Orion VII EPA10 User manual

OPERATOR’SMANUAL
ORION VII HYBRID VEHICLE
ACADEMY EXPRESS HYBRID 1368A
Printed: December 21, 2010

CONTACT INFORMATION:
Daimler Buses North America
350 Hazelhurst Road
Mississauga, Ontario
Canada L5J 4T8
Telephone [phone]
Daimler Buses North America
165 Base Road, PO Box 748
Oriskany, New York
USA 13424
Telephone [phone]
© 2010 DAIMLER BUSES NORTH AMERICA

Table of Contents
Page 1
INTRODUCTION ...............................................................................................................................1
GENERAL ......................................................................................................................................... 2
HYBRID ELECTRIC VEHICLE (H.E.V.) SAFETY INFORMATION ...................................................3
Hybrid Electric Vehicle Propulsion System ................................................................................3
High Voltage Hazards ................................................................................................................ 3
OPERATOR’S COMPARTMENT ......................................................................................................4
FRONT INSTRUMENT PANEL .........................................................................................................9
WARNING LIGHTS AND INDICATORS .........................................................................................13
DRIVER’S SIDE CONTROL PANEL ...............................................................................................19
MASTER SWITCH ..........................................................................................................................25
Engine Stop Position ................................................................................................................25
Day Run Position .....................................................................................................................25
Night Run Position ...................................................................................................................25
Park Position ............................................................................................................................25
DESTINATION SIGNS ....................................................................................................................26
Electronic Destination Sign ...................................................................................................... 26
Operator’s Display and Keyboard (ODK) .................................................................................26
Destination Sign Dimming Feature ..........................................................................................28
DRIVER’S SEAT .............................................................................................................................29
USSC™ Q91 Driver’s Seat ......................................................................................................30
Driver’s Seat Belt .....................................................................................................................31
AIR BRAKE SYSTEM OPERATION ...............................................................................................32
Loss of Air Pressure .................................................................................................................32
Wet Weather Operation ...........................................................................................................33
Emergency/Parking Brake Control Valve .................................................................................33
Brake Interlock .........................................................................................................................34

Table of Contents
Page 2
Rear Axle Brakes Safety Circuit ...............................................................................................34
Anti-Lock Braking System (ABS) .............................................................................................35
ABS Warning Light ...................................................................................................................35
ENGINE OPERATION ....................................................................................................................36
Pre Start-Up Inspection ............................................................................................................36
Starting an Electronically Controlled Engine ............................................................................36
Engine Warm Up ......................................................................................................................37
Operating the Engine ...............................................................................................................37
High Idle ...................................................................................................................................37
Stopping the Engine .................................................................................................................38
Starting Engine From Rear Control Panel ...............................................................................38
Stopping Engine From Rear Control Panel .............................................................................. 39
Engine Protection System - Electronically Controlled Engines (Cummins ISB™) ................... 39
B.A.E.™ HYBRID PROPULSION SYSTEM ....................................................................................41
Hybrid Electric Vehicle (HEV) Propulsion System Operation ...................................................41
Propulsion Control System (PCS) ............................................................................................41
Alternating Current Traction Generator (ACTG) ......................................................................41
Alternating Current Traction Motor (ACTM) ............................................................................. 42
Motor Speed Warning Indicator ...............................................................................................42
Electric Alternator System (EAS) .............................................................................................42
Propulsion Control System (Emergency) Override Switch .......................................................43
Throttle and Brake Pedals .......................................................................................................43
Gear Range Selector Position .................................................................................................43
Stop HEV Indicator ..................................................................................................................44
DRIVER’S PRE-SERVICE INSPECTION .......................................................................................45
Driver Walk Around Test .......................................................................................................... 45

Table of Contents
Page 3
Exterior Inspection ...................................................................................................................45
Interior Inspection ....................................................................................................................45
LIGHTING AND ELECTRICAL ........................................................................................................47
Lighting Operation ....................................................................................................................47
Interior Lighting ........................................................................................................................ 47
Exterior Lighting .......................................................................................................................48
Batteries ................................................................................................................................... 49
Disconnection of Electrical System ..........................................................................................49
HEATING, AIR CONDITIONING, AND VENTILATION ................................................................... 51
Front Heat/Defrost Blower Switch ............................................................................................51
Climate Control System ...........................................................................................................52
Climate Control System Switch ................................................................................................52
Driver’s Booster Blower Switch ................................................................................................52
Fresh Air Ventilation .................................................................................................................53
Driver’s Fan ..............................................................................................................................53
IntelligAIRE™ Climate Control System ....................................................................................54
PASSENGER ENTRANCE AND EXIT DOORS .............................................................................56
Accelerator Interlock ................................................................................................................56
Door System Operation ...........................................................................................................56
Pull Cord Stop Request ...........................................................................................................57
Speed Sensing Interlock ..........................................................................................................57
Malfunction in Opening and Closing Front Door ......................................................................57
Door Master Switch ..................................................................................................................58
Malfunction in Opening and Closing Rear Doors .....................................................................58
External Front Door Access Switch .........................................................................................59
EMERGENCY ESCAPE EXITS ...................................................................................................... 60

