Series production of the new Setra TopClass 400 has been under way since the beginning of 2008. With this series the Ulm-based brand is continuing its tradition of quality, innovative technology, comfort and safety to achieve high future sales figures, positive customer responses and numerous international awards. Accordingly, the development engineers and designers have worked together closely with Production and Sales to incorporate a large number of technical solutions and further developments into all the models in the TopClass 400 touring coach generation, which is now even more mature and attractive than ever. Werner Staib, CEO of Setra Buses & Coaches: "The aim of the model facelift was to achieve the maximum number of technical improvements while minimising the visual changes."

Safety was given the highest priority during this extensive model facelift. Once again Setra has adopted a pioneering role in this respect, and equips the TopClass 400 series with a module that moves the cockpit back out of the danger zone in the event of a crash, as well as an integrated, energy-absorbing structure, as standard. The interaction between these two systems has been optimised in countless crash simulations, resulting in a major increase in safety for the driver and courier. The effectiveness of this safety system has also been verified by several crash tests. Both the crash module with its moveable cockpit and the absorber structure are elements of the new Front Collision Guard (FCG), which also features an underride guard according to ECE-R 93 for the protection of any other parties involved in an accident. In future the three letters FCG therefore mean protection at the highest level for the driver and passengers in Setra touring coaches.

While the FCG significantly improves passive safety, there are other new features in the field of active safety. When the vehicle turns off at a junction, for example, the relevant foglamp acts as a cornering light to illuminate the junction area ahead. This function is automatically activated by the indicators at speeds below 40 km/h.

The two front end-outline lights at the upper front corners are now in LED technology, and therefore have a considerably longer operating life. A new wiper control system ensures that at the fastest wiper setting, the wiping speed is slowed down before the reversing point to prevent the blades from lifting off the windscreen, which significantly reduces noise.

Another quality improvement is not apparent at first sight, but all the more obvious when pressing the accelerator. This is because coach operators can now rely on even more power The Setra will overcome even the steepest gradients in comfort. Considerably more powerful engines are now installed under the newly designed engine flap, which is no longer a lift-up flap, but rather a rainwater-repelling top-hinged flap integrated into the rear end. The S 415 HD, S 415 HDH, S 416 HDH and
S 417 HDH are available with the OM 457 LA six-cylinder in-line engine developing 315 kW/2100 Nm or 335 kW/2 200 Nm. On request the three-axle variants can be equipped with the OM 502 LA V8-engine developing 370 kW/2 300 Nm – this is standard for the S 431 DT double-decker coach. The compact S 411 HD touring coach is powered by the OM 501 LA V6 unit developing 300kW/1 900 Nm. Another new addition is the GO 240-8 Powershift automated 8-speed transmission, which is available as a alternative to the ZF-AS Tronic. All the engines are also able to meet the Euro 5 standard if required.

The new TopClass 400 not only delivers more power, but also scores definite comfort points with passengers and drivers thanks to a 200 mm front-end extension.
An extra 14 centimetres of bodyshell allows even more adjustments for the driver, while the courier benefits from seven centimetres that provide legroom at the level of 4-star seating. The S 411 HD has a shorter front-end extension. With its compact length of 10.16 metres, the Setra "Club Bus" remains the most manoeuvrable member of the touring coach family from Ulm.

The wheelbase of the S 415 HDH has been extended by 100 mm, and the overall length of this three-axle coach is now 12.30 metres. Moreover, relocating the driver’s rest room behind the rear entry means that the super high-decker S 415 HDH, S 416 HDH and S 417 HDH have additional space for a second courier seat. Entering and exiting these vehicles in the rear door area is now even more convenient, as Setra has fitted the super high-decker models in the new TopClass 400 with additional easy-exit features.

Turning to ride comfort, here too Setra passengers are treated with the utmost gentleness. By means of controlled counteraction, the anti-pitch/roll control available as special equipment ensures that the coach glides along as smoothly as possible both when cornering and on uneven road surfaces. This is also partly due to the trailing axle with independent suspension and electronic control that has been integrated into the European TopClass 400 for the first time. The elimination of a hydraulic coupling ensures outstanding smoothness and reduces the kerb weight of the coach by 160 kilograms.

