Mar 3, 2016 | News & Press
Urban transit buses represent a prime opportunity for electrification. Their typical duty cycles allow them to be conveniently recharged at terminals, and the savings on fuel and maintenance can be enormous. Furthermore, cities around the world are revitalizing and beautifying their downtown districts, so getting rid of noise and diesel smoke is a welcome benefit.
Battery-electric buses are operating in pilot programs in dozens of cities in North America, Europe and Asia, and in EV hotspots such as California and China, they’re already being phased into regular service.
However, municipal transit authorities face the same dilemma that individual car buyers do: while an EV may save a lot of money over its lifetime, the purchase price can be almost double that of a legacy vehicle. Fortunately, there’s an elegant solution.
Complete Coach Works (CCW), founded in 1986, is one of the country’s largest remanufacturers of transit buses. The California company is now offering remanufactured buses with electric drive at prices comparable to new diesel buses, with the additional environmental benefit of recycling the chassis and many of the parts.
There are several reasons that a transit agency might choose to remanufacture vehicles, from replacing worn-out engines to modernizing older buses with new technology, such as accessibility features to comply with the Americans With Disabilities Act. These days, a growing number of transit authorities are remanufacturing buses in order to upgrade legacy diesel drivetrains to more modern options.
CCW’s Zero Emission Propulsion System (ZEPS) battery-electric buses fit the bill perfectly. Charged recently spoke with ZEPS Sales Manager Ryne Shetterly about the advantages of taking the remanufacturing route.
“We really like to stick to our model of sustainability,” says Shetterly. “By remanufacturing vehicles that are already in service, or that have already gone through a useful life period, we’re saving about ten times of raw materials, and that’s something that we take great pride in. It’s having a big impact on the environment. We’re re-using chassis that are in perfectly good working condition.”
CCW built its first prototype ZEPS bus about five years ago, and now has electric buses in operation in about half a dozen US cities, with several more on order. CCW’s biggest order to date (and the largest fleet of electric transit buses in the country) consists of 21 buses it sold to the Indianapolis Public Transportation Corporation (IndyGo), which operates approximately 157 buses on 31 routes in Indiana’s capital.
“A lot of people are looking at that project as kind of the indicator of success,” says Shetterly. “For us to actually execute and deliver a successful project like that has really heightened interest, and we’re getting calls from all over the country.”
CCW remanufactures a lot of Gillig, New Flyer and Orion buses, but it works with anything and everything in the transit world. The team has worked with other alternative fuels in the past, including LNG, CNG, and “clean diesel” technologies. “We installed one of the first hybrid packages that was available way back in the day,” says Shetterly, “but that’s not a viable option anymore. We’re always trying to stay on the cutting edge of clean technology, but now we’re all in on electric.”
Shetterly wouldn’t say exactly what percentage of CCW’s business the electric buses represent, but said that it is “a healthy portion…and we do see it being a much larger portion of what we do in the future.”
An offer cities can’t refuse
The cost of a remanufactured battery-electric bus is in the neighborhood of what a new diesel bus would cost with all the options, Shetterly tells us. “We’re coming in at about $580,000. That’s about $200,000-$300,000 less than a brand-new electric bus from one of the OEMs that are currently in production.”
Savings on fuel and maintenance are expected to add up to about $440,000 over the useful life of the bus.
The ZEPS on-board charger (100 amp, 50 kW), is designed to require no special charging infrastructure beyond 480-volt, 3-phase electrical service, which would normally be installed at an overnight depot.
Some transit authorities send CCW their buses to be completely refitted, an option that is not only cheaper, but faster than buying new vehicles. “You can go buy a brand-new bus for X amount of dollars, or you can come to CCW and spend a fraction of that, and have a bus in six months, versus the standard 18-24 month lead time that you see with the OEMs.”
Another advantage of a remanufactured bus is that many of the components are already familiar to maintenance staff. “We’re taking a bus that has been on property for the last ten years or so, and the maintenance team is already familiar with how to take care of the preventive maintenance,” says Shetterly. “None of the parts are going to change, so there’s not going to be any new parts inventory required. The drivers are already familiar with the buses. We keep the OEM build as close as possible to where it was when it came off the line. We rebuild what we can rebuild – obviously some of the essential parts get swapped out for the electrical components, but mostly everything is going to stay the same.”
“The fact that it’s a refurbished bus with a chassis we currently operate in our fleet makes it practical in terms of interchangeability of parts – it’s a great benefit to us,” agrees Mario Delgado, Transit Director of McAllen, Texas, which bought two ZEPS buses. “The response from the drivers so far has been very good. They are excited about how quiet and smooth the ride is.”