Table of Contents
Page 4
Push Out Egress Windows ......................................................................................................60
Rear Roof Hatch ......................................................................................................................60
KNEELING SYSTEM ......................................................................................................................61
Kneeling System Operating Procedure ....................................................................................61
WHEELCHAIR RAMP SYSTEM .....................................................................................................63
Ramp Malfunction ....................................................................................................................63
Operation .................................................................................................................................63
WHEELCHAIR RESTRAINT SYSTEM ...........................................................................................65
Mobility Device Securement Instructions .................................................................................65
ENGINE COOLING SYSTEM .........................................................................................................67
Checking and Replenishing Engine Coolant ............................................................................67
High Coolant Temperature .......................................................................................................68
Low Engine Coolant Level .......................................................................................................68
Modular Traction System (MTS) Coolant ................................................................................. 69
AMEREX™ FIRE SUPPRESSION SYSTEM ..................................................................................70
Fire Suppression System .........................................................................................................71
Automatic Operation ................................................................................................................72
Manual Operation ....................................................................................................................72
EXTERIOR COMPARTMENT AND SERVICE ACCESS DOORS .................................................74
GENERAL DATA AND TECHNICAL INFORMATION ....................................................................77
Reporting Safety Defects .........................................................................................................78

Introduction
Page 1
INTRODUCTION
This manual describes the operating features and safety equipment of the Orion VII EPA10 Hybrid Vehicle. All
personnel involved in the operation of this vehicle should read this manual before providing any public service.
For additional information or assistance, refer to the contact information located at the back of this manual.

General
Page 2
GENERAL
The Orion VII EPA10 hybrid vehicle incorporates specially designed features that provide transportation to the mobility
impaired and physically challenged. It is the operator’s responsibility to assist each passenger in boarding, seating,
attaching and securing restraining belts, and to provide assistance when leaving the vehicle.
Special features of the vehicle fulfill passenger needs in the following areas:
• Kneeling and wheelchair ramp
features allow coach floor to
street level access for the
wheelchair bound individual.
• Restraining belts and
securement devices are
located at all wheelchair
positions.
• Pull cords and push buttons
alert the operator of the NEXT
STOP request, are easily
accessible.

Hybrid Electric Vehicle (H.E.V.) Safety Information
Page 3
HYBRID ELECTRIC VEHICLE (H.E.V.) SAFETY INFORMATION
Hybrid Electric Vehicle
Propulsion System
Due to extremely high voltage
supplied by the energy storage
system (ESS), the propulsion
system contains a battery isolator
switch which allows the operator to
cut off propulsion system power in
special circumstances such as a
vehicle accident. This switch is
located in the curbside battery
compartment. See “Disconnection
of Electrical System” on page 49.
High Voltage Hazards
Although the operator would rarely
have access to any of the
propulsion system components,
he/she must be made aware of the
potential hazards.
Should a problem exist which
requires attention to the propulsion
system, the matter should
immediately be brought to the
attention of qualified service
personnel. For further information
on the HEV system, refer to BAE
Systems™ maintenance manual.
DANGER
Use extreme caution if any work
has to be performed on the
engine while it is running. High
voltage is present at the
generator terminals, traction
motor terminals, and all high
voltage cabling connecting the
generator and traction motor to
the Propulsion Control System
(PCS).
DANGER
Use of the Battery Isolator
Switch is mandatory during
propulsion system maintenance.
If the vehicle was running just
prior to conducting
main99tenance, allow four
minutes for propulsion system
components to discharge
electricity before proceeding.
DANGER
Even with the Battery Isolator
Switch in the OFF position, the
traction battery system remains
a severe shock hazard because
the battery modules themselves
are not disconnected by the use
of this switch. Always use
extreme caution when working
around the rooftop tub.

