Daimler Buses has partnered with FEV, a globally recognised engineering service provider, to develop the first hydrogen fuel cell-powered Setra coach, named the “H₂ Coach”. The technology demonstrator represents a major step forward in enabling locally emission-free long-distance coach travel.
Built on a conventional Setra coach platform, the H₂ Coach has been developed specifically for testing and validation purposes. The demonstrator highlights the practical potential of hydrogen fuel cell technology, offering short refuelling times, a driving range of at least 800 kilometres per tank fill, and exceptionally quiet operation—key attributes for sustainable long-haul passenger transport.
Daimler Buses and FEV jointly executed the complete system transformation, converting the vehicle from a diesel powertrain into a fuel cell electric vehicle (FCEV). Following the development of the overall vehicle concept, FEV led the mechanical and electrical/electronic (E/E) integration.
A defining feature of the H₂ Coach is its multi-platform system architecture. Core components—including fuel cells, high-voltage batteries, electric motors, hydrogen tank systems, control units, and vehicle software—originate from different technology platforms within Daimler Buses and Daimler Truck. FEV successfully integrated these diverse systems into a fully functional and cohesive powertrain within the vehicle.
Safety played a central role throughout the development process. Comprehensive measures were implemented to address multiple crash load scenarios, as well as functional safety, high-voltage safety, and hydrogen system safety, ensuring the demonstrator meets stringent engineering and operational standards.
“The ‘H₂ Coach’ impressively demonstrates how complex subsystems can be integrated into a testable, safe complete vehicle when vehicle, powertrain, and E/E expertise come from a single source,” said Klaus Wolff, Vice President Project Management at FEV. “With our one-stop-shop approach, we quickly and efficiently delivered the desired customized solution to our customer – from concept to approval.”
After successful approval by German technical inspection authority TÜV and passing electromagnetic compatibility tests, FEV handed over the vehicle to Daimler Buses in the summer of 2025 after approximately two years of joint project work.
Key performance indicators “H₂ Coach”:
- Cellcentric fuel cell unit with 300 kW electrical output
- Two H₂ tanks with a total capacity of 46 kg (101 lbs)
- Central motor with 320 kW continuous output and 400 kW maximum output
- Integrated battery system for intermediate and peak load storage
“A key success factor in recent months has been the open, trusting cooperation with Daimler Buses,” said Wolff, summarizing the successful project.
