The revamped interurban bus Setra MultiClass 500 L: extraordinary, economical and impressive across the board

• Extended range: the new Setra MultiClass quartet
• Unique design: the iconic look of the
  MultiClass 500 LE
• Versatile passenger compartment: flexibility is key
• Exemplary cockpit: one series, three driver’s workplaces
• New: Predictive Powertrain Control (PPC) in interurban transport
• Outstanding safety: state-of-the-art assistance systems, new Preventive Brake Assist 2
• Proven drive system: low-emission, economical, versatile
• Highly economical: hybrid models, compatible parts, assistance systems, digitisation, unique services
• Comprehensive testing: mature by the start of production

The completely revamped Setra MultiClass 500 LE sets new standards among low-entry interurban buses with a unique and exciting design, exceptional versatility and flexibility, maximum efficiency, highest safety standards, and practical solutions down to the tiniest detail. Companies, passengers and drivers alike all benefit from the unique low-entry (LE) models of the new MultiClass 500 LE bus. To embrace the theme of the launch campaign, the new Setra MultiClass 500 LE has many extraordinary features and is unquestionably economical.

Setra: A traditional brand with a cutting-edge lineup of buses

Setra's vast range has always been a particular strength of this major, legendary bus brand. In addition to top-class coaches, they also produce extremely economical and functional interurban and city buses. From the very first generation of Setra buses manufactured in the 1950s to the 100, 200, 300 or 400 series, the brand's elegant coaches have always been supplemented by purpose-built interurban buses. The low-entry interurban buses of the MultiClass 400 LE business series have recently achieved great success.

After launching the next generation of striking Setra ComfortClass 500 and TopClass 500 coaches, Setra is now writing a new chapter in this segment by introducing the completely revamped low-entry interurban buses of the MultiClass 500 LE series. And in unmistakable Setra quality. Setra provides a range of buses that is not only contemporary and highly advanced but also unique in the industry. The new MultiClass 500 LE buses also embody typical Setra brand values with their impressive efficiency and quite astonishing individuality.

Extended range:  the new Setra MultiClass quartet

Setra MultiClass – this name has always been a cornerstone of the range because the Setra MultiClass traditionally successfully covers the entire interurban bus transport sector. The new MultiClass 500 LE can do even more and now also handles urban and suburban transportation. It comes in a particularly wide range of variants – four models are now available instead of the previous three. As a low-entry (LE) vehicle, the quartet combines two worlds: low-floor convenience and comfortable travel. Designed with a low-floor layout extending right up to the rear axle, passengers can board and alight quickly and easily in the front section. This benefits all passengers, especially people with restricted mobility. In front of the rear axle, three shallow steps lead up to the rear compartment. The coach-based drive and chassis technology sets new standards of comfort even on long journeys.

With the launch of the new Setra MultiClass 500 LE , the low-entry range has been extended to include a compact version and now features urban buses ranging from 10.51 to 14.52 metres in length. They are designed to accommodate a wide range of operations, from urban transportation to long-distance interurban travel in sparsely populated regions. These buses can be registered either as class 1 (scheduled city bus) or class 2 (scheduled interurban bus).

The combination of low-floor technology with varied equipment options and different configurations of doors, platforms, seating, cockpits, engines and transmissions means that the new MultiClass 500 LE is also ideal for use in urban traffic. This new generation of buses proves its worth in classic scheduled and school bus applications, when used as shuttles or in feeder and factory transport. In fact right across the board wherever a maximum of individuality and economy are required.