Operator’s Compartment
Page 4
OPERATOR’S COMPARTMENT
LEGEND
1. IntelligAIRE III™ Display Panel
2. Passenger Stop Request Chime
Unit
3. Destination Sign Keypad
4. Driver’s Booster Blower Vent
5. Driver’s Pull Down Sunvisors
6. Door Master Switch
7. Exhaust Regeneration Override
Switch
8. Regenerative Braking Switch
9. Gooseneck Microphone
10. Horn Button
11. Front Instrument Panel
12. Brake Pedal
13. Accelerator Pedal
14. Directional Signal Foot Control
Switches
15. Driver’s Seat
16. Headlight Dimmer Foot Control
Switch
17. Side Control Panel

Operator’s Compartment
Page 5
The following features and special
equipment are used for normal
vehicle operation.
1. IntelligAIRE™ Display Panel
This display panel includes 4
touch keys, a 3 digit display and
various display indicators. The
panel provides outside and
inside temperature readouts
and setpoint adjustments only.
See “IntelligAIRE™ Climate
Control System” on page 54.
2. Passenger Stop Request
Chime Unit
A single chime will be heard
from this unit when a
passenger, requesting a stop,
activates the touch tape. A
double chime notifies the
operator that a wheelchair
passenger is requesting a stop.
3. Destination Sign Keypad
This keypad is used for
destination sign message
selection and programming.
See “Operator’s Display and
Keyboard (ODK)” on page 26.
4. Driver’s Booster Blower Vent
An auxiliary blower and vent
located inside the overhead
panel, above the operator’s
roadside window, provides the
operator’s area with additional
climate control. See “Fresh Air
Ventilation” on page 53.
5. Driver’s Pull Down Sunvisors
These adjustable pull down
mechanisms,locatedabovethe
operator windshield and
operator’s side window,
prevents eye exposure to
sunlight. A scissor type
reinforcement retains the
shadesrigidity andprevents the
shade from excessive swaying.
6. Door Master Switch
The Door Master switch is a
guarded two position (NORM,
DISABLE) toggle switch used
to override a door malfunction
that is activating the door
interlocksystemandpreventing
the service brakes and
accelerator interlocks from
releasing.
7. Exhaust Regeneration
Override Switch
The Exhaust Regeneration
Override switch is used in
situations where the front dash
HEST lamp is illuminated and
18. Alternating Current Traction
Motor (ACTM) Gear Selector
19. Door Emergency Release Valve
20. Driver’s Door Control Push
Buttons
21. Tilt/Telescopic Steering Column
Lever
LEGEND
CAUTION !
Apply the parking or service
brakes before removing the door
master switch from its normally
guarded position to prevent the
vehicle from rolling.

Operator’s Compartment
Page 6
the vehicles exhaust outlet is
near an area that could be
effected by high temperatures.
8. Regenerative Braking
Disable Switch
This two position (ON, OFF)
toggle switch enables the
operator to deactivate
regenerative braking in the
hybrid propulsion system. The
Regenerative disable switch
should be used only during
slippery, hazardous road
conditions.
9. Gooseneck Microphone
This microphone allows for
flexible operation of the
vehicles’ public address
system. A switch on the
microphone allows the operator
to activate the Public Address
system.
10. Horn Button
Pressing the disk in the center
of the steering wheel activates
two electrical horns.
11. Front Instrument Panel
This panel, located in front of
the operator, contains gauges,
indicator lights, and controls for
operating and monitoring
various vehicle systems. See
“Front Instrument Panel” on
page 9.
12. Brake Pedal
This foot-operated treadle
valve, located on the
compartment floor to the
immediate right of the steering
wheel, applies the vehicle
service brakes.
13. Accelerator Pedal
This foot operated pedal,
remotely controls the engine
fuel governor control, which in
turn controls the speed of the
vehicle.
This pedal is located on the
compartment floor to the right
of the brake pedal.
14. Directional Signal Foot
Control Switches
These two foot switches,
located on the floor to the left of
the steering wheel, activate the
left and right turn signal lights.
Each switch must be pressed
and held for the duration of the
signal.
15. Driver's Seat
The driver’s seat is equipped
with comfort options to
accommodate most operators.
See “Driver’s Seat” on
page 29.
NOTE
A "creep forward" mode is
present in all EPA10 hybrid
vehicles; as a result, the vehicle
will creep forward when the gear
range selector is in the D (drive)
position and the brake pedal is
released.

