ROAD TEST

MOTOR COACH INDUSTRIES / 2015

Putting the new J4500 throughPlachno’s paces

DAiMLeR A POSITIVE INFLUENCE

Setra paving new future at MCI.

MCIReliability Driven

Rick Heller discusses MCI’s commitment to quality and customers.

YEARSand growing

The full history of the industry leader.

80+

Proven Success/ Every day nearly 1,000 techemployees are getting aregal ride to work...

“Deal Closer” Setra S 417/Makes Delaware debut...

Pre Owned Re-energized Coaches/Customers familiar with MCI pre-owned programs...

Road Test/Putting the new J4500 through Plachno’s paces...

Keeping it Simple/Rick Heller interview focuses on core business, customer service, value...

Daimler/Setra paving new future at MCI...

MCI J4500/We’re proud of what we’ve built...

SETRA TOPCLASS S 417/There is nothing so perfect that it can’t be improved. And now...

APTA Expo/Reliable, green, efficient...

MCI D Series Commuter/ Style to fit your fleet...

80+ Years and Growing/Most people familiar with MCI history know the major mile-stones...

BUSRide J4500 Test Drive/New brake, axle and suspensionsystems...

NEW CommuterCoach Coming Soon/ Now it test-trials...

We’re proud of what we’ve built. Proud of our engineers who are driven to create the most reliable coaches, of our safety record, and of the trust that customers, drivers and passengers place in us every day. We continue to be the leading supplier of motor coaches to the combined public and private sectors in the U.S. and Canada. We’re honored that the D-Series ranks as the top-selling coach of 2014, the most popular ever. And we’re just as honored that the J4500 holds the top private-sector sales position for 2014, making it the leader for 11 consecutive years.We’re also proud of where we’re going. Thanks to the great support of our customers, we are stable, profitable and able to reinvest in our product, factory and people. The latest generation of MCI coaches is a testament to our world-class manufacturing processes, our quality suppliers and our culture of reliability. With improvements including tighter turning, better-handling IFS (Independent Front Suspension), easier-to-service brakes with more progressive automotive feel, sturdier components that better resist corrosion, lower operating costs, better fuel efficiency, more impactful curb appeal and a comprehensive

Questions and feedback:

200 East Oakton StreetDes Plaines, Illinois 60018Phone: 866-MCICOACHEmail: info@mcicoach.comwww.mcicoachcom

At MCI we live our Reliability Driven philosophy /

Rick HellerMCI CEO

FIND US

warranty including our Super 60 five-year warranty, it’s clear that our past is pointing toward our future.That future now includes Setra coaches that redefine North American luxury travel; Quality at Source processes that are transforming MCI manufacturing and service; and after-sale support like no other, including unparalleled field support and new online technician training. We continue to invest heavily where operators see the most tangible benefit: in our products, in our parts, in our service network and in our people.We have long been the North American industry leader. Today, with our Daimler partnership and a firm financial footing, we are better positioned than ever to be long-term partners in our operators’ success. And that’s something we can all be proud of.Thanks again for your support, we are glad to share our progress with you.

4 www.MCIcoach.com

Keeping it Simple

MCI focuses on core business, customer service, valueMotor Coach Industries CEO Rick Heller doesn’t like to make predictions about the future of the industry. But if the improved financial health of MCI, the largest coach manufacturer in North America, is any indication, the industry could be on the mend.MCI, which was saddled with crippling debt and was forced to downsize after filing for bankruptcy protection in 2008, has experienced a dramatic turnaround over the past few years under Heller’s leadership.It has refinanced and reduced its debt, grown its workforce and greatly upgraded its quality control system.“We’re on the right track,” says Heller. “I’d say sales are back to a normal level. I’ve learned not to predict the future of the industry, but I think there is some optimism out there.” He said the company now has 1,700 workers, an increase of about 500 from three years ago, “and we are hiring as needed as we grow.” MCI’s fortunes began improving in 2010, when a New York private equity fund, KPS Capital Partners, took control of the company and brought in Heller as CEO. The ownership change occurred roughly 17 months after MCI emerged from bankruptcy reorganization in early 2009.

The company got another boost two years ago when it struck a deal with Daimler Buses to become the exclusive North American distributor of the German company’s Setra line of coaches. That deal gave Daimler a minority ownership stake in MCI, and it gave MCI a new model and the cachet of the Mercedes brand. Heller said the Setra coaches have nicely complemented the company’s industry leading J4500 model and long-running D-series coaches. MCI’s financial picture further improved in October when KPS completed a $130 million recapitalization of MCI debt. Proceeds from the recapitalization are being used to refinance outstanding debt at better interest rates to support company growth. “This successful recapitalization validates the incredible transformation MCI has made under KPS ownership and we are pleased to return capital to our stockholders,” Heller said when the deal was completed. He noted that capital investment in the company is at its highest level in a decade. Even before the recapitalization, MCI had made great strides in improving its operations, says Heller. It accomplished that by going back to the fundamentals

of the business. “We improved our product quality so we are building buses with greater consistency, and we are offering our customers better aftermarket support,” he said. “Those are the fundamentals of the industry, and we went back and made them better.” For the past two years, MCI has been focusing on what is known as “quality at source,” which basically involves doing things right the first time when manufacturing buses. Whenever a problem arises in the production process, the root cause

Rick HellerCEO, Motor Coach Industries

5www.magazineonline.com

MCI focuses on core business, customer service, valueis immediately found and fixed so the problem doesn’t reoccur, thereby eventually forcing defects out of the system.“Quality at source has allowed us to build buses on time and more cost effectively with first-time quality,” said Heller, who in the past has held senior executive positions at Fortune 500 companies ConAgra and PepsiCo. MCI also is looking for increased efficiencies at its six sales and service centers. The company has invested in stateof- the-art tools and paint booths at two expanded facilities in Des Plaines and Montreal. MCI’s main customers — public-transit agencies and private- sector tour, charter and line operators in the U.S. and Canada — were hit hard by the Great Recession and its prolonged aftermath, and have only recently started showing signs of improvement. Public-transit agencies receive the majority of their funding from federal and local governments, and the downturn forced cutbacks in such funding.Heller said public funding is starting to increase, and many public-transit agencies are nearing the end of their 12- to 14-year replacement cycles, meaning they will be looking to replace aging buses.

“In the private sector, what we are hearing from customers and the industry is that they are doing better now than a couple of years ago,” Heller said. “More people are traveling and operators have a little more money to spend on their fleets.” He said the motorcoach industry goes through cycles, and right now it’s around mid-cycle. “Coach sales are average, not exceptionally high. Operators are being cautious in terms of adding to their fleets.” As for MCI, the company plans to continue its focus on producing its two

most-popular lines and distributing Setras. “We continue to produce the highest-quality and most-reliable products in the industry, and we are putting our resources into that rather than expanding our model line,” Heller said. “We are going to focus on our core business, and on offering better aftermarket support and value to our customers.”