A modular system, meticulously designed down to the smallest detail, forms the foundation of the new model lineup. All vehicles have a uniform front overhang of 2710 millimetres and rear overhang of 3300 millimetres. The doors are also identically positioned in front of the drive axle and 1540 millimetres from the centre of the axle. Only the wheelbase and the number of axles vary. The result is a model range that covers all interurban transportation requirements:

• MultiClass S 510 LE: the new compact interurban bus. This new model has a wheelbase of only 4500 millimetres and is 10.51 metres long. It has a remarkably tight turning circle of just 17.3 metres and can accommodate up to 39 seats when fully equipped. This exceptionally manoeuvrable compact bus is ideal for navigating narrow and winding mountain passes, tight roads in old towns or routes with low passenger volumes.
• MultiClass S 515 LE: This low-entry, classic bus is 12.21 metres long, has two axles and a seating capacity of up to 51. It is a versatile all-rounder suitable for almost any urban or rural application over short or long distances.
• MultiClass S 516 LE: The 516 variant is 12.92 metres long and has two axles allowing it to be fitted with up to 55 seats. This makes it extremely economical when used as an interurban bus, shuttle, school bus or works transport vehicle.
• MultiClass S 518 LE: With room for up to 63 seats, this is the titan of the low-entry segment. The longest Setra in the new series is 14.52 metres long and has three axles. High-volume scheduled services, school transport and long interurban routes are its specialities.

In addition to the standard layout, the new MultiClass 500 LE is a highly customisable interurban bus that can be equipped to suit any requirements. Numerous door variants are available along with several different cockpits, platform designs, various seating options and ramps and lifts for passengers with restricted mobility. One thing is certain: for all its practical advantages, it is still a real head-turner.

Unique design: the iconic look of the Setra MultiClass500LE

Setra is synonymous with captivating and enduring design. Planning a low-entry bus is a twin challenge for designers. For interurban buses, practicality comes first coupled with attractive packaging. For low-entry buses, the fact that the vehicle is divided into two segments further complicates matters. The difference in height between the low-floor section at the front and the high-floor area at the rear unavoidably results in a step in the window line.

The designers of the new Setra MultiClass 500 LE have turned this problem into an advantage: the outside of the new low-entry bus is deliberately divided into two distinct sections. The clear division of the passenger compartment into "stalls" (lower floor section) and "boxes" (upper floor section) makes the exterior of the new interurban buses more elegant. The two segments are tied together by a wide vertical strip. The exterior is clad in aluminium panels painted in the vehicle's colour. The panel edges are pleasingly rounded and quite different from the boxy designs typically associated with scheduled service buses.

On the right side of the vehicle, the doors blend seamlessly into the bodywork thanks to a tinted glass panel above the door leaves. The dark-framed, rounded A-pillars at the front, and the similarly shaped corner profiles at the rear dissolve the usual boxiness and give way to smooth and flowing forms.

The roof of the interurban bus appears to float above its body. The result is a light, airy design that is unique within the industry and free from the austerity typically associated with conventional interurban buses. The look is particularly striking when customers choose the darker tint option for the side windows.

The front of the MultiClass 500 LE has the new Setra family face introduced by the brand for its current range of coaches. The confident chrome brand logo rests on a glossy black front panel framed in matte silver. To the left and right, black headlights with full LED lamps as standard really stand out. They not only look the part but also provide excellent illumination – very important for an interurban bus during darker seasons and off-peak hours. They also save energy and last for the vehicles' entire service life. They significantly lower costs and improve safety throughout many years of service in frequent interurban applications.

The new LED lighting elements above the headlights resemble eyebrows. They work as combined turn signals, position lights and daytime running lights. These stylish lights come from the new generation of Setra coaches and are identical on the left and right. This simplifies spare parts management in the event of minor damage that can occur during demanding interurban transport. At the same time, they accentuate the family resemblance among Setra's bus series.

Above, the windscreen is visually extended downwards by a black panel. A contour edge running across the entire width of the vehicle separates the area below. The newly adopted brand emblem, a K in a circle, is prominently displayed in this area as on the brand's coaches.

No matter where the you look, every detail of the new interurban buses has been meticulously crafted. This attention to detail extends to the contours of the joints, the frame around the front panel, the raised letters of the brand name and the headlights. Lastly, the fog lights are integrated into black panels at the bottom left and right. This not only gives the buses a sturdy presence on the road but also creates space for integrating future optical systems for advanced driver assistance features, such as the second generation of the Predictive Brake Assist 2 active braking system.

