2007 Orion VII: complaints, problems and recalls

A PORT AUTHORITY OWNED 2006 ORION VI DIESEL POWERED AIRPORT SHUTTLE BUS WAS DESTROYED BY FIRE ON 6/28/08 AT ABOUT 12:00 A.M. FORTUNATELY THE BUS WAS NOT CARRYING PASSENGERS AT THE TIME, AS THE FIRE SPREAD QUICKLY AND DESTROYED THE BUS EVEN THOUGH IT WAS EQUIPPED WITH AN ON-BOARD FIRE SUPPRESSION SYSTEM THAT DISCHARGED AGENT INTO THE ENGINE COMPARTMENT. FOLLOWING AN INVESTIGATION BY A FORENSIC ENGINEER WITH EXTENSIVE EXPERIENCE IN DIESEL FIRES, IT WAS DETERMINED THAT THE PROBABLE CAUSE OF THE FIRE WAS THE WEAR AND SHORTING OF WIRES FROM THE AL…

Owner-reported narrative. 40,000 miles reported. Look up ODI 10239647 at NHTSA ↗

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: 2009-03-25 (March 25, 2009)

DAIMLER BUS IS RECALLING 804 MY 2006-2009 TRANSIT BUSES EQUIPPED WITH A NEW YORK CUSTOM SEAT HEATER. CURRENTLY, THE TERMINAL CONNECTION OF THE SEAT HEATER IS IMMEDIATELY LOCATED NEXT TO THE SEAT BUS BAR. SHOULD CONDUCTIVE MATERIAL OR DEBRIS, SUCH AS A WASHER, ENTER BETWEEN THE TERMINAL CONNECTION AND THE SEAT BUS BAR, A SHORT CIRCUIT COULD OCCUR.

Consequence: A SHORT CIRCUIT BETWEEN THE SEAT BUS BAR AND THE ADJACENT TERMINAL CONNECTION COULD OVERHEAT THE WIRE, POSSIBLY RESULTING IN A FIRE.

Remedy: DEALERS WILL INSPECT BUSES FOR DEBRIS AND WILL RELOCATE THE TERMINAL CONNECTION AWAY FROM THE BUS BAR. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING APRIL 2009. OWNERS MAY CONTACT DAIMLER BUSES AT 905-403-7807.

Reported: 2009-06-11 (June 11, 2009)

ORION IS RECALLING 286 MODEL YEAR 2007 THROUGH 2009 TRANSIT BUSES MANUFACTURED BETWEEN DECEMBER 2007 AND APRIL 2009. THE BOND OF THE GLASS TO THE ALUMINUM FRAME OF THE PASSENGER WINDOWS IS NOT ADEQUATE ENOUGH TO HOLD THE WINDOW ATTACHED TO THE FRAME.

Consequence: THE WINDOW COULD DISLODGE FROM THE BUS WHILE IN OPERATION, POSSIBLY BECOMING A ROAD HAZARD TO OTHER MOTORISTS WHICH COULD RESULT IN A VEHICLE CRASH.

Remedy: ORION WILL NOTIFY OWNERS AND THE MOVING WINDOW PORTION WILL BE REPLACED FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN ON OR BEFORE JULY 15, 2009. OWNERS MAY CONTACT HEHR INTERNATIONAL AT 1-989-845-3067 OR ORION AT 1-800-716-7466.

Reported: 2009-08-07 (August 7, 2009)

DAIMLER BUS NORTH AMERICA IS RECALLING CERTAIN MODEL YEAR 2006 THROUGH 2009 ORION VII TRANSIT BUSES MANUFACTURED FROM DECEMBER 2007 THROUGH JULY 2009. THE PASSENGER WINDOWS HAVE A TIP-IN TRANSOM WINDOW WHICH IS ATTACHED BY SCREWS. THESE SCREWS MAY LOOSEN AND THE WINDOW MAY DISLODGE AND FALL INTO THE BUS.

Consequence: A COLLAPSING WINDOW COULD INJURE PASSENGERS.

Remedy: AN INTERIM NOTICE WAS SENT TO OWNERS ON OCTOBER 21, 2009 INSTRUCTING THEM TO CHECK THAT THE SCREWS ARE PROPERLY TIGHTENED AND TO INSPECT THEM PERIODICALLY. A PERMANENT REPAIR IS NOW AVAILABLE AND OWNERS WILL BE PROVIDED INSTRUCTIONS TO REPAIR THE BUSES FREE OF CHARGE. AN OWNER NOTIFICATION ADVISING OWNERS ABOUT THE PERMANENT FREE REMEDY WILL BE MAILED ON OR ABOUT AUGUST 27, 2010. OWNERS MAY CONTACT DAIMLER BUSES NORTH AMERICA 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.

Reported: 2014-03-05 (March 5, 2014)

Daimler Buses North America (DBNA) is recalling certain model year 2007-2012 Orion VII transit buses manufactured January 2007 through October 2012 equipped with certain Cummins Westport Model ISL G engines. Condensation in the intake manifold may freeze during cold weather conditions and interfere with the proper operation of the intake manifold pressure sensor.

Consequence: The improper operation of the sensor could induce elevated exhaust temperatures or flames from the exhaust pipe, increasing the risk of a vehicle fire or burn injury to a person near the exhaust pipe.

Remedy: Cummins Inc. and Cummins Wesport Inc. will notify owners, and authorized Cummins service facilities will upload a new ECM calibration, free of charge. The recall began on April 12, 2014. Owners may contact DBNA at 1-905-403-7807 or Cummins Inc. at 1-800-343-7357. Cummins' number for this recall is C1462 (for ISL G engines) or C1461 (for ISX12 G) engines.

Reported: 2015-05-15 (May 15, 2015)

Daimler Buses North America (DBNA) is recalling certain model year 2007-2012 Orion VII natural gas-powered transit buses manufactured January 1, 2007, to October 1, 2012. Excessive engine crankcase pressures may cause the 90-degree elbow of the vent tube assembly to detach from the crankcase ventilation breather, possibly allowing engine oil to come into contact with hot surfaces.

Consequence: If the engine oil comes into contact with hot surfaces, it can increase the risk of a vehicle fire.

Remedy: Cummins will notify owners on behalf of DBNA, and dealers will secure the ends of the 90-degree elbow. In addition, the electronic control module (ECM) will be reprogrammed with software that can adjust the engine output under misfire conditions to limit crankcase pressures. These repairs will be performed free of charge. The recall began on June 12, 2015. Owners may contact DBNA at 1-905-403-7807 or Cummins Inc. at 1-800-343-7357.