Operator’s Compartment
Page 7
16. Headlight Dimmer Foot
Control Switch
This foot switch, when
activated, selects the headlight
high or low beam settings.
17. Side Control Panel
This panel, located on the left
hand side of the operator,
contains controls and switches
necessary for various vehicle
systems operations.
These systems include climate
control, front and rear door
control, master control of the
vehicle electrical system,
lighting, etc. See “Driver’s
Side Control Panel” on
page 19.
18. Alternating Current Traction
Motor (ACTM) Gear Selector
Drive modes available on this
selector are Drive (D), Neutral
(N), and Reverse (R). See
“Gear Range Selector
Position” on page 43.
19. Door Emergency Release
Valve
This rotary air valve overrides
the air system to allow front
doors to be opened manually.
See “Malfunction in Opening
and Closing Front Door” on
page 57.
20. Driver’s Door Control Push
Buttons
The rear and front door
controller push buttons allow
the operator to activate the
front and/or rear doors. Press
once to open and press again
to close the doors.
21. Tilt/Telescopic Steering
Column Lever
The steering column is
equipped with adjustment
features that accommodate the
size and height of most
operators. Tilt and height
features are adjusted using a
lever on the left hand side of
the steering column.
To adjust the tilt angle:
a. Pull back on the lever.
b. Grasp the steering wheel
and adjust the angle forward
and aft until the desired
angle is reached.
WARNING
Stop the vehicle and apply the
parking brake before adjusting
the steering column. Failure to
do so could result in loss of
vehicle control, causing personal
injury and/or vehicle damage.

Operator’s Compartment
Page 8
c. Push down slightly on the
lever and gently articulate
the wheel until the column
locks in place.

Front Instrument Panel
Page 9
FRONT INSTRUMENT PANEL

Front Instrument Panel
Page 10
The front instrument panel is a
collection of gauges, controls, and
warning indicators used to operate
and monitor various vehicle
systems.
1. Parking/Emergency Brake
Control
ThisPush/Pullvalveapplies the
rear wheel spring brakes when
parking. It may also be used to
stop the vehicle in an
emergency situation.
PULL on the valve knob to
apply brakes, and PUSH to
release brakes. See
“Emergency/Parking Brake
Control Valve” on page 33.
2. Wiper Control Lamp
This fixture illuminates the
wiper controls.
3. Diesel Emission Fluid (DEF)
Gauge
This gauge measures the
amount of DEF in the 10.6
gallon reservoir tank. Diesel
emission fluid is mixed with hot
exhaust, resulting in an
alteration of the chemical
composition of the exhaust to
make it EPA10 compliant.
A solid red light indicates an
initial warning level of 16.6%;
under such conditions,
removed the vehicle from
service immediately.
A flashing red light indicates a
critical warning level of 11%;
under such conditions,
immediately move the vehicle
to a safe location and shutdown
the engine.
4. Air System Pressure Gauge
This dual indicator gauge
monitors brake circuit air
pressure for both primary and
secondary air circuits.
Normal air system pressure
should not register below
70 psi.
The spring brakes will gradually
apply automatically if pressure
LEGEND
1. Parking/Emergency Brake
Control
2. Wiper Control Lamp
3. Diesel Emission Fluid (DEF)
Gauge
4. Air System Pressure Gauge
5. Engine Coolant Temperature
Gauge
6. Diesel Fuel Gauge
7. LED Warning Lights and Indicator
Panel
8. Speedometer/Odometer Gauge
9. Kneeling System Switch
10. Wheelchair Ramp Switch
11. Manual Fire Suppression Button
12. Automatic Fire Suppression
System (AFSS) Display Panel
13. Accessory Tank Air Pressure
Gauge
14. Windshield Wiper/Washer Control
Valve
15. Driver’s Temperature Control
16. Driver’s Heat/Ventilation Control
17. Driver’s Heater/Defroster Control

Front Instrument Panel
Page 11
is lost, and will be fully applied if
pressure drops to 40 psi. See
“Air Brake System
Operation” on page 32.
5. Engine Coolant Temperature
Gauge
This gauge registers the engine
coolant temperature. The
gauge is designed to register a
temperature range from 100° -
260°F (38° - 127°C). The
normal operating temperature
is between 180° - 200°F (82° -
93°C). If the temperature
continues to rise above this
range, the excessive high
temperature will trigger an
audiblealarmandilluminatethe
CHECK ENGINE indicator on
the front instrument panel. If the
engine temperature continues
to rise above 212°F (100°C),
the engine control unit (ECU)
will commence shutdown
sequence.
6. Diesel Fuel Gauge
This gauge indicator monitors
the amount of diesel fuel in the
125 gallon fuel tank.
Approximately 18 gallons of
fuel remains in the fuel tank
when the low fuel light on the
gauge illuminates. An EMPTY
reading indicates 11.7 gallons
of fuel remaining in the fuel
tank.
7. LED Warning Lights and
Indicator Panel
The vehicle is equipped with a
visual and audible signal
system that is designed to
indicate the various warnings
and normal operating
conditions during vehicle
operation. See “Warning
Lights and Indicators” on
page 13.
8. Speedometer/Odometer
Gauge
This combination needle
indicator and digital counter
registers vehicle speed and
records distance travelled. In
addition, the speedometer is
equipped with and audible text
messaging feature which will
notify the operator if a Low
Coolant, or Low Oil Pressure
situation exists.
9. Kneeling System Switch
Kneeling is controlled by this
momentary switch which lowers
the front of the vehicle
approximately 3 1/2 inches, to
enable easier access when
boarding the vehicle. See
“Kneeling System” on
page 61.
10. Wheelchair Ramp Switch
This rocker switch controls the
operation of the front door
NOTE
The vehicle will run out of fuel
with 5.37 gallons remaining in
the fuel tank.