This clever feature is just one of many that show the practicality of these new interurban bus designs. The front left and right corner bumpers can be folded out without tools should any repairs be necessary. The same applies to the front panel, behind which the container for the windscreen washer fluid is now conveniently located for easy access.

On the sides above the front wheels, the trademark shows the pedigree of the new MultiClass 500 LE – it is a genuine Setra through and through. This is also shown by the brand logo on the distinctively designed rear of the bus. The top features an aerodynamic roof with a trailing edge; at the bottom, the rear lights have the familiar basic shape but are equipped with full LED technology and a completely unique lighting pattern. It is related to the red stripes found on the new Setra coaches whilst remaining unmistakably distinct. Keen observers will notice the brand logo within the rear lights serving both as a subtle statement and also preventing product piracy.

Numerous door options: Welcome aboard!

The exceptional versatility of the new Setra MultiClass 500 LE begins with the selection of doors. For entrance one, a single-leaf door is available in two widths of 900 and 1150 millimetres. There is also a new option for a wider door with two leaves, providing a passage width of 1380 mm. Entrance two can be chosen as a single-leaf door or as a double door (1150/1380 millimetres). On request, all models can also be equipped with a third door located behind the rear axle (900 millimetres wide). All doors fully glazed down to the floor.

Depending on the specific door position and door variant, companies can choose between outward swivelling doors, inward swivelling doors or swivelling/sliding doors to suit their specific needs and preferences. Many other details also speak of great practicality. For example, the support arm of the outward swivelling door at entrance one is mounted above. This prevents the door from hitting or getting damaged by, for instance, contact with embankments, high curbs or tight and banked bends on mountain passes.

Depending on the door variant and tyre size, entrance two offers a range of ramp options, including a mechanical folding ramp, a double ramp with a combination of electric and mechanical functions, and an electric wedge ramp.

A mechanical folding ramp for door one is also available for the first time. It can be fitted in variants without a platform as they have the required aisle width to allow wheelchair users to safely reach the special use area opposite entrance two. In this area, wheelchairs can be safely secured either using convenient mushroom head fittings and belts or with belts integrated into the platforms. Alternatively, a special use area can be fitted on the right in the direction of travel.

The boarding height of city buses in the front section at entrance one (excluding the kneeling function) is only between 311 and 314 millimetres when equipped with 275/70 R 22.5 tyres. With interurban bus tyres of size 295/80 R 22.5, boarding height only increases to 355 to 358 millimetres.

Destination displays from a range of manufacturers can be fitted to help passengers spot the correct bus at the bus stop and so that companies can select their preferred supplier.

Versatile passenger compartment: Flexibility is key

What would you prefer? A fully low-floor front section, 210 mm platforms on the left or right, or platforms on both sides available in both long and short versions? The new Setra MultiClass 500 LE offers almost limitless possibilities when it comes to configuring the passenger compartment.

The interior is designed to be functional and welcoming – glass partition walls with high or half-height screen printing over a variety of floor decors, smooth side wall coverings with decorative films or cosy needle felt surfaces, a wide range of handrails and a combination of light and dark panelling. Three shallow steps, ranging in height from 159 to 170 millimetres, provide access to the high-floor area at the rear of the bus.

Glass roof hatches, optionally electrically operated, make the interior even more bright and inviting. The ceiling lights are centrally positioned and feature subtle night lighting.

The seating options are equally diverse, ranging from scheduled city to excursion configurations. The MultiClass 500 LE comes as standard with the Setra Transit interurban seating and optionally with the even more comfortable Setra Route coach seating. On request, both options can be equipped with seat belts. Setra Passage seating is alternatively available. This features seat shells in the low-floor segment. They have cantilever frames similar to those found in low-floor city buses instead of traditional chair bases. Every seating configuration is manufactured in-house and is available in a wide range of designs. Optional folding seats in both forward-facing and rearward-facing positions can also be installed in the special use area.

On request, luggage racks can be provided for the passengers' hand luggage. These have perforated bases for easy visibility of belongings from below to prevent passengers from forgetting items in the bus. Depending on the seating configuration, companies can choose from various storage options above the wheelhouse panelling of the front axle.