In this area too, there is plenty of good news where these reengineered touring coaches are concerned. This is because despite a number of weight-increasing features, the kerb weight of these coaches has in fact been reduced by one percent. The measures responsible include eliminating a luggage compartment flap on the left side, a new arrangement that also makes access to the luggage compartment far more convenient.

It is not only this change that alters the appearance of these coaches, as the rubber windscreen surround is also a thing of the past, with a consequent reduction in fuel consumption.

The newly integrated cornering lights, the increased angle of approach and the redesigned front end help to ensure that the Setra face has an even friendlier "smile" in future.

The facelift is also of great benefit to the drivers, who will feel even more at home thanks to a number of new, exclusive features that make the cockpit increasingly similar to that of a passenger car. These include a redesigned joystick, a leather-lined multifunction steering wheel with numerous integrated key functions and the new instrument cluster with a clearly laid-out 3D appearance.

With the presentation of the TopClass 400 in 2001, Setra entered a new dimension in touring coach engineering that guarantees travel at the highest level for the driver and passengers. Examples include innovative comfort features with seats designed for a healthy posture, multimedia systems, versatile kitchen facilities and the unique glass roof over the centre aisle. The ergonomically designed cockpit combines elegant functionality with visual appeal.

It was not without reason that just eight months after first appearing, the TopClass 400 was voted "Coach of the Year 2002" by European bus journalists. The reasons the jury cited for making its choice included the convincing technology and striking design as a symbiosis of form and function. Numerous international awards and prizes have followed since. For example, the 8500 participants in the reader’s vote for "The best commercial vehicles of the year 2007" voted the Setra TopClass 400 the winner in the "High-deck touring coach" category for the third time.

The TopClass 400 is also state-of-the-art where safety is concerned. All models are equipped with disc brakes, the Electronic Braking System (EBS), the anti-lock braking system (ABS), acceleration skid control (ASR), Brake Assist (BA) and the Electronic Stability Program (ESP), an active system that improves handling safety and stability. Setra touring coaches have been optionally equipped with proximity cruise control since 2005, a system that eases the driver’s workload on motorways and highways. When the system recognises a slower-moving vehicle travelling ahead, it automatically brakes the coach until a distance preset by the driver has been reached, and this is constantly maintained. Setra has also offered the engine brake limiter ex factory since 2005. This brakes the coach if it exceeds the legally prescribed maximum speed of 100 km/h, e.g. as a result of gravitational acceleration on a downhill gradient. Lane Keeping Assist is also available as special equipment. This system uses a video camera to detect any tendency for the vehicle to leave its lane by continuously monitoring the distance between the side of the coach and the lane markings. If the vehicle seems likely to cross this line, the driver is immediately warned by a pulsating movement in his seat which goes unnoticed by his passengers. The warning is given when the outer edge of the lane marking is reached, so that the driver has the greatest possible scope for corrective action. Lane Keeping Assist is activated automatically from a speed of 70 km/h.

At the end of last year Setra delivered the first S 416 HDH with Active Brake Assist (ABA). This system responds to slower-moving vehicles travelling ahead by warning the driver in several stages and if necessary initiating emergency braking action if the danger of a rear-end collision threatens. This system is linked to the proximity control system, and uses its sensors to detect "obstacles" travelling ahead. It therefore actively helps to prevent rear-end collisions and save lives.

The TopClass 400 generation comprises the 10.16-metre long S 411 HD Club Bus, the 12.2-metre long S 415 HD, the super high-decker S 415 HDH with three axles and length of 12.3 metres, the three-axle, 13.19-metre long S 416 HDH and the 14.05-metre long super high-decker S 417 HDH. The flagship model in this premium Setra model range is the 13.89-metre long S 431 DT double-decker coach. Setra has designed the S 417 specifically for the North American market, adapting it to meet the national regulations. It was first presented in the USA in spring 2003.