Click to watch Rick Heller explain how listening to

customers led to the company’s Quality At Source initiatives

6 www.MCIcoach.com

Every day nearly 1,000 tech employees are getting a regal ride to work thanks to Royal Coach Tours. As the leading pro-vider of employee transportation for a top Silicon Valley company, Royal Coach Tours, San Jose, California, is expanding its fleet, adding seven new MCI J4500 coaches to accommodate its high-profile client.

The new coaches feature its client’s sig-nature specifications, including a silver-painted exterior and high-end interior with black leather seating for 50 with three-point passenger seatbelts. Riders furthermore enjoy power outlets at each seat, and a private-client Wi-Fi network that enables productivity en route. An Ayses destination sign makes it easy for commuters to know they’re boarding the right coach. The new coaches are also equipped with clean-diesel Detroit-Diesel engines and Allison transmissions to meet the environmental goals of both Royal Coach Tours and its client. The coaches also come with standard safety systems including Electronic Stability Control, SmartWave® tire pressure monitoring and a fire suppression system.

The client company, which offers trans-portation to employees to cut down on the use of cars, began its relationship Royal Coach Tours five years ago. Today, Royal Coach Tours gives daily rides to more than 1,000 of its client’s employees from several pick-up locations around the Bay Area, dedicating 28 of its 80 coaches to the service. Employees are able to track

more and more employers are

seeing the beni-fits that employ-

ee transportation solutions offer

thier companies.

the location of the coaches via an app.

“In addition to exceptional growth with our Silicon Valley client, we’re adding new customers and expanding our tour and charters with more trips to our national parks and with sightseeing tours through San Francisco and Napa Valley’s wine country,” said Greg Gallup, Royal Coach Tours Chief Operating Officer, who joined the 54-year old family-owned company in 2012. “We’ve had double-digit growth each year over the past four years. We are a people-oriented company dedicated to exceptional service.”

Royal Coach Tours was founded in 1960 by Joanne Smith and her husband with a 37-passenger motor coach to transport employees from Fremont, California, to the Lockheed Missiles and Space Com-pany in Sunnyvale. Charters followed two years later.

In late 1970, Joanne Smith changed the company name to Royal Coach Tours, a title meant to convey to clients the type of first-class, “royal” service her company offered. The torch was then passed to her two children, Sandy Allen and Dan Smith, who together have grown the company and brought a new level of service to the charter bus industry. Learn more at www.royal-coach.com.

Proven Success/

7www.MCIcoach.com

Proven Success/

8 www.MCIcoach.com

“Daimler has had a very positive influence on the company,” said Rick Heller, CEO of Motor Coach Industries (MCI) of Des Plaines, Illinois, USA, in response to the following question by Truck & Bus Builder at APTA in Houston, Texas, last month: ‘What impact has Daimler’s 10% shareholding in MCI over the past two years had on MCI’. Heller explained that with Daimler’s 10% equity stake in MCI, not only had the company benefited from having Hartmut Schick, head of Daimler Buses (the world largest and most advanced bus builder in the world) on its main board, it had given MCI access to Daimler’s expertise in manufacturing and engineering technology. Heller said that a number of its MCI engineers had travelled to Germany regularly and had benefited from receiving training in the quality of product, production and production process methods used at Daimler. Heller added that with the Setra brand (since mid- 2012 MCI has been responsible for sales and sales support of the Setra S 417, Setra S 407 and Setra parts in the US and Canada.) it had been able to offer a real top of the range product to its North American customer base. Another advantage was that with Detroit Diesel being a Daimler subsidiary it had been able to offer the Detroit Diesel engine as an option to the Cummins ISX in its J series travel and tourist coach range. Furthermore, Heller announced that with the Detroit Diesel (DD13) engine recently having become ‘Buy America’ compliant, it was reviewing the prospect of engineering it into its D series coach an alternative power unit for the transit coach range. Heller said that since mid-2012, it had embarked on Quality At Source (QAS) assurance programme to be able to continuously assess and improve the standard of the manufacturing process and quality Daimler – a positive influence says MCI boss Manufacturing of the final coach

product at its three production plants. After two years of work, Heller stated, the company had almost completed its first pass through of the scheme at all three facilities. Heller said that implementation of its own QAS standard had started with implementation on one station on one line, with the goal being: “First-time quality within the ‘allocated’ tack time.” The key driver of its QAS programme, said Heller, was to improve product quality, product reliability and safety at all its plants. The benefits of the scheme could already be seen, Heller said reassuringly; he explained that the average warranty cost of a new coach sold today had been halved already when compared with just two years ago. Heller also said the numbers of quality defects on its coaches were down by some 80% compared with two years ago and that safety during the production process had been improved considerably with accidents at its factories lower by 25%.Heller added that MCI’s goal was to achieve automotive reliability; this, he said, was a notable challenge given that the automotive sector had highvolume with low customisation; whereas, the coach building industry had completely the opposite i.e. low volumes and high levels of customisation. MCI’s legacy had always been reliability, said Heller, and this was why its new motto was ‘Reliability driven.’ Its aim was to continue and improve its quality and therefore reliability in the future. This process of review, implementation and improvement would be continuous, Heller emphasised, adding that that the next major stage in this process was to make sure its suppliers were installing QAS and to the same standards as itself. “Our goal is to get better and better at our core business as the leading motorcoach manufacturer in North America.”

a positive influence says MCI boss

Our goal is to get better and better at our core business as the leading motorcoach

manufacturer in North America.

9www.MCIcoach.com

Our goal is to get better and better at our core business as the leading motorcoach

manufacturer in North America.

“Deal Closer” Setra S 417 makes Delaware debut.

10 www.MCIcoach.com

“Deal Closer” Setra S 417 makes Delaware debut. This past fall, Delaware Express took its recently purchased Setra TopClass S 417 on a tour to Cape Cod. "Everyone was seriously raving about it," said President Gerry Frenze, who was aboard, but keeping a low profile. "A veteran cruise line director got on board and said it was the nicest coach she had seen all season. Several drivers from other companies also stepped onboard to see what the hype was about and were equally impressed."

Raves aren't uncommon for the Newark-based company, which also runs a fleet of about 24 MCI coaches plus other vehicles for a total fleet of 75. But Delaware Express' first-ever Setra is helping to set it even farther apart from competitors. Offering a level of luxury that hasn't been seen in the market before, the 2014 Setra S 417 earns its kudos with its distinctive European styling, German engineering and wealth of custom-tailored options. Frenze optioned his with a glass roof, custom seating, tables and several other upgrades — luxuries he credits with helping him win a three-year contract with a major-league sports team. Says Frenze, "The Setra S 417 is a real deal-closer."