Great climate: powerful heating, twin air conditioning systems

In addition to the spacious interior, ample headroom of approximately 2600 millimetres and comfortable seating, the air conditioning system creates a pleasant climate on board these new buses. The heating, ventilation and air conditioning systems of the Setra MultiClass 500 LE are designed to meet specific needs. The side windows can be single-glazed or double-glazed. Powerful fan heaters and the front box are responsible for quickly heating up the passenger compartment. Ventilation is provided by hinged windows as standard. It is also supported by the two glass roof hatches, which also serve as mandatory emergency exits, and powerful air vents located above the rear section of the bus.

If air conditioning is desired, operators once again have a choice. The basic version is a climate-controlled driver's workplace. A new version called EvoCool Light Basic with two roof-mounted climate modules each with an output of 12 kW is ideal for use in temperate regions where temperature control of the passenger compartment is sufficient. In this case, the air vents are located centrally on the underside of the climate modules above the centre aisle. The classic roof-mounted air conditioner, EvoCool Basic, is particularly powerful with an output of 32 to 39 kW depending on the model. It distributes cooled air throughout the passenger compartment via roof ducts with outlets. Vehicles with rooftop air conditioning systems can be optionally equipped with air vents and reading lights – yet another example of the  versatility of the new MultiClass 500 LE. All air conditioning systems come with antiviral filters as standard.

Exemplary cockpit: one series, three driver's workplaces

The driver's workstation of the new Setra MultiClass 500 LE is equally as versatile as the passenger compartment. Three variants are available: Cockpit City (urban), Cockpit Basic City (urban/interurban) or Cockpit Basic (interurban), tailored to the specific application. All models come as standard with a closed rear panel, available in either opaque plastic or plexiglass, and a driver's cab door. It welcomes boarding passengers with the branded logo and can be equipped, on request, with a protective shield or even full glazing.

Two different types of driver's seats are available. These seats can be mounted in four different positions. They are adjustable in many ways and can be individually equipped up to and including air conditioning.

The standard version is the Cockpit Basic for interurban use. It is practically designed to accommodate ticket and point-of-sale systems for scheduled services. The new optional communication technology compartment (NT compartment) with slide-in pockets above the driver's area accommodates electronic devices. It has been significantly enlarged compared to the previous model. This makes it easier to install equipment or perform maintenance tasks. Alternatively, a driver's storage compartment is available instead of the NT compartment. If luggage racks are ordered, storage compartments can be fitted in the front section on the left and right.

The driver's area is ergonomically perfect and driver-focused. The design is based on extensive ergonomic studies with test subjects of different heights conducted using virtual reality (VR) technology. From its appearance to the controls and instrumentation with large round dials and a central colour display, the high-quality cockpit comes up to full coach standards. Together with the standard multifunction steering wheel, it is a significant upgrade compared to conventional interurban buses.

All this is complemented by solid material quality and meticulous design, including well-thought-out colour schemes: The upper part is black to avoid glare, while the lower level is designed in a friendly and functional grey. It brightens up the interior, creating an inviting and spacious atmosphere.

On the right side of the cockpit, there is space for an optional roomy storage cabinet. In addition, a variety of storage compartments within the driver's cab and on the inside of the cab door can accommodate items ranging from small accessories to beverages, and even a driver's bag in the format of a pilot's case.

In the MultiClass 500 LE, with the extra-wide, double-leaf inward swivelling door at entry one, both the centre console - with slide-in pockets for devices - and the railing and base on the door side have been significantly modified. The result is the Cockpit Basic City. It creates the necessary space for the inward swivelling front door panel, providing more aisle width for boarding passengers and even for accommodating wheelchairs. The Cockpit Basic City is also available with other door variants as an optional feature, showcasing the versatility of the new Setra MultiClass 500 LE. This modification changes the character of the driver's workplace in the MultiClass 500 LE. It also sets new standards in terms of form and colour scheme in its vehicle category. Furthermore, it combines the aesthetics, instruments, and storage compartments of a coach with the exceptional functionality of a city bus.