Front Instrument Panel
Page 12
ramp, allowing wheelchair
access.
When activated, the green
warning light flashes and an
audible alarm sounds. See
“Wheelchair Ramp System”
on page 63.
11. Manual Fire Button
This button allows the operator
to manually activate the fire
bottle. To operate, break the
seal, pull out the ring and press
the FIRE button.
12. Automatic Fire Suppression
System (AFSS) Display Panel
This display panel includes
basic to read LED’s and audio
alarm indication. Detailed
EVENTS are documented on
the Vacuum Fluorescent
Display (VFD) panel.
13. Accessory Tank Air Pressure
Gauge
This gauge monitors the
amount of air remaining in the
front accessory air tank.
14. Windshield Wiper/Washer
Control Valve
This rotary knob controls the
left and right windshield wiper
and has a built in washer
control.
Push in and hold to dispense
washer fluid.
15. Driver's Temperature Control
This rotary control knob
enables the operator to
regulate the temperature in the
operator’s area compartment.
See “Heating, Air
Conditioning, and
Ventilation” on page 51.
16. Driver's Heat/Ventilation
Control
This three position (OFF, HEAT,
VENTILATION) rotary control
knob allows the operator to
select either heat or air flow
ventilation mode.
17. Driver’s Heater/Defroster
Control
This three position (LOW,
MEDIUM, HIGH) control knob
allows air to flow to the front
windshield, and the front
operator’s area.
NOTE
The methane functions are not
applicable to this vehicle.

Warning Lights and Indicators
Page 13
WARNING LIGHTS AND INDICATORS

Warning Lights and Indicators
Page 14
These LED warning lights and
status indicators illuminate to alert
the operator to normal operating
conditions, as well as conditions
that may affect normal vehicle
operation.
All lights illuminate briefly at
start-up, when the Master Switch is
placed in the DAY RUN position.
The operator should verify all LED
illuminations on a daily basis and
report any dimmed or failed units to
service/maintenance personnel.
Distinct audible alarms and
illuminated indicators indicate
conditionsthatrequireanimmediate
response.
1. Stop Engine Indicator
This red indicator illuminates
when a serious malfunction is
detected in the engine system.
This malfunction could
potentially prohibit safe
operation of the engine and
vehicle.
If this condition occurs,
immediately remove the vehicle
from service to a safe location,
and shutdown the engine.
Report the fault to
service/maintenance personnel
immediately.
LEGEND
1. Stop Engine Indicator
2. Left Turn Signal Indicator
3. Alternator Indicator
4. Low Air Pressure Indicator
5. Brake ON Indicator
6. Parking Brake Applied Indicator
7. Check Hybrid Electric Vehicle
(HEV) Indicator
8. High Beam Indicator
9. Kneeling Indicator
10. Next Stop Indicator
11. Wheelchair Stop Indicator
12. Rear Door Indicator
13. Right Turn Signal Indicator
14. Wheelchair Ramp Indicator
15. Warning Interlock Deactivated
Indicator
16. Door Alarm Indicator
17. Air Conditioning (A/C) Fail
Indicator
18. Motor Over-Speed Warning
Indicator
19. Low Steering Fluid Indicator
20. Stop Hybrid Electric Vehicle
(HEV) Indicator
21. Class Door Indicator
22. Regenerative Braking Applied
Indicator
23. Regenerative Braking OFF
Indicator
24. High Exhaust System
Temperature (HEST) Indicator
25. Exhaust Regeneration Inhibit
Indicator
26. Wait to Start Indicator
27. Anti-Lock Braking System (ABS)
ON Indicator
28. Check Engine Indicator
29. Hybrid Coolant Low Indicator
LEGEND