Gary Frenze Delaware Express

11www.MCIcoach.com

Most NATIONAL BUS TRADER read-ers are aware of the recentimprovements to the MCI J4500

model including ZF axles and Bendix air discbrakes. MCI held Reliability Rally eventsaround the country to provide informationfor coach owners and to showcase these newcomponents. Hence, when the people atMCI asked whether we would like to takeone of the new J4500 coaches with the ZFaxles and Bendix brakes out for a test drive,we replied in the affirmative and set a date.

The number of improvements andenhancements MCI has provided to theirJ4500 model in recent years is fascinating. Inspite of the fact that the J4500 has been the bestselling motorcoach in our market for nearly10 years, MCI continues to make changesalmost annually to make it more attractive,safer and more economical to operate.

The J4500 is a bit of a Cinderella story. Intro-duced in 2001 as a more simply attired ver-sion of the E4500, it moved up to the topsales position in 2004. That is when the"fairy godparents" at MCI management andengineering began to enhance and improveit at regular intervals. It was soon recog-nized as worthy of royal attention, and theJ4500 turned into a beautiful state-of-the-art coach – and without a pumpkin insight.

In this case the sequel turned out to bemuch more popular than the original. BrentMaitland from MCI told us that operatorsthat formerly purchased the E4500 havebeen switching over to the J4500. Astuteoperators will realize many of the E’s stylingcues from vertical rear fins, to elevated pro-file, present a much taller, more impressiveentrance.

Recent Past Improvements

Just in the past two years the J4500 hasgone through two rounds of improvementsthat are worth mentioning. In the Novem-ber 2012 issue of NATIONAL BUS TRADER wetook the new J4500 for 2013 for a test driveand a look at its new features. I should men-tion that by this time the J4500 already hadthe new wide ride suspension supported byKoni frequency selective dampening shockabsorbers. My personal opinion is that thiswas one of the best improvements in rideand handling that I had ever seen.

By this time a number of safety featureshad already become standard equipment.These included electronic stability control,the SmartWave Tire Pressure Monitoring sys-tem, digital wheel end sensing, a smart steer-ing wheel and the optional trailing axle. A

22 • National Bus Trader / October, 2014

Test Driving the New MCI J4500ZF Axles, Bendix Air Disc Brakes and a Cinderalla Story

by Larry Plachno

MCI recently improved their J4500 model with ZF axles and Bendix air disc brakes. Hence,we could not turn down the opportunity to take one of the new coaches out for a test drive.This photo of the test drive coach was taken in front of the new MCI facility on Oakton Streetin Des Plaines, Illinois. We noted that the coach was so clean that the yellow bumper postand door frame was reflected on its side. NBT.

12 www.MCIcoach.com

round of improvements fostered by cus-tomers and staff included emphasis onreduced corrosion and improved curb appeal.

Noteworthy was the new extrusionabove the windows that gave the impres-sion of height while keeping the J4500 lowenough to fit into a 12-foot garage door. Thisdesign continued to a cleaner rear cap. Thenew daylight running lights and turn sig-nals added a great deal to the appearance ofthe coach. There were also improvements inexterior lights, energy absorbing bumpers,HVAC brushless motors and a new multi-plex system.

When MCI introduced the new J4500 for2014, they also announced another round ofimprovements. Overwhelmed by all theseimprovements in so short a period of time,our review and test drive article in the Jan-uary 2014 issue of NATIONAL BUS TRADERwas subtitled “What does a leader do for anencore?”

While the J4500 improvements for 2013were mainly based around design and appear-ance, the 2014 improvements were more con-centrated in areas equally important but notso obvious. The important ones includedimproved fuel economy, improved diagnos-tics, improved corrosion mitigation andimproved suspension. What MCI was tryingto do with many of these improvements is toreduce the cost of ownership and operation.

A major step forward was the MDSS, MCIDynamic Suspension System that moved sus-pension up to the electronic level. The coachnow had full rise front and rear and alsoneeded less air to operate. Cummins providedan improved torque curve on their engine thatimproved fuel economy. Extra sensorsimproved onboard diagnostics, making thetechnician’s job easier. Group leaders likedthe new Media Center connection behind thedriver’s seat and we drivers liked the new dri-ver’s vent as standard equipment.

Current Improvements

While there are other improvements onthe J4500, the two major items are movingto ZF axles and Bendix air disc brakes. Nei-ther component is new to the market. Thereare people who claim that the “C” in MCIstands for “conservative,” and that is cer-tainly true in this case. Initial plans to movein this direction date as far back as 2007-2008.

Both components have been used onother buses for years and have been wellproven. In addition to the past track recordof these components, MCI put them throughtheir paces at the Bosch Proving Grounds inNew Carlisle, Indiana. MCI also put severalpilot coaches in actual field tests with oper-ators around the country testing the most

extreme environments from high mileage,to extreme cold and dust.

The new ZF axles replace Meritor axlesthat were offered previously. Standard equip-ment on the J4500 will now be the ZF RL 80 Eaxle with independent front suspension. Itseparates steering forces from axle load forcesand has the advantage of a high wheel cut fora better turning radius. The independent frontsuspension provides a smoother ride overbumps and offers better control in crosswinds.

ZF’s A 132 will be used as the drive axle.It can be ordered with different axle ratiosso you can lean towards more economy ofoperation if you would like. The tag axle onthe J4500 will be the ZF RL 80 E IndependentTag. As some of our readers have pointed

The test coach had wood-look flooring all theway down the aisle, on the front steps and onvarious trim pieces. This woodgrain look isincreasingly popular on new MCI coaches. NBT.

A ZF A 132 is now used as the drive axle on the J4500 while a ZF RL 80 Eindependent tag with a trailing or castering feature is used on the tag axle.NBT.

Major improvements on the new J4500 include Bendix air disc brakes andnew axles. The front axle is now a ZF RL 80 E with independent suspen-sion. NBT.

24 • National Bus Trader / October, 2014

Other improvements worthy of note are the newparcel racks that hang down less and make theaisle more open as well as new passenger com-fort modules under the parcel racks. NBT.

Article from National Bus Trader Magazine.

13www.MCIcoach.com

out, this is not a “steerable” axle but actu-ally more of a trailing or castering axle inthat it follows the coach around a turn. Thisreduces wear on the tag tires and probablyhelps the turn in most situations.

For clarification, I should mention thatMCI’s D models will also get a ZF front axle,but it will be a solid beam. The ZF indepen-dent tag is also optionally available on theD models.