This is even more apparent in the third cockpit variant – known as Cockpit City –, which has a driver's area designed according to the guidelines of the VDV (Association of German Transport Companies). It comes with a completely revamped, standardised instrument panel that can be adjusted together with the steering wheel. This instrument panel also features large and clearly structured round gauges, an informative colour display and a multifunction steering wheel. The instrument cluster is integrated into a newly designed console. Due to the adjustable instrument panel, the MultiClass 500 LE also features a newly developed window sill.

Overall, the quality of the Setra brand is reflected in the design and features of the cockpit. No matter which cockpit the transport company chooses, the new MultiClass 500 LE supports the driver's in their responsible job in the typical Setra way. From the standard rain-light sensor to the electronic parking brake, these helpful features come as standard. As if by instinct, the hand naturally falls on the conveniently mounted and ergonomically designed, comfortable knob.

The electronic parking brake combines easy handling with high safety standards. The driver manually activates the parking brake by either pulling the lever or pressing the P button. The parking brake can be released either by stepping on the accelerator pedal or by pressing the P button again. The integrated Hold function is activated when the vehicle is at a standstill by applying additional pressure to the brake pedal. The service brake is released only when the driver presses the accelerator pedal again. The system also helps the driver during hill starts with the integrated hill start assist feature. Finally, the parking brake is optionally activated automatically when the MultiClass 500 LE is stationary, the driver releases the seat belt and leaves his seat. This protects the bus against unintended rolling.

The optional 360° camera system provides perfect all-around visibility when manoeuvring and navigating tight spaces. This system allows the driver to detect pedestrians, cyclists and obstacles in areas that are otherwise difficult to see or obscured entirely. The immediate surroundings of the vehicle are captured by a total of four cameras located at the front, rear and above the side windows, creating an indirect 360° panoramic view. The corresponding image from a bird's-eye view is displayed on a 10-inch monitor located on the A-pillar. The screen is divided into two sections. This provides a total of five different viewing options: a full-screen, 360° bird's-eye view and the option to supplement it with images from individual cameras. The second image on the monitor varies according to the driving situation. For example, it will automatically switch to the corresponding side when the indicator is activated or when reverse gear is engaged.

The driver can also select the desired image from an on-screen menu. The views from the 360° cameras are available during forwards motion up to a speed of approximately 30 km/h and at all times when reversing. Driver orientation is facilitated by markings indicating the front and rear edges of the bus and a suggested driving corridor. The images provide a field of view of approximately five to six metres, ensuring that the adjacent lane is covered.

The surround lighting for reversing is another significant aid when manoeuvring. The LED lights pointing diagonally to the rear are mounted on the wheel arch flaps of the drive axle.

New: Predictive Powertrain Control (PPC) in interurban transport

In conjunction with the fully-automated GO 250‑8 PowerShift transmission, the latest version of the intelligent fuel-saving cruise control system, Predictive Powertrain Control (PPC), assists the driver. It integrates a driving style adapted to the topography into the automatic transmission system. The extended map data of PPC now covers nearly all rural roads in Europe as well as motorways and highways. PPC takes into account intersections and roundabouts and is linked to the adaptive cruise control system. Based on the stored map data, PPC automatically reduces the vehicle's speed when entering built-up areas, before tight bends on country roads or at obstacles such as roundabouts and stop or yield intersections. This has numerous advantages: drivers receive effective support as the constantly adjusted driving style improves safety while reducing fuel consumption.

In addition to innovative assistance systems, the MultiClass 500 LE also comes with impressive classic features to improve the driver's normal workday. For example, there are exterior storage compartments for accommodating snow chains or tools. The Aquablade windscreen wipers are exceptionally efficient. There is also an optional safe located in the step leading to the driver's cab.

