORTH AMERICA IS RECALLING CERTAIN MODEL YEAR 2002 THROUGH 2009 ORION TRANSIT BUSES EQUIPPED WITH LUMINATOR HORIZON LED SIDE DESTINATION SIGNS. THE CONNECTOR BOARD CAN CORRODE DUE TO AN ACCUMULATION OF MOISTURE UNDER THE CONNECTOR.

Consequence: A SHORT COULD OCCUR, POSSIBLY CAUSING SMOKE AND A FIRE.

Remedy: ORION WILL NOTIFY OWNERS AND THE BUSES WILL BE REPAIRED BY LUMINATOR FREE OF CHARGE. PLEASE SEE LUMINATOR'S DEFECT REPORT 09E-054. THE SAFETY RECALL IS EXPECTED TO BEGIN DURING NOVEMBER 2009. OWNERS MAY CONTACT LUMINATOR AT 1-972-516-3033 OR ORION AT 1-800-716-7466.

Reported: 2010-01-21 (January 21, 2010)

DAIMLER BUSES IS RECALLING CERTAIN ORION TRANSIT BUSES EQUIPPED WITH THE MORSE REMOTE THROTTLE CONTROL. THE MORSE REMOTE THROTTLE CONTROL PANEL IS LOCATED IN THE ENGINE COMPARTMENT AND A SWITCH ON IT IS LABELED, "THROTTLE"; "OFF" OR "FRONT" AND "ON" OR "REAR" SELECTING THE ACTIVE ENGINE CONTROL STATION. IF A PERSON OPERATING THE ENGINE FROM THE "REAR" POSITION (AT THE ENGINE) FAILS TO PLACE THE SWITCH IN THE "OFF" OR "FRONT" POSITION AND THE ENGINE RPM WAS SET TO ABOVE IDLE DURING MAINTENANCE FOR EXAMPLE, WHEN THE BUS IS STARTED FROM THE DRIVER'S STATION THE ENGINE COULD CHANGE TO THE HIGHER RPM RESULTING IN UNWANTED ENGINE POWER.

Consequence: THE BUS COULD ACCELERATE AT A HIGHER RATE THAN ANTICIPATED INCREASING THE RISK OF A CRASH.

Remedy: DAIMLER WILL PROVIDE INSTRUCTIONS TO MODIFY THE WIRING TO THE MORSE THROTTLE CONTROL SWITCH. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON APRIL 1, 2010. OWNERS MAY CONTACT DAIMLER BUSES AT 1-800-716-7466.

Reported: 2013-09-27 (September 27, 2013)

Daimler Buses North America Ltd. (DBNA) is recalling certain model year 2003-2008 Orion V and model year 2002-2010 VII buses equipped with Sure Power equalizers and DC-DC Converters. The specific potting compound used in the equalizers and convertors for insulation was found to be capable of conducting electricity after being exposed to heat.

Consequence: Once electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.

Remedy: DBNA will notify owners and Sure Power representatives will change out the equalizer and/or convertor, free of charge. The recall is expected to begin during November 2014. Owners may contact DBNA at 1-905-403-1111.