Like the ZF axles, the Bendix ADB22X airdisc brake has been around a long time. Itoffers several advantages including dual pis-tons to provide a more even distribution ofbraking force, a monoblock caliper design tokeep debris out and a two-pin design betweenthe caliper and the carrier to keep them par-allel and slide freely. A nice advantage of theseair disc brakes is that brake fade is much lessa concern than with drum brakes. The reasonfor this is that on the disc brakes the rotorexpands into the brake pads when it gets hot.

This Bendix-Knorr ADB22X system hasbeen made in the United States since 2005. Duein part to the new Bendix brakes, MCI claimsthat the new coaches stop 42 feet shorter thantoday’s drum brakes from 60 miles per hourand 100 feet shorter from 70 miles per hour.Compared to the current disc brakes they stopslightly shorter with better brake feel.

A major feature of the new Bendix brak-ing system is Wingman Active Cruise Brak-ing. If you set cruise control, a radar sensormounted on the front of the coach monitorsup to 32 objects in front of you. If the vehi-cle ahead slows down and closes the dis-tance between you, Wingman will auto-matically reduce the throttle on your coach,then progressively apply the Jake brake. Ifthe distance keeps diminishing, it will applyyour regular foundation brakes. If you arenot in cruise mode, the Wingman system canstill operate but it will only supply distancefigures and a warning.

Other improvements in the J4500 includethe new MCI dynamic suspension system.It offers both front and rear raise and is moreefficient in that it requires less air. Passen-gers will note the new parcel racks in theJ4500 that hang down less and make the aislemore open. There are also new passengercomfort modules with air flow and readinglight controls above the seats. Available onboth the J4500 and D models is the CumminsISX 12 engine that has a new Engine Con-trol Module and offers a two percent betterfuel economy over 2012.

The Test Drive

We started out from MCI’s new facilityin Des Plaines, Illinois. Brad Lamothe, MCI

senior technical advisor, and Maitland, MCIVP of Marketing and Product Planning, tookthe time to introduce me to the new J4500and its new features. We also spent a fewminutes with the display above the dash forthe new Wingman system.

The coach for the test drive did have thenew interior. With the new parcel racks thecoach offered a more open interior and thenew passenger modules were obvious belowthe parcel racks. One nice feature about thetest coach was wood pattern flooring, on theparcel racks and even on the driver’s sidepanel. It also had three-point seat belts and110-volt outlets. Maitland indicated that thewoodgrain flooring has become very pop-ular on new MCI coaches.

Looking more and more like an airplane, the new passenger comfort mod-ules include the usual reading light and vent controls but now add a seatbelt light. NBT.

Here, Brad Lamothe and Brent Maitland from MCI explain the new Ben-dix Wingman system and dash display to your editor prior to the J4500test drive. PAT PLODZEEN/MCI.

National Bus Trader / October, 2014 • 25

Brad Lamothe, MCI senior technical advisor engineering; Larry Plachno, editor and publisher ofNATIONAL BUS TRADER and Brent Maitland, MCI vice president of sales and marketing, discussthe new features of the J4500 prior to the test drive. The photo was taken in front of MCI’s newfacility on Oakton Street in Des Plaines, Illinois. PAT PLODZEEN/MCI.

14 www.MCIcoach.com

Our route took us along four-lane sub-urban business streets, expressway drivingand a few two-lane suburban roads up intothe north suburbs. Maitland knew the roadsbetter than I did and kept us from gettinglost. We never did find a bumpy road toreally test the independent front suspension,but it did fine on the regular roadways.

I certainly could not fault the ride or sus-pension. When I first drove buses like theTDH4509 and the PD4103, they had leafspring suspension. The PD4104 with its airride was a major step forward. Many of uswent through the swing and sway with theMC-8 and MC-9. I thought that moving tothe 102-inch width coaches helped the sus-pension.

In my book, the single biggest improve-ment came when the J4500 moved to thewide ride suspension. I would suggest thatall other things being equal, having sus-pension points further apart is a majoradvantage in ride and suspension. Hence,in my opinion, the J4500 already had a greatsuspension. At this point MCI is simply“tweaking” it for continued improvements.

Turning was impressive. With the newindependent front suspension and trailingtag axle MCI claims a turning radius of 40 feetand 11 inches for the J4500 – less than itslength. We did do some tighter turns duringthe test drive. I watched the back end in theright side mirror as we went around cornersand was reasonably impressed. When we gotback to Des Plaines, I did some small dough-nuts on the front apron of the shop entranceand could see the remarkable turning radius.Those of you who need to get around tightcorners in cities will like this coach.

I had no problem with the brakes or brak-ing system. We did not have any long hillsto test for brake fade, but I certainly wouldhave to admit that all brake applicationswere smooth and effective.

On the longer stretches on the interstate,I was able to test and use the Wingman sys-tem. The display was located above and onthe left side of the dash where you couldmonitor the distance of the vehicle ahead. Itdoes have several levels of sensitivity, but I

could see that it would not have much appli-cation in rush hour traffic where you wouldbe afraid to set the cruise control.

Once you set the cruise control, Wing-man starts monitoring the vehicles ahead ofyou and it puts readings on the display. Ona couple of occasions we had cars slow downin front of us. Wingman then reduced throt-tle and put on the Jake brake. If the distancecontinued to close, it put on the regularbrakes. On one occasion, a truck pulledabruptly in front of us and Wingman tookimmediate action. While it certainly is not areplacement for a driver, Wingman has obvi-ous safety advantages.

I also tried Wingman without cruisecontrol. In this mode you get distances,lights and warnings in the display butWingman takes no action. If you fail totake action yourself, Wingman will beepat you. This is probably how you wouldhave to operate on city streets or in rushhour traffic.

The left side mirror was right up againstthe side of the coach and seemed to be tooclose. Maybe my legs are too short and I hadthe seat too far forward. However, I am surethat the mirror arm could be adjusted to bea little further from the bus.

In general, the new J4500 passed with fly-ing colors. As I sometimes like to say, it is acoach that makes the driver look good. Inthe case of this new J4500 with the ZF inde-pendent front suspension, I would recom-mend it for any coach application but par-ticularly for those of you who need to makesharp turns on city streets. ❑

Here is a closer look at the Bendix Wingman display. While using cruise control, the Wingman sys-tem maintains a safe distance from the vehicle ahead by reducing the throttle, applying the Jakebrake and then applying the foundation brakes if necessary. With cruise control off, it still alertedthe driver to conditions ahead. NBT.

26 • National Bus Trader / October, 2014

The driver cockpit area on the J4500 continues to be practical and very workable. I particularlyliked the convenient controls on the smart steering wheel and the convenient left side panel withthe transmission buttons. The new Bendix Wingman display is the small white box to the right ofthe center post. NBT.

Article from National Bus Trader Magazine.