Outstanding safety: state-of-the-art assistance systems, new Preventive Brake Assist 2

Safety is a quintessential topic for Setra and every Setra bus is truly safe bus. The new MultiClass 500 LE is a perfect example. In addition to proven assistance systems such as the Electronic Stability Program (ESP), Anti-lock Braking System (ABS) and Traction Control System, the next generation of the world's first active brake assist for specialised scheduled service buses from Daimler Buses, called Preventive Brake Assist 2, will be available upon request.

Preventive Brake Assist 2 utilises a combination of short-range and long-range radar sensors as well as a camera. This allows it to react to stationary and moving objects including pedestrians and cyclists. The system is capable of processing multiple objects simultaneously. Within the system limits, objects off the carriageway, such as traffic signs, parked vehicles or traffic in adjacent lanes, are also detected more accurately, which minimises false warnings.

The assistance system warns the driver of potential collisions with stationary or moving objects. Warnings are issued visually by means of a red flashing alert on the central display and audibly. It automatically initiates a partial braking manoeuvre at the same time. The braking action is maintained until either the driver intervenes, the situation is no longer critical or the bus comes to a complete stop. The warning cascade and brake intervention are specifically designed for use in scheduled service with the aim of protecting standing passengers. Preventive Brake Assist 2 will be available as an optional feature for all models of the new Setra MultiClass 500 LE starting from spring 2024. It is another milestone in the protection of vulnerable road users in particular.

Despite all the assistance and safety systems, it is never possible to completely eliminate accidents. The developers of the new Setra MultiClass 500 LE have also included precautions for such situations. An underride guard reduces the consequences of rear-end or frontal collisions. It protects both the driver and the occupants of the other involved vehicle. Furthermore, the MultiClass 500 LE complies with the requirements of ECE R 66.02 for the rollover test and, on request, voluntarily meets the requirements of the pendulum impact test according to ECE R 29.

In preparation for the MultiClass 500 LE, additional assistance systems are being developed, such as the Sideguard Assist 2, which is installed on both sides.

Proven drive system: low-emission, economical, versatile

The drive system of the Setra MultiClass 500 LE is based on proven and economical components that have been extensively tested. They are perfectly coordinated and customised in numerous combinations to suit the individual operational profile.

A compact inline six-cylinder OM 936 engine with a displacement of 7.7 litres is at work in the rear of the two-axle models. It is available in two power variants: 220 kW (299 hp) with 1200 Nm of torque and 260 kW (354 hp) with 1400 Nm of torque. The three-axle flagship model, the MultiClass S 518 LE, is always equipped with the inline six-cylinder OM 470 engine with a displacement of 10.7 litres. It has an output of 290 kW (394 hp) and a powerful torque of 1900 Nm.

A wide range of transmissions are available for power transmission. The two-axle variants are equipped with the GO 190 manual transmission or the fully-automated GO 250‑8 PowerShift transmission (only for the 260 kW/354 hp power variant). If companies would prefer an automatic transmission with torque converter, they can choose between the ZF Ecolife 2 with six gears, which is more fuel-efficient and has an optimised lifespan compared to the previous model, or the new Voith Diwa NXT transmission, which now has seven gears thanks to an additional overdrive. For the three-axle MultiClass S 518 LE, customers can choose between the fully-automated GO 250‑8 PowerShift transmission and the ZF Ecolife 2 torque converter automatic transmission.

The fuel supply of the MultiClass 500 LE is just as flexible. If a company would prefer to have a front passenger compartment area without platforms, the fuel tank is located to the right above the front axle in the direction of travel. For vehicles with platforms, the fuel tank is located as standard in the platform on the right in the direction of travel or alternatively on the left of the vehicle. The only exception is the MultiClass S 510 LE compact bus: In this vehicle, the fuel tank is always positioned above the front axle. In all cases, the tank volume is around 300 litres.

The AdBlue tank is always positioned near the engine and to the right in front of the drive axle. Its volume of 53 litres is sufficient for covering long distances. There is also an optional separate heating oil tank with a capacity of approximately 50 litres for the auxiliary heater (not available for three-door models).

