MUNK Günzburger Steigtechnik docks with the ICE

"The super train for Germany" meets innovative maintenance equipment from Günzburg: When the vehicles of the 407 series ICE family are inspected and repaired at the DB Fernverkehr AG ICE plant in Frankfurt/Main-Griesheim, the technicians rely on a modular system with aluminium access equipment from the Bavarian quality manufacturer Munk Günzburger Steigtechnik. The access technology specialist has already equipped the Griesheim ICE plant with platforms for the 406 series and with numerous individual components such as access platforms and bridging steps.

"I am pleased that we have found the optimal maintenance technology in a joint project with Munk Günzburger Steigtechnik," explains the production engineer for the mechanics, running gear and brake area at the ICE plant in Frankfurt-Griesheim. At the Griesheim site, which employs more than 300 people, not only all trains of the 407 series of Deutsche Bahn that are destined for international traffic are maintained in three maintenance halls, but also the systems used within Germany and the existing series of the previous 403 and 406 versions of the ICE. The factory has a total of three halls, the third, with a length of 230 m, was newly built especially for the maintenance of the 407 series.

For the team, maximum safety and maximum flexibility are important in the day-to-day maintenance work. For this reason, together with the specialists from Günzburger Steigtechnik, they developed a multi-modular system consisting of two side working platforms, a centre working platform and an additional working platform to be placed on the two side working platforms. A big advantage in practice: the platforms, each of which has checker plate platforms, can be used on their own or in combination, depending on the purpose.

"The most important thing for us is short set-up times, and that is exactly what we achieve with the modular system. The individual platforms can be moved by our team within a very short time along the total of three maintenance tracks, so that we are quickly ready for use again," say the specialists on site. The access equipment from Günzburger Steigtechnik also offers maximum efficiency in that several technicians can work in different places at the same time. "The tasks were to replace the top lighting and work on the windscreen wiper system. The relatively light, yet very stable design is convincing when it comes to assembly, with which a windscreen replacement is now also possible," explains the production engineer.

The two side working platforms are each 3,000 mm long and, with their width of 1,000 mm each as well as the up to 600 mm wide contour adaptation made of checker plate, together offer a working area of more than six m2. The platforms are each accessed via a stepladder that can be folded vertically to save space. The safety of the employees is ensured by a surrounding railing on three sides and a safety door in the area of the ascent. Towards the train, the working platforms are precisely contoured to the outer skin of the ICE, so that the technicians can work with a gap dimension of zero. This not only increases work safety, but also comfort during maintenance, because the contour adaptation (with protective rubber edge) also prevents tools from falling down. The side platforms have a floor running gear with four 200 mm swivel castors each. If the side platforms are used individually, i.e. without a front end platform, an additional side railing can be swivelled in each case to optimally secure the technicians during work at the end of the train. All railings are equipped with foot and knee rails.

The 1,800 x 1,000 mm front end platform has also been extended to include contour adaptation and can be docked onto the front end of the ICE with a zero gap dimension. It enables windscreen replacement and offers the best working conditions for changing windscreen wipers. A special feature of the centre working platform is its two-way running gear, which is equipped with braked flanged rollers in 1435 mm gauge. This means that the platform can be moved both on the track and on the hall floor. The end platform also has a three-sided all-round railing; for use without side platforms, two additional folding or telescopic plug-in railings can be inserted.

For the repair or replacement of the upper tip light on the new ICE, the technicians in Frankfurt-Griesheim use a connecting walkway that is placed on the two side working platforms and thus serves as an additional working platform. The platform width is 800 mm, so that a platform length of 3,200 mm results in an additional working area of 2.5 m2. Climbing is done from the roof working platform or the side working platforms via access ladders, which also serve as supports. Safety doors serve as fall protection on the ascent sides, and the railing can be inserted at the rear. When there is no work to be done on the upper toplight, the connecting walkway is simply stowed directly on one of the two side platforms to save space. This way, it doesn't get in the way and is still always at hand, without having to be transported.

"For us, the overall concept is important, and here Munk Günzburger Steigtechnik simply offered the best solution," say the technicians, who are pleased, among other things, that the top light platform not only docks seamlessly to the outer skin of the 407, but also provides a stepless transition to the installed walkway systems in the maintenance hall.

Ferdinand Munk, owner and managing director of the Munk Group, and his team are honoured by the trust placed in them. "Project competence and know-how in consulting have distinguished us for many years. We are only satisfied when we have really found the optimal solution for our customers. It is nice that we have once again succeeded in doing so with the Velaro project," the company boss is pleased to say.