15www.MCIcoach.com

16 www.MCIcoach.com

MCI J4500/We’re proud of what we’ve built. Proud of our engineers who are driven to create the most reliable coaches, of our safety record, and of the trust that customers, drivers and passengers place in us every day. We’re also proud of where we’re going. The next generation of our coaches is a testament to our world-class manufacturing processes, our quality suppliers and our culture of reliability. With improvements including tighter turning, better handling IFS (Independent Front Suspension), easier to service brakes with more progressive automotive feel, sturdier, more corrosion-resistant components, lower operating costs, better fuel efficiency,

more impactful curb appeal and a comprehensive warranty including our Super 60 five-year warranty, it’s clear that our past is pointing toward our future.

We believe our coaches must be dependable as well as technologically and aesthetically well designed. There is an artful balance of design and functionality in elements like our spiral stepwells. Examine the semi-monocoque construction and you’ll understand why the J4500 is the industry’s leading coach.

17www.MCIcoach.com

18 www.MCIcoach.com

19www.MCIcoach.com

20 www.MCIcoach.com

The 2015 MCI J4500/

O F F I C I A L

BUSRide Road Test:

By David Hubbard

21www.MCIcoach.com

The 2015 MCI J4500/

BUSRide Road Test:New brake, axle and suspension

systems reflect MCI’s attention totechnical and mechanical detail

The strategic effort by Motor Coach Industries (MCI), Des Plaines, IL, to bring its J4500 and D-model coaches closer together has been a work in progress since 2008. According to the company, its mission has been to unify the componentry and systems in terms of manufacturing and maintenance.

Improvements and new features of the MCI J and D models reflect MCI’s attention to technical and mechanical detail. Unlike the recent restyling of the J4500 model, these updates are not about curb appeal.

“We are out to improve both functionality and performance in both models,” says Brent Maitland, vice president, MCI Marketing and Product Planning. “By increasing the commonality of these key systems, we create efficiency in engineering, improve our manufacturing, and make parts that service easier for our customers, with the overall result being improved reliability of our product.”

The move to ZF axle and suspension

The central focus to this significant upgrade has involved the incorporation of ZF axle and independent suspension system that promises to significantly reduce the turning radius and smooth out the ride. ZF manufactures these products in Gainesville, GA. ZF notes the key features of the ZF RL 80 E Independent Front Suspension:

• 55 degree wheelcut for MCI

• The manner in which the suspension upright separates the steering forces from the axle road forces allows a quicker response of the suspension and more precise steering.

• The double–wishbone design with maintenance-free rubber-metal bearings at the mounting points and wheel ends with unitized bearings reduce maintenance costs.

• The systems are lightweight and maneuverable.The ZF system takes the MCI models from solid beam to independent suspension.

22 www.MCIcoach.com

23www.MCIcoach.com

24 www.MCIcoach.com

25www.MCIcoach.com

“Efficiency, emissions reduction, and growing comfort requirements are key criteria for public transportation providers,” says Rolf Lutz, member of the Board of Management of ZF Friedrichshafen AG responsible for Commercial Vehicle Technology. “This is why coach and bus operators worldwide are modernizing their vehicles and are drawing on ZF’s expertise more and more often. The fact that we have now received orders from MCI is a resounding success and testimony to our established international presence garnered on the basis of advanced technology.”

Bendix Air Disc Brake

The new coaches offer the proven Bendix Air Disc Brake (ADB) 22 X brake system, made in the U.S. since 2005, which will also offer the additional safety of adaptive cruise control.

Maitland says this undertaking is more than just plugging the new systems into the MCI platform.

“This type of project requires engineering and testing as there are modifications to integrate the systems into the coach,” he says. “This is where the design and testing comes into play. We need to thoroughly understand how the changes affect the coach performance and ride dynamics.”

“The advantages of an independent suspension system are no secret to the industry,” Maitland adds. “In our application, it offers significant improvement in terms of ride quality and feel, as well as a much tighter turning radius.”

According to MCI, the current standard turning radius on the J4500 model is roughly 47 feet; 45 feet with optional rear-steering. The new J4500 with ZF is 40 feet, 11 inches.

“While the ZF axle system makes the coach significantly more maneuverable, it may require some additional training for drivers,” Maitland says. “But ultimately, they will enjoy many major advantages.”

To help prove the reliability of the systems, MCI sent the J coach to the arduous Bosch Durability Testing Facility, New Carlisle, IN, where tech put it through the equivalent of one-million miles of wear, tear and abus over 10,000 miles of actual track mileage.

“They pounded the coach over cobblestones, chatter bumps and other features designed to stress the system,” Maitland says. “They beat it up pretty good. Also a testament to the design of our J is that we’ve used the same coach through multiple durability tests and it just kept ticking for more than one million miles of real world equivalent testing.”

With these technologies already proven in other heavy-duty commercial vehicles, MCI has built 12 pilot J4500 coaches featuring the ZF and Bendix systems, nine of which are in service with MCI operators across the country for

BUSRide Road Test: Continued

26 www.MCIcoach.com

independent field testing in everyday highway conditions and normal operations.

“We are doing thorough testing and we look forward to getting detailed feedback from these companies,” he says. “For instance, a maintenance tech may notice some minor difficulty in reaching a new part or fitting that we can still address.”

Arrow Stage Lines

Arrow Stage Lines, a longstanding MCI customer headquartered in Omaha, NB, with operations in 11 locations, is one such company to test drive the new J4500. BUSRide called on Arrow Stage Lines, Kansas City, MO, for a report of its early experiences.

Dave Zibro, a seasoned driver of nearly every sort of commercial vehicle for most of his life, was the first of four Arrow Stage drivers to take the J out on the road for charter service. He transported the Columbia High School Choir on a six-day trip from Kansas City, MO, to Nashville, TN, which he says presented a tremendous opportunity to experience handling and maneuverability in assorted weather from clear skies to wind and rain.

“I noticed a difference on the very first turn out of our yard,” Zibro says. “At that point I was not aware of the steer tag axle, but I felt the difference immediately in that quicker turn with less tail swing. For the rest of the trip I couldn’t ask for the steering and handling to be any better. It’s a wonderful ride.”

Recognizing this is a new model J, Zibro says he is anxious to see how its holds up after 40,000 miles. Considering its performance on the Bosch test track, he should have no complaints.

“I especially like how the front seems to turn shorter than previous MCIs I have driven,” he says. “With the rear axle steer providing greater maneuverability, I was able to get into so many places that would be much more difficult without the steer tag.”

MCI says the tighter turning capability with the help of the rear steer feature should reduce tire wear.

During one of the choir performances, Zibro conducted his own informal test in the parking lot to get a better sense of the tighter turning radius.

“I simply lined the coach up with the painted lines and made a sharp left U-turn,” he says. “I didn’t take any accurate measure, but the radius was considerably less than anything I had experienced in our other coaches. Maneuvering in traffic around town and in parking lots was a pleasure because it was so easy. I was very glad to have this coach in Nashville for the week.”