Reduced fuel consumption makes the MultiClass500LE even more economical

Even seemingly small details can have an impact on fuel consumption. The optional intelligent battery sensor in the on-board electrical system optimises battery charging voltage, raises the idle speed of the engine when needed, monitors the electrical consumers and efficiently maintains the voltage of the electrical system. During deceleration phases, the charging voltage is increased to utilise regenerative energy and charge the battery. Conversely, the charging voltage is reduced during acceleration phases or when driving uphill.

The vehicle is fuel-efficient and low in emissions by design, but consumption can be reduced still further with a recuperation module. Double-layer capacitors, also known as supercapacitors or Supercaps, store the electrical energy generated during deceleration phases and make it available for auxiliary consumers. When the bus drives off again, the Supercaps supply the on-board electrical system. During this time, the alternators run at idle speed, which means they do not place a significant load on the engine. This combination of idle-running alternators and onboard electrical system management can reduce fuel consumption by approximately three percent.

The MultiClass 500 LE is even more economical with the OM 936 in conjunction with the optional hybrid module. It is simple and robust in design: a disc-shaped electric motor is integrated into the powertrain between the engine and transmission. When the bus is coasting or braking, the electric motor functions as a generator and produces electricity without consuming fuel. The electrical energy is stored in two storage modules on the roof, which are also supercapacitors. In load situations, such as when pulling away, the 14 kW electric motor uses energy from the supercapacitors to support the combustion engine. This relieves the load on the engine and therefore consumes less fuel.

Engines with hybrid modules have the same power values as combustion engines because the additional power from the electric motor is solely used for fuel efficiency purposes. If sufficient energy is stored in the supercapacitors, the electric motor also supports the engine when idling and improves the efficiency of the combustion engine. The hybrid module technology features a separate 48-volt electrical system and eliminates the need for a complex high-voltage system and the associated safety requirements.

The new model series is also already prepared for future full electrification of the drive. Implementation will start in the middle of the decade.

Comfortable suspension: Components from city buses and coaches

The chassis components are based on well-known hardware, primarily the ZF RL 82EC low-floor front axle, which is also used in other Daimler Buses. The quiet and fuel-efficient RO 440 hypoid drive axle is a comfortable coach axle. Suitable for various applications and transmissions, now even more gear ratio options ranging from i=3.1 to i=5.87 are available to choose from. This means that the MultiClass 500 LE always has a perfectly adapted powertrain. The third axle of the MultiClass S 518 LE is an actively steered trailing axle with independent wheel suspension.

It is fitted with tyres of the typical city bus size 275/70 R 22.5 or the classic interurban format 295/80 R 22.5. Both the front axle and drive axle of the MultiClass 500 LE can be fitted with snow chains. Chains, tools or cleaning utensils can be stored in the externally accessible storage compartments located around the rear axles.

Lower weight for reduced fuel consumption and more seating

One key development goal of the new MultiClass 500 LE was to be the lightest bus in its class. Therefore, every component and detail of the vehicle was thoroughly examined during its development. As a result, its weight has been significantly reduced by approximately 300 kilograms compared to the previous model. For example, the MultiClass S 515 LE, with its classic length of around twelve metres, weighs just under twelve tonnes in the standard configuration. The reduced weight lowers fuel consumption with the same number of seats or even a greater number of passenger seats. Depending on the model, the number of passenger seats can increase by up to six.

A variety of components contribute to this lower weight. The developers achieved weight savings in a range of areas compared to the previous model. They have reduced the weight of the bodyshell by 80 kilograms, cut 65 kilograms from the interior, 50 kilograms from the chassis with modified stabiliser bar connections on the front and rear axles and air springs with plastic pistons, 30 kilograms from the HVAC system and 17 kilograms from the axle drive.

Highly economical: Hybrid models, carryover parts, assistance systems, digitalisation, unique services

The low weight is just one of many factors contributing to the exceptional efficiency of the new MultiClass series. As with every Setra, it is particularly clear when looked at as a whole. The multiple tried-and-tested components of the powertrain, including options like the recuperation module and hybrid variants, are just as significant in this regard as are the numerous carryover parts from other vehicles. These include the windscreen from the Mercedes‑Benz Intouro, the front marker lights from Setra coaches, the front axle from the Mercedes-Benz Citaro, the seating from both the Citaro and Setra models, the air conditioning system from the Intouro, components of the hybrid variant and the rear module from the Mercedes-Benz Intouro including the engine compartment door and bumper. This simplifies spare parts management and reduces costs. Yet the new MultiClass 500 LE has its own special character.

