TS1-OIL Rev. U

TS1 OIL 16. February 2012

TS 1 Revion U

No

Audited Item

Open Item

Remark

Action by PT. INKA / Result

Status

Close have checked the √ (17032011) function and added in the report

1

Cheek sheet of components installation

- Number of speed sensor (TC1/TS1)

1 speed sensor miss to be checked

will be checked

2

Cheek sheet of components installation

- Ground contact

Not yet checked and must add to the check documentation

will be checked and added

have checked and added √ (21032011) to check sheet of Component Installation

3

Quality Plan Procedure (ITP)

- Create an Overview about routine test & type test are requested for total process

will be showed to HC

have added to Vehicle Record Book

4

Static test procedure

- Anti trap don't install

Don't list at the contract of project. Hamburg Consult state that there must Anti trap at the door (according to the international standard/state of art). Anti trap don't describes at the detail of contract.

see list of deviation in the √ (17032011) Vehicle record book

5

Static test procedure

- There is difference between Bogie number (Component identification number and Bogie Serial Number)

INKA use number of Bogie frame when bogie load test (July 2010), and use

update of document

√ (17032011)

6

Static test procedure

- Bogie number inspection Doc. number E0.20.402. Measurement value outside tolerance (Point 8 & 9)

Check of target value

clarification in the document

√ (24032011)

7

Static test procedure

- Some test only have Test Record, not yet for the Test Procedure

Test Procedure will be added

8

Static test procedure

- Create separate folder for Test Record and Test Procedure

will be created

9

Static test procedure

- Static tolerance of axle loads

The maximum difference of wheel loads of one wheel Repeat for the weight test set in leveled track more than 4% in relation to the average wheel loads for empty vehicles. The maximum differences between wheel loads of two related bogies shall not be more than 2%

carried out and balanced √ (04042011)

10

Static test procedure

- Check lubrication on Inspection Sheet Bogie Assembly Trailer Car (TC1/TS1)

Not yet checked, will describe which lubrication must will be checked be checked

have checked, inspected and recorded

√ (22032011)

11

Static test procedure

- E0 20-401 E020 08 005 (Bogie)

have checked, mistyped

√ (17032011)

12

Static test procedure

- Coupler measurement on TC1,M1,M2,TC2

Procedure how to filled up the coupler measurement check sheet.

Repeat the measurement

13

Static test procedure

- Inspection Sheet of Insulation test (Megger Tester 500V) (M2)

some test are missing

will be checked and measure

have measured the missing test

√ (17032011)

14

Static test procedure

- Check of Compresor preparation on (M2)

It can be changed/referred to another document

Delete the existing rows

The rows have been deleted and referred to another document

√ (21032011)

15

Static test procedure

- Actual time of lowering pantograph

write the value (seconds)

will be added

have added the value (in seconds)

√ (17032011)

16

TCMS

- Exchange of connector for the monitoring of Battery charger Over temperature & Charger failure.

INKA still waiting for new connector

335433966.xls

Check the value under crash load

Page 1 of 7

√ (24032011)

√ (16022012) existing

√ (04042011)

√ (26092011)

√ (22112012)

22.11.2012

No

Audited Item

Open Item

Remark

Action by PT. INKA / Result

Status Close

17 March 2011 17

List of drawing

- Add list of drawing (drawing number & version) in the Vehicle record book

Will add to the Vehicle record book

18

Test on safety related equipment

- Add test procedure for inspecting existing equipment (emergency hammer, extinguisher including checking label) and safety labeling

Will add to the Check Sheet of components installation and Inspect on the train

19

Curve test

- Add curve test (turn out test) procedure for coupled train

will check directly to the test track (min curve R = 80m)

the procedure have been √ (21032011) added to the curve test (on routine test)

20

Door emergency handle

- Door emergency handle not yet installed

will be installed

was installed. Please refer √ (31032011) also to List of deviation

21

Door leaves

- Door leaves can't close perfectly (there is small gap)

will re-adjust the door, check before dynamic test and add task to the dynamic test procedure at incoming inspection

Door rubbers are changed √ (16022012) to male/female design

22

Safety device label

- Safety device label (emergency window, fire extinguisher, door handle)

23

Interior & exterior

- Cleaning the interior & exterior

24

Interior & exterior

- Loud speaker screw (scratch paint)

25

Interior & exterior

26

Door emergency handle is listed at the document of contract.