One of Zibro’s additional responsibilities is to test-drive

various coaches in the Arrow Stage fleet and keep copious notes on what he finds needing attention.

“I have found nothing to make note of,” he says. “This coach is a dream to drive.”

While charter customers may not be cognizant of the technology and componentry responsible for the easier handling and smoother ride, Arrow Stage Vice President of Sales Chuck Gunnels believes it contributes to their improved rider experience.

“Coach passengers are certainly aware of how their driver is performing,” he says. “If he is not having to back up as often in tight situations, and the ride goes generally uninterrupted, they feel more secure and are more at ease.”

Arrow Stage Line Director of Maintenance Wade Freeman says that in the time Arrow Stage has had possession of the pilot coach, he has not seen or heard anyone reporting a mechanical issue.

“Generally, the set up on this new J4500 is much preferable over previous models, particularly with the Bendix brake system,” he says. “I particularly like the use of unitized wheel hubs on the steer and tag axles. They can be easily changed out in the event of wheel-bearing issues.”

Service requires replacing only the bearings rather than the entire hub, and there is one common rotor part rather than two.

“We strongly believe that the fundamental design of the bearings and wheel ends is going to keep out significantly more contaminates,” Maitland says. “They are more reliable, which owners will appreciate.”

Van Galder Bus Company

Van Galder Bus Company, Janesville, WI, essentially provides year-round non-stop regular scheduled service from Janesville and its hubs in Madison, WI; Rockford, IL; and into downtown Chicago with service to Midway and O’Hare Airports — an ideal venue for the operator feedback MCI is looking for in this pilot program. According to General Manager, Allen Fugate, Van Galder is using its J4500 primarily for regular service to O’Hare from Rockford, but every driver throughout the system is getting the chance to slip behind the wheel and offer feedback.

“Without disclosing a lot of technical detail, MCI asked us to maximize mileage on our test coach and report on what we experience out on the road.” says Fugate. “With our goal of 70,000 miles, we have kept it very busy. Proabably 30 different drivers have taken the coach out on their runs. From the comments we have heard, the new coach has a very nice feel; not significantly different than any other J models, but enough to notice.”

27www.MCIcoach.com

Fugate says the maneuverability is the most noticeable feature from a driver’s standpoint, noting that with the new trailing tag axle, drivers need to be aware of more backend tail swing. “It shortens the turning radius and is probably similar to the MCI E Model MCI,” he says. “This new setup is great for maneuverability, especially getting in and out of tight spots. I drove it through some pretty stout winds and it handled fine, but not necessarily any better or worse than other J4500s.”

Fugate says his team has already suggested a tweak in the programming on the ride levelizer. Like the E Model, it was highly active. We asked them to just soften it some.

Van Galder Maintenance Director Ron Thompson appreciates the ease on tire wear the ZF brings in tighter turns. “This axle with not jump a curb or slide going around a corner,” he says. I don’t see any scuffing with the trailing axle.”

Thompson also finds the more open framework underneath is now easier to access and maintain, a point he says is important to the people working on the coach.

Bendix Brake ADB System

According to Maitland, the Bendix ADB system will feel more like automobile brakes. “We feel these brakes should be an easier adjustment for new coach drivers used to an automotive feel,” Maitland says. “The actual brake performance is roughly

the same, but the stopping distance is way less than FMVSS standards.”

MCI says it is moving to include the Bendix Wingman System, which offers adaptive cruise control as well as collision mitigation.

“These functions are becoming more common in the automotive market,” Maitland says. “We think this is a very important safety feature that we can bring to MCI coaches.”

The Bendix adaptive cruise control detects a coach’s position behind other vehicles and automatically reduces the throttle or applies the brakes to maintain safe following distances.

It is also billed as improving the functionality of cruise control and fuel economy.

Coaches are in testing with the Bendix System, and when MCI determines it is ready, the system can be retrofitted into the new ZF-fitted pilot coaches for customer feedback.

28 www.MCIcoach.com

29www.MCIcoach.com

SETRA TOPCLASS S 417/There is nothing so perfect that it can’t be improved. And now we have succeeded in making the S 417 an even more valuable asset for you. With over 30 innovations and enhancements in key areas in 2014, the Setra TopClass S 417 is now even easier to operate, more comfortable and safer than ever before. The Setra TopClass S 417 incorporates innovative technology that significantly improves driver and passenger safety. The Front Collision Guard (FCG) is a unique passive safety system engineered to protect the driver and passengers in the event of frontal impact. New cornering lights, passenger seatbelts and rain/light sensors are just a few of the recent features found on the Setra TopClass S 417 that contribute to an unparalleled high standard of safety. Passengers can look forward to the

latest in on-board entertainment and comfort with premium multi-channel sound and electronic system, wireless internet, next-generation luxury seating and interior LED lighting enhancements, to mention just a few. The Setra’s state-of-the-art cockpit features a new multifunction steering wheel, optimized color displays and many more advancements to facilitate the driver’s task. And finally, the Setra TopClass S 417 is equipped with the environmentally friendly OM 471 engine (336 kW), coupled with an Allison B500R automatic transmission. The engine and power train technology, combined with new insulation in the engine compartment, significantly improves both fuel consumption and emissions, while ensuring a quieter, smoother and more comfortable ride.

30 www.MCIcoach.com

31www.MCIcoach.com

32 www.MCIcoach.com

33www.MCIcoach.com

34 www.MCIcoach.com

35www.MCIcoach.com

36 www.MCIcoach.com

37www.MCIcoach.com

38 www.MCIcoach.com

39www.MCIcoach.com

40 www.MCIcoach.com

41www.MCIcoach.com

New Motor Coach Industries commuter express

Only MCI currently manufacturers a Commuter Coach which is Buy America-compliant, Altoona-tested and available in clean-diesel, hybrid and CNG options. Ranked as a best-seller in 2014, the MCI Commuter Coach has earned its leadership position in express transit service by offering low ownership cost; a lower per-seat cost with 42% more seating capacity than a typical 40-foot transit bus; and an excellent MDBF rate, measured as the #1 performer with the fewest failures per vehicle among all bus types. Ideal for higher-speed routes, the MCI Commuter Coach features a high-floor design that elevates passengers and the driver above traffic, along with a long-travel suspension for a smooth, stable ride.

MEASURED AS THE NUMBER

ONE PERFORMER

MCI D Series Commuter/

Reliable and economical, the MCI D-Series coaches offer low-cost, high quality performance over and over again. Built with legendary MCI quality to deliver a unique combination of dependability and passenger comfort.

MCI’s D-Series tour and charter coaches, available in 40- and 45-foot configurations, are designed to deliver a unique combination of practicality and amenity.