Economic efficiency has many facets in the new MultiClass 500 LE. The new Driver Score assistance system supports the driver on request. It evaluates the current driving behaviour based on various parameters and the use of driver assistance systems. It provides individual feedback and suggestions on the display, enabling drivers to quickly improve their driving behaviour. The Driver Score allows the driver to continuously optimise their driving style.

The comprehensive services of Omniplus are also an essential component of the outstanding economic efficiency of the new Setra MultiClass 500 LE: Some of the classic topics include having the largest and most extensive bus-specific service network in Europe, as well as offering custom service contracts, such as Basic, BasicPlus, Premium, or Premium Regional.

One completely new addition to the range of services is the Omniplus ExpertHandling training course especially for the Setra MultiClass 500 LE. This training course turns professional drivers into real experts who can fully utilise the potential of safety and efficiency features. This marks a new chapter for training courses focused on low-entry buses and their assistance systems.

Economical also means digitalisation in the new MultiClass 500 LE. The Bus Data Center is standard equipment on board and serves as an interface for data transmission and a key to the numerous digital services of Omniplus On, the collection of all digital services offered by the Omniplus service brand.

For example, Omniplus On Uptime pro is a digital service that is perfectly tailored to large fleets with their own workshops. The complete transparency of messages from the driver's display significantly supports communication between the traffic controller and the driver. This increases availability on the route.

The Omniplus On Portal gives fleets access to all relevant diagnostic information at any time and in real-time. Critical error messages are immediately pre-interpreted and automatically translated into specific recommendations for the workshop.

With Omniplus On monitor, fleet managers always have their vehicle fleet in sight, wherever they are. The driver card and mass storage download feature lets owner/operators download the driving and resting times of their bus drivers from the portal at any time. Automated downloads mean operators can effortlessly fulfil the legal documentation obligation to download driver card data every 28 days and to backup the mass storage data every 90 days.

Where is my bus? And what route has the bus actually taken? The tracking services of Omniplus On monitor lets fleets query the position of their vehicles, routes and the status of journeys in real time and from any mobile device. This way, they always know the status of every vehicle . From the evaluation of fuel and energy consumption to recording of vehicle-related events, valuable information can be gleaned to let fleets travel even more economically. This and other data can also be provided for integration into internal systems via Omniplus On Data Packages.

Comprehensive testing: mature at Start of Production

From the very beginning, the new Setra MultiClass 500 LE is delivered to bus companies as a fully mature vehicle. Daimler Buses has thoroughly tested the vehicles in proven ways to ensure this. It is true that comprehensive computer simulations and many kilometres on test stands have long since shortened the testing phase. But in keeping with an old footballer’s saying – it's what happens on the pitch that matters– the results have to be tested on the road.

This included, for example, a thorough winter test at icy temperatures with the compact S 510 LE model and a comprehensive summer test. And finally, a bad-road test at the state-of-the-art test site of the Daimler Truck Development and Test Center (EVZ) in Wörth. This involved the accelerated torture of man and machine over various terrible road surfaces. 1000 kilometres of test track is equivalent to around 120,000 kilometres on public roads. The Setra MultiClass 500 LE covered 8500 kilometres in Wörth, corresponding to 1,000,000 kilometres in public transport.

Continuous ramp-up: the new range will be ready in a few months

Like the predecessor series, the new Setra MultiClass 500 LE will also be manufactured at the Daimler Buses Hosdere factory near Istanbul, in the European part of Turkey. The start of production for the traditional two-axle models around 12 and 13 metres in length is planned from autumn 2023. The compact S 510 LE and the three-axle S 518 LE are expected to follow from the beginning of 2024.