The rebirth of a bus
The transformation of a bus begins by dismantling it down to the chassis level. The diesel engine, transmission, radiator and belt-driven accessories are removed, and the differential is remanufactured to a taller gear ratio of 6.1 from the existing ratio of 5.4. Shock absorbers, air bags, tie rod ends and wheel hubs are replaced with new parts. New composite flooring, seating, an electric air compressor and a power steering pump are installed.
Several upgrades help to maximize the vehicle’s operating range, including lightweight flooring and seats, lightweight aluminum wheels, low rolling-resistance tires, energy-efficient heating and cooling, and LED lighting.
The ZEPS bus has a 131 kW liquid-cooled electric motor. “The torque on it is just absolutely amazing,” says Shetterly. “You’re looking at about 1800 pounds of torque. So, it’s great for pulling grades – it operates really well on an intercity route, where there’s a lot of start and stop.”
CCW uses Samsung lithium-ion battery cells, and offers a couple of range options. The standard pack has 311 kWh of energy storage (250 usable), which delivers a range of about 150 miles. It also offers a half-pack option: a 154 kW hour pack coupled with WAVE inductive charging technology (see sidebar).
Battery-electric technology is not suitable for every bus route. “You’ve got some transit buses doing 300 miles a day,” says Shetterly. “Right now, there’s really not an electric bus that will meet those needs. But with the progression in technology, and where the market is heading, it may be something that’s available in the not too distant future.”
Story courtesy of KSBW.com Action News 8.
Mar 1, 2016 | News & Press
For Immediate Release
March 1, 2016
RIVERSIDE, CA — Complete Coach Works (CCW) is pleased to announce it has completed the replacement of forward-facing flip seats with safety barriers on 171 buses of Foothill Transit’s buses. Foothill Transit is the premier provider of public transit services in the San Gabriel Valley, just east of Los Angeles, California.
The work was strongly recommended by the bus manufacturer after it became clear that passengers sitting in forward-facing flip seats with no barriers in front of them could be thrown forward and injured if the driver had to brake hard or make an evasive maneuver.
Some transit agencies have opted to address the issue by locking the flip seats in the up position so they cannot be used, while others have had them taken out.
“Foothill has opted to remove the seats and install the barriers. It is not the most affordable route, but it is the safest option for their riders.” said Kevin O’Brien, General Sales Manager for CCW.
Roland Cordero, Foothill Transit’s Director of Maintenance and Vehicle Technology, said his agency is having the work done on all 171 buses, even though some of them are due to be retired within a year and a half.
“We still have to provide safety to our customers, whether we’re going to be replacing these buses or not,” Cordero said.
“Foothill Transit has contracted a number of projects with CCW and has been pleased with the work that has been done,” shared Cordero. “They have the knowledge, the expertise and the experience. They are very quick to respond and correct issues. We’re happy with their performance and service.”
Complete Coach Works (CCW) is the largest U.S. bus remanufacturing and rehabilitation company and the leading provider of a vast array of transportation solutions with over 28 years of dedicated service in the transportation industry. CCW a pioneer in the business and strives to continually provide cleaner air through innovative design and engineering, resulting in the world’s first and only remanufactured all-electric battery powered bus. Developed and integrated by CCW, the Zero Emission Propulsion System (ZEPS) technology provides customers a highly cost effective alternative to green transportation, potentially revolutionizing the transportation industry while supporting the environment for future generations. Regardless of how small or large the job, CCW provides an exceptionally experienced team of over 350 experts, committed to customer service and satisfaction
Foothill Transit is the largest municipal transit operator in Los Angeles County, second only in size to regional provider Metro. Foothill has 315 buses powered by compressed natural gas and 15 that are fast-charge electric. The agency operates on 36 local and express routes that serve 327 square miles of the San Gabriel and Pomona Valley. Ridership is more than 48,000 a week, or approximately 14 million a year.
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Jan 26, 2016 | News & Press
For Immediate Release
January 26, 2016
RIVERSIDE, CA — Complete Coach Works (CCW) is pleased to announce it has delivered two Zero Emission Propulsion System (ZEPS) buses that include a wireless charging system provided by Wireless Advanced Vehicle Electrification (WAVE) to the City of McAllen’s Transit Department, Metro McAllen (McAllen).
“We are excited about the project, it will be a great benefit to our community and it’s going to be a project that will potentially help advance ZEPS, a product that can revolutionize the industry,” shared Mario Delgado, Transit Director for McAllen.
The ZEPS powered buses create significant carbon savings by eliminating activities involved in manufacturing a new bus. The rehabbed buses cost a fraction of what a new all-electric bus would cost, helping minimize budget and environmental impact.
Delgado states, “The fact that it’s a refurbished bus with a chassis we currently operate in our fleet makes it practical in terms of interchangeability of parts, it’s a great benefit to us. The ZEPS bus produces zero emissions; it’s all around better for the environment.”
The two ZEPS buses will reduce the cost of maintenance and fuel, and are also five feet longer than the current buses in the McAllen fleet, permitting a larger capacity limit.
“The response from the drivers and those that have looked at it so far has been very good. They are excited about how quiet and smooth the ride is, it’s a different tune,” mentioned Delgado.
McAllen will have a rollout ceremony on January 28, 2016 at 10:00am at the McAllen Bus Terminal located at 1501 W. Highway 83.
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Complete Coach Works (CCW) is the largest U.S. bus remanufacturing and rehabilitation company and the leading provider of a vast array of transportation solutions with over 28 years of dedicated service in the transportation industry. CCW is a pioneer in the business and strives to continually provide cleaner air through innovative design and engineering, resulting in the world’s first and only remanufactured all-electric battery powered bus. Developed and integrated by CCW, the Zero Emission Propulsion System (ZEPS) technology provides customers a highly cost effective alternative to green transportation, potentially revolutionizing the transportation industry while supporting the environment for future generations. Regardless of how small or large the job, CCW provides an exceptionally experienced team of over 350 experts, committed to customer service and satisfaction.
The City of McAllen’s Transit Department (McAllen) was created in 2001 in order to manage and maintain Central Station, the City’s International Transit Terminal Facility. Metro McAllen currently operates seven (7) intercity bus routes and a paratransit bus service for eligible patrons. The bus system hubs out of the downtown terminal facility where passengers can connect to an array of international, national, regional and intercity destinations. The bus service days of operation are Monday through Saturday.
WAVE (Wireless Advanced Vehicle Electrification) is a technology company based in Utah that develops high power wireless charging solutions for electric vehicles including transit and shuttle buses, fleet vehicles, streetcars, and off-road industrial vehicles. WAVE tackles the problem of heavy and expensive vehicle batteries through wireless power, transferring electricity between vehicle and roadway.
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Jan 22, 2016 | News & Press
For Immediate Release
January 22, 2016
RIVERSIDE, CA – Complete Coach Works (CCW) is about one-third of the way through a project with Orange County Transportation Authority (OCTA) to install new CNG engines,and cooling systems along with upgrading the transmissions in 199 buses.
As of late December 65 buses had been repowered at CCW’s Riverside location and returned to service in Orange County.
“The new CNG engines are more powerful and emit significantly less pollution,” said Kevin O’Brien, general sales manager for CCW. “CCW has been contracting work with OCTA for 30 years and this it is one of the most rewarding projects to date.”
“Work on the 2007 and 2008 low-floor buses is moving along at the rate of about a bus a day” shares O’Brien.
The work includes installing new engines, upgrading the transmissions and switching from hydraulic cooling to electric cooling systems. The electric system uses seven fans, which requires upgrading to 450-amp alternators.
OCTA destroys the old engines and provides documentation of that work to the South Coast Air Quality Management District, which in return provides funding to help pay for the project.
The project is expected to be completed by mid-2016.
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Complete Coach Works (CCW) is the largest U.S. bus remanufacturing and rehabilitation company and the leading provider of a vast array of transportation solutions with over 28 years of dedicated service in the transportation industry. CCW is a pioneer in the business and strives to continually provide cleaner air through innovative design and engineering, resulting in the world’s first and only remanufactured all-electric battery powered bus. Developed and integrated by CCW, the Zero Emission Propulsion System (ZEPS) technology provides customers a highly cost effective alternative to green transportation, potentially revolutionizing the transportation industry while supporting the environment for future generations. Regardless of how small or large the job, CCW provides an exceptionally experienced team of over 350 experts, committed to customer service and satisfaction.
Orange County Transportation Authority (OCTA) provides transportation throughout the 34 cities and unincorporated areas of Orange County, California. Over 97 percent of the agency’s 544 buses operate on CNG or LNG and OCTA has reduced its particulate matter emissions by 95 percent and its NOX emissions by nearly 78 percent since 2002. OCTA strives to reduce freeway congestion, improve safety and efficiency on local roads, provide bus service and regional multimodal connections, encourage carpooling, and provide convenient transportation to people with special needs.
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Jan 7, 2016 | News & Press
For Immediate Release
January 7, 2016
RIVERSIDE, CA – Complete Coach Works (CCW) is pleased to announce it has delivered the last of the 21 rehabilitated Zero Emission Propulsion System (ZEPS) powered electric buses to Indianapolis Public Transportation Corporation (IndyGo).
As the world’s first and only of its kind, the remanufactured ZEPS bus is rebuilt with lightweight flooring, low resistance tires, and energy-efficient heating and cooling, while ensuring a reach of 130 mile range on a single battery charge. Each 40 foot electric bus carries 36 seated passengers plus standees and is equipped with air operated doors, brakes, suspension, hydraulic power-steering, stainless steel bike racks, LED lighting, and lightweight seats.“The buses look remarkable, almost like brand new buses,” said Director of Maintenance at IndyGo, Victoria Learn.
The ZEPS powered buses create significant carbon savings by eliminating activities involved in manufacturing a new bus. IndyGo now has the largest remanufactured electric fleet in the country. The rehabbed buses were acquired at a fraction of the cost of new all-electric buses, helping minimize cost and environmental impact.
“IndyGo is proud to be a transit leader in alternative energy. We feel it’s important to push the envelope and utilize newer technologies to make our operation as efficient as possible,” said President and CEO of IndyGo, Mike Terry.
*Featured above: last ZEPS IndyGo bus loaded for delivery.
ZEPS electric buses also:
- Reduce the nation’s reliance on foreign oil
- Use electricity from the grid, a renewable energy source
- Serve as a viable alternative to fossil fuels
- Eliminate hazardous waste and reduce air pollution
Learn mentions, “With this project, our focus was a reduction of fossil fuels, providing a cleaner, quieter ride for our passengers. The community loves that there is less pollution emitted in the atmosphere and it is a much quieter ride.”
“We, at CCW, are excited and honored to have been selected through a competitive bidding process for the IndyGo project. We value their business and relationship and look forward to the opportunity of working together again in the future. We are happy to be a part of the continued evolution of transit,” said Regional Sales Manager for CCW, Jay Raber.
*Featured in introductory photo: part of the CCW IndyGo team (left to right: Rigo Fregoso, Guy Wright, Thomas Hoskins, Don Krug and Tony Camposano).
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Indianapolis Public Transportation Corporation, IndyGo, is a Municipal Corporation of Indianapolis – Marion County and the largest public transportation provider in the state of Indiana. It operates 31 bus routes throughout the county, providing 10.29 million passenger trips in 2014. IndyGo provides quality public transportation throughout the year with approximately 157 buses in its fleet. Visit IndyGo.net, follow @IndyGoBus on Twitter, or call (317)635.3344 for more information.
Complete Coach Works is the largest U.S. bus remanufacturing and rehabilitation company and the leading provider of a vast array of transportation solutions with over 28 years of dedicated service in the transportation industry. Not only is CCW a pioneer in the business, but continually strives to provide cleaner air through innovative design and engineering resulting in the world’s first and only remanufactured all-electric battery powered bus. Developed exclusively by CCW, the ZEPS technology was integrated in order to provide customers an affordable route to eco-friendly transportation, potentially revolutionizing the transportation industry while supporting the environment for future generations. Regardless of how small or large the job, CCW provides an exceptionally experienced team of over 350 experts, committed to customer service and satisfaction. For more information about the ZEPS electric bus and other services, please visit www.zepsdrive.com.
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Dec 30, 2015 | News & Press
For Immediate Release
December 30, 2015
RIVERSIDE, CA – Complete Coach Works (CCW) is pleased to announce that it has completed the installation of Lift-U Bi-Fold Ramps on 86 buses operated by the San Francisco Municipal Transportation Agency.
The work was done at the CCW North facility in Alameda, with CCW providing transportation of the buses from SF Muni to Alameda to begin their up-fitting.
“We outfitted these buses with the latest and greatest technology that will allow for more consistent and safe loading and unloading of ADA passengers,” said Kyle Carson of CCW.
The new ramps fold flush with the floor when not in use and have a substructure that can be adjusted when the ramp is deployed to create a smooth and level surface, allowing passengers who use wheelchairs or have difficulty climbing steps to easily and safely board or exit the bus.
Gary Chang, the project engineer for San Francisco Municipal, said the project was “seamless and smooth. I have done several projects with CCW,” he said. “They know our expectations and they have done very well.”
“CCW was very responsive. They know our buses and we know the ramps, so it was a perfect fit,” Chang said.
Including the completion of this project, CCW has successfully rehabbed a large portion of San Francisco Municipal’s fleet.
Complete Coach Works (CCW) is the largest U.S. bus remanufacturing and rehabilitation company and the leading provider of a vast array of transportation solutions with over 28 years of dedicated service in the transportation industry. CCW is a pioneer in the business and strives to continually provide cleaner air through innovative design and engineering, resulting in the world’s first and only remanufactured all-electric battery powered bus. Developed and integrated by CCW, the Zero Emission Propulsion System (ZEPS) technology provides customers a highly cost effective alternative to green transportation, potentially revolutionizing the transportation industry while supporting the environment for future generations. Regardless of how small or large the job, CCW provides an exceptionally experienced team of over 350 experts, committed to customer service and satisfaction.
SF Municipal Transportation Agency serves more than 700,000 passengers on an average weekday over 75 transit lines. Muni, formed by San Francisco voters in 1912, is the nation’s first publicly owned transit system. It directly oversees five transit modes: bus, bus trolley, light rail, historic streetcars and cable cars, as well as paratransit vans. The agency’s goal is to operate the greenest, most efficient and quiet technology available.
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