Passengers enjoy a host of standard amenities, including 10” video monitors, overhead reading lights and air-flow comfort controls.

Standard safety features are robust, with an emphasis on ESC and an updated fire detection and suppression system plus integrated tire-pressure monitoring with always-on sensors.

42 www.MCIcoach.com

Private and public sector...

43www.MCIcoach.com

44 www.MCIcoach.com

45www.MCIcoach.com

46 www.MCIcoach.com

At the October American Public Transit Association (APTA) EXPO in Houston, Texas, MCI showcased Houston Metro’s newest MCI Commuter Coach, part of a 95-coach order; and displayed its CNG version in tribute to this year’s delivery of 147 CNG Commuter Coaches to New Jersey Transit.

Patrick Scully, MCI Executive Vice President of Sales and Mar-keting, welcomed Tom Lambert, Chief Executive Officer, Met-ropolitan Transit Authority of Harris County (Houston, TX); and Gilbert Garcia, chairman, Houston METRO to the MCI booth, presenting them with a canvas photo portrait of their newest MCI Commuter Coach. All together Houston Metro operates 300 MCI Commuter Coaches.

MCI booth events included a press briefing with MCI CEO and President Rick Heller, who gave an overview of how MCI’s Quality-at-the-Source initiatives are leading to higher-quality coaches and a safer workplace.

A record-breaking 800 exhibitors attended APTA EXPO, which was expected to draw more than 12,000 attendees from 65 countries.

Patrick Scully, MCI Executive Vice President (third from left), meets with Houston Metro executives and staff in MCI’s booth at APTA EXPO.

Reliable, green, efficient Commuter Coaches go to show

47www.MCIcoach.com

48 www.MCIcoach.com

Customers familiar with MCI pre-owned programs know that MCI offers a wide selection of coaches, including the Select Plus models that come “ready to roll,” backed by inspections and warranties. But some lucky customers have also benefitted from a new range of pre-owned coaches that come as close to being new coaches as possible.The “Re-energized” program coaches are all currently newer hand-selected J4500s with little or no corrosion. All have undergone a 210-point inspection, with any detected issues addressed. Most notably, each “Re-energized” coach gets a remanufactured engine (Cummins or Detroit Diesel) and remanufactured transmission (Allison or ZF Astronic), along with new ECMs and harnesses. Customers can additionally request new seats with or without seatbelts, any options available to the model, and custom paint or decals.The warranties are attractive as well — MCI’s 60-day limited

Pre Owned Reenergized coaches/The best way to buy used.

coach warranty, and a two years warranty provided by the powertrain component suppliers, a special arrangement worked out between MCI and those suppliers.“Whether it’s a coach, or a car, or a bike, or a rickshaw, everyone wants an extended warranty,” says Mitch Guralnick, director of MCI pre-owned coach sales and creator of the program.The work is currently done at MCI’s service centers or its affiliates, which are uniquely are outfitted to do major repairs and over hauls. They’ll also do the same work for individual customers who want to upgrade one of their own coaches.“Our program is different because it allows customers to pick and choose,” says Guralnick. “From the engine to the interior, to outside color, it’s almost like buying a new coach. And with the warranty, it’s real peace of mind.”

49www.MCIcoach.com

50 www.MCIcoach.com

51www.MCIcoach.com

Ventcho “Vinnie” Pantchev, owner of Chicago Motor Coach, Arlington Heights, Illinois, says that he ordered his “Re-energized” coach, a J4500 with new seats and seatbelts. “It’s a good deal,” says Pantchev, who has so far always bought pre-owned MCI coaches for his business. “It looks brand-new, and it makes sense. People like it. They ask, ‘Have you bought a new bus?’ We’ll probably get another one in March.”Ray Robbins, owner of H & R Tours, has traditionally chosen new MCI coaches for his fleet, but he was attracted to the “Re-energized” coaches and ended up buying two J4500s. “These are the first used coaches I’ve ever bought,” says Robbins. “So far, so good. With the new engines and the transformation underneath, it’s like getting two new coaches for the price of one.”Robbins, a 25-year MCI customer who has MCI D-Series and J4500s in his fleet, as well as an E4500, says his customers mostly can’t tell the difference between his new and old coaches — in part because he keeps them so clean.Guralnick points out that some customers have gone all out with their coaches, ordering Wi-Fi, 110-volt outlets, satellite television and custom decals. In addition, MCI sales staff will generally invite customers to come check out their coaches in Loudonville to see the re-energizing process in action.So far, the program is popular, with all current inventory spoken for. But new coaches are being added nearly every day. And while all coaches have so far been J4500s, for customers wanting D- or E-Series coaches, “we can make it happen,” says Guralnick.In addition, Guralnick says, the program has passed muster with the financial community, so customers in good standing should be able to find loans and other financing arrangements.“There’s a lot of value added,” says Guralnick. “One of the big things is, this allows the customer to really get involved in the planning of their coach. And the work we do extends the life of an already well-built, well-engineered coach.”Customers interested in the “Re-energized” program can contact their MCI pre-owned sales professional.Reprinted from FYI from MCI

Whether it’s a coach, or a car, or a bike, or a

rickshaw, everyone wants an extended warranty,

52 www.MCIcoach.com

Most people familiar with MCI history know the major mile markers: Harry Zoltok’s founding of the company in 1933, the Greyhound years, a march of MCI models, and, more recently, the ascent of the J4500 as the industry’s best-selling coach for nine years running, as well as the D-Series’ achievement of becoming the best-selling model family in industry history.

But MCI didn’t do it alone. In fact, in many cases, MCI’s own customers paved the industry way.

The full history of the industry leader

80+ Years and growing/

53www.MCIcoach.com

As 1980 opened, more than 70% of the coaches on the highways were MCIs

80+ Years and growing/ 1930s

Harry Zoltok came to Canada the old-fashioned way — he stowed away in a freighter in 1928, leaving his native Russia. He incorporated his Fort Garry Motor Body and Paint Works in 1932, and already, the bus industry was growing.

Eventual longtime MCI customers Peter Pan, Martz, Cyr Bus, Fullington, Lewis Stages and Brewster were among those who were already shaping the fledgling industry. The Martz Group got its start in 1908 as the White Transit Company, with the Frank Martz Coach Company being formed in 1922. Fullington Trailways likewise got its start in 1908. John T. Cyr started his Maine transportation company in 1912. Lewis Stages, first known as Bingham Stage Lines, formed to

transport Salt Lake City-area miners via Ford Model T to the Bingham mine starting in 1914 — it took its present name once founder Orson Lewis convinced his brothers to help him grow the business. Brewster was there at the start as well, acquiring motor coaches in 1916 to augment the Canadian Rockies guide business brothers Bill and Jim Brewster began in 1892. Peter Pan got its start in 1920 when Peter Carmine Picknelly put together a small New Jersey transit company. And though it was formed in 1888, it was in 1923 that Boston’s Plymouth & Brockton Street Railway bought its first bus — and by 1928, it went to an all-bus fleet, turning away from its electric trolley roots.