Not complete installed.

to be reduced.

List of drawing have been √ (28032011) added to the Vehicle record book √ (04042011)

will install

√ (16022012)

will be cleaned before train sent to Jakarta

√ (22112012)

touch up the painting

have touch up

√ (22032011)

- Loud speaker cover (scratch paint)

touch up the painting

have touch up

√ (22032011)

Interior & exterior

- TC1 (right side) : damage of side wall over baggage rack

will be repaired and repainting

have repaired and repainted

√ (22032011)

27

Interior & exterior

- Spot welding area isn't clean

will be cleaned

√ (16022012)

28

Bogie and Carbody

- Safety mark of the screw/bolt are missing

the safety relevant bolt will be marked

√ (07062011)

29

Jumper cable coupler (on the roof)

- Jumper cable coupler will be inspected during dynamic test in Jakarta

The cable are to long.

Definition of the fixed length and reduce the cable

√ (07092011)

30

Flexible hose

- flexible hose touch against and chafe against the bogie frame

Hamburg Consult is accepted about flexible hose protector.

will give protector to flexible hose

√ (07062011)

31

Co-masinis chair

- TC1 : co-masinis chair (second chair) not yet installed

will be installed after dynamic test

is installed

√ (21032011)

22 March 2011 32

Door

- Adjustment of the exact door signal (open and close)

Safety relevant

33

Door

- Maintainability to the door mechanism is not given

the reason is LCD cover hit against the ceiling when the cover is opened. LCD is requested by DGR

335433966.xls

Page 2 of 7

re-adjusted and tested Check the design and define maintenance task

√ (24032011) √ (09082011) update maintenance manual later

22.11.2012

No 34

Audited Item Test Record car body shell

Open Item

Remark

- Clarification between under frame and car body number

Action by PT. INKA / Result will be clarified

has added in Vehicle record book, point number 9

on TS3

move to TS3

Status Close √ (22032011)

23 March 2011 35

Lifting ability test

- Can the train lift with the bogie

carrying out at type test

36

De-railment

- Procedure of re-alignment

add re-alignment procedure for the train to the maintenance manual/driver guide

37

Braking software

38

TCMS

- Updating software procedure for end customer.

39

TCMS

40

√ (09082011) update maintenance manual later

Doc. E0.20-406.2 page 5, target value of software version must be added

clarified Standard Operating Procedure how to update software from Bombardier to Customer

√ (28032011)

√ (25032011)

Clarification by BT

√ (10082011)

- What is the meaning Consist 1 & Consist 2 (Doc. 3EST000220-2673)

Clarification by BT

√ (10082011)

TCMS

- Explanation about (*) remark at TCMS routine test. Step 5.5.4 DX8C; 5.5.5 DX8D (Doc. 3EST000220-2673)

Clarification by BT

√ (22112012)

41

TCMS

- BVI test, Step 5.5.6 AX84 (Doc. 3EST0002202673)

Update Test Specification & Test Report document. Step 5.5.6 AX84 (Doc. 3EST000220-2670)

Clarification by BT

√ (22112012)

42

TCMS

- Verify/Check test point number 7 &8. Step 5.5.8 DX36 (Doc. 3EST000220-2673)

Verify test point number 7 & 8 after new connector installed

Clarification by BT

√ (22112012)

43

TCMS

- Update the document Step 5.6.6 AX84 (3EST000220-2670)

Test record must be updated as standard for the next Clarification by BT train set

√ (10082011)

44

TCMS

- Update the document Step 5.6.7 AX85 (3EST000220-2670)

Test record must be updated as standard for the next Clarification by BT train set

√ (10082011)

45

TCMS

- Add a note about the impact when updating software on document 3EST000220-2675.

Give remark (*) under the table Chapter 4.1

Clarification by BT

√ (10082011)

46

TCMS

- Update the Test Specification and Test Report

About document number 3EST0002202670/2671/2672/2673/2674/2675

Clarification by BT

√ (10082011)

47

TCMS

- BT will repeat the open item test (nb. item that need to be repeated and item that can't be checked at INKA)

Because the installation of new software version

Clarification by BT

√ (22112012)

48

Clarification of driver's procedure

- Add of additional test for Online test at Jakarta. Results are implemented at driver manual guide

Emergency brake handle is activated when the train move (standstill, 5 km/