Almost like new again: ICE 3 redesign completed

3,000 new monitors, 27,000 square metres of new carpet and almost 22,000 new seats. This list of superlatives could be continued. But with just these three figures it quickly becomes clear: DB Fahrzeuginstandhaltung has moved a lot for the redesign of the ICE 3 fleet (403 series). After ten years, the joint project with DB Fernverkehr ("Long-distance Traffic") is now coming to an end. After a preparatory period, a total of 50 trains were brought up to date within seven years: in terms of interior, exterior and also under the bonnet. With the redesign, the trains were equipped with the ETCS train control system from Alstom, among other things.

Previously, the vehicles could hardly deny their age. "The feel-good factor for our passengers has declined over the years," explained Martin Baier, Head of Vehicle Management at DB Fernverkehr. It was time to act. Not just with a simple replacement of the interior, but with some further measures: So the train got said 3,000 new monitors and a new passenger information system. On top of that, the toddler compartment was redesigned, the galley was retreaded, a full-fledged on-board restaurant area was created, a break room for the train crew was added and a new seat in the driver's cab was installed. "Now you have a completely different feeling on the train," Baier sums up. He thanked his colleagues for a really great project, a great vehicle and the cooperation in a spirit of partnership.

Reaching the goal together

This was exemplified by the two project managers: Helmut Schroers at DB Fahrzeuginstandhaltung and Florian Fuchs at DB Fernverkehr. "The challenges in the project were always solved at eye level," says Schroers. For example, the expansion of the seating capacity provided additional weight. "The ETCS equipment also adds a few kilograms to the scales," explains Fuchs. But with a new lightweight floor, on which the carpet was no longer glued but clipped on, these kilogrammes could be saved again.

Next challenge: The 403 series consists of two different construction series. "With the sample train of the second series, we noticed that the circuit diagrams of the air conditioning system did not correspond to reality," says Fuchs. Together we investigated, measured and checked the cables. With success: "It was great that we still managed to complete the sample train in the planned time.

Finally, the corona virus also tried to torpedo the schedule. Will the material still arrive in time? Which colleagues can work on the vehicle and, above all, how closely together? Many questions arose at once. "But by taking active and timely countermeasures, we were able to get through this time almost without a hitch," explains Fuchs.

Most recently, the DB Fahrzeuginstandhaltung team needed only 50 days to complete a multiple unit.

Currently, they are already working on the next task in Nuremberg. Part of the factory is being rebuilt so that the ICE 3 can come back - namely for the standard overhaul. The eight-unit train can then be processed in Nuremberg in its full 200-metre length. So the ICE 3 is not letting go of the employees in the Nuremberg maintenance depot.