Transporting groups of people on American and Canadian roads was a far different experience in those pre-highway days. The roads were tough, but oftentimes, the vehicles that plied them were not. It was said that one stretch of Canadian road held some 700 wrecked and abandoned vehicles. It was in 1933 that a Canadian Greyhound driver was forced from the road by a truck, causing a fatal accident as a pipe sheared through the wood-framed bus. Greyhound president George Fay started looking for a stronger, steel-framed vehicle — and he found it in the shop of Harry Zoltok.

In 1933, Zoltok built his first coach, a sturdy 11-passenger body atop a Packard chassis. And in 1937, Zoltok’s young company built its first own-chassis coach, for Grey Goose Bus Lines, Winnipeg. It was made of steel. Fay approached the company that same year to rebuild some of Greyhound’s

54 www.MCIcoach.com

older coaches, and he liked what he got. MCI’s long association with Greyhound was off to a strong start. The same year, Peter Pan took its current name.

In 1936, another business formed that would greatly influence MCI and its customers: Trailways Transportation System. The Frank Martz Coach Company was one of the founding members.

In 1939, the future MCI created its first real transit coach, the 150. It was revolutionary for its time, sporting stainless steel panels, a windshield atop the radiator and a “pancake” engine mounted midship. And the young company was on its way.

1940s

1940 was a big year for MCI and many of its customers. MCI opened its first real factory at Erin and St. Matthews streets. Peter Pan Bus Lines won approval to offer service to Boston, and other companies were pursuing their goals with similar youthful enthusiasm.

In 1941, Harry Zoltok’s company officially became Motor Coach Industries Limited. But the new plant was soon producing something other than innovative new coaches. Like so many other manufacturing plants during World War II, the MCI factory was tapped for wartime production. MCI made Jeep trailers, boat trailers, truck bodies, even bridge sections — more than 40,000 such items in all.

MCI customers pitched in for the war effort as well, transporting troops and contributing to their communities. Cyr Bus was one such company — the United States government earmarked its vehicles to transport German prisoners of war to detention camps. Serving area airmen, Lewis Stages managed to run a bus every six minutes between Camp Kearns Army Air Corps Base and Salt Lake City.

In 1942, Greyhound Lines bought 80% of Western Canada Greyhound as well as 10% of MCI. MCI built the first Canadian-built electric trolley bus, perhaps foreshadowing MCI’s future in hybrid and CNG coaches.

By the mid to late 40s, MCI was turning out some truly innovative coaches, including the rear-engine Courier 100, which also featured an integral welded tubular steel alloy frame. In a move that would set the stage for today’s MCI coaches, the Courier was promoted as costing 50% less to maintain. Beaver Bus Lines took delivery of the model in 1947. And in 1948, Brewster Transportation purchased several Courier Skyview coaches with curved glass roofs that afforded passengers exceptional views of the Canadian Rockies.

Greyhound continued to rely heavily on MCI models, and, in 1948, bought a controlling interest in MCI.

1950s

In many ways, the late 1940s and early 1950s were a golden

55www.MCIcoach.com

age for the silver cruisers of the infant interstate highway system. Americans were more mobile than ever as GIs returned from the war, travel-related rationing was lifted, and people were able to find the time and money to travel.

In 1951, MCI built its first diesel coach, the Courier 85, which gave customers a 40% bump in fuel economy. Courier models 95 and 96 were real passenger pleasers, boasting big tinted windows and even lavatories. The 1950s also ushered in the era of the MC Series. The MC-1 impressed operators with its engineering advances, including a forward-thinking cooling system, and a translucent roof for ambient light.

Many of MCI’s customers were expanding their services and exploring charter service, even as line-haul operators continued to consolidate.

In 1958, Greyhound bought MCI in its entirety.

1960s, 1970s and 1980s

In 1963, MCI entered the U.S. market in a big way, opening a plant in Pembina, North Dakota. Greyhound, predictably, took delivery of the first completed shell. The MC5 made its debut that year, and MCI’s 1969 followup, the MC6, was the industry’s first 102-inch-wide coach.

1971 was a big year, with the 1,000th MC7 shell built and delivered to the Kerrville Bus Company, Texas. Harry Zoltok retired, and the following year MCI linked up with Gerald

Hausman to create an avenue for selling coaches directly to operators.

MCI coaches also started showing up in fleets beyond North America. MCI’s MC Challenger coaches went down under to Australia in 1972, and, starting in 1979, MCI started making coaches with right-hand drives and double roofs to serve the super-heated roads of Saudi Arabia. MCI coaches would eventually also ply the roads of Taiwan, Mexico and beyond.

Closer to home, MCI was serving plenty of customers beyond Greyhound. Longtime driver and tour leader John Fehr bought Beaver Bus in 1972, creating a new legacy. Peter Pan bought its first MCI, an MC-8, in the early 1970s after being impressed with the durability of the MC-5s.

In 1973 MCI bought parts manufacturer Frank Fair Industries, allowing the company to expand its parts manufacturing.

As 1980 opened, more than 70% of the coaches on the highways were MCIs. It was even making inroads with entertainers, thanks to Custom Coach in Ohio. At least 30 MCI coaches had been converted into tour buses, including one for Loretta Lynn. Johnny Cash, Dolly Parton, Ray Charles and others would be seen in MCI coaches over the years as well. Lesser known personages had their own dependable MCIs. The popular 96-Series coaches debuted in the mid-1980s, followed by the 102 Series. Wheelchair lifts would make their production debut in 1985. The last of the great MCs, the MC-12, entered production in 1982.

1990s

After a series of ownership changes that started at Greyhound Lines, MCI became an independent corporation in 1993. But for all the ownership changes, MCI’s vehicles were rock steady. The D-Series made its debut in 1992. And in 1997, MCI introduced the Renaissance (later to be renamed the E4500).

The new millennium

When MCI introduced the J4500, it was billed as combining the sleek good looks of the Renaissance E4500 and the simplicity of the D-Series. In many ways, it managed to outshine them both. Peter Pan was the first to put its faith in the new model, ordering the first 12 in 2001. It would also be the first to order the J4500 after a redesign in late 2012.

MCI’s other customers? Many, like Martz, Cyr and Brewster, have celebrated centennials. Plymouth & Brockton Street Railway hit 125 years this June. Others have proudly recorded 75, 50, 25 or even 10 years in business. MCI continues to serve them with reliable coaches, parts and service designed to make even bigger milestones more possible.

Reprinted from FYI from MCI.

the future of motorcoach travel. Today.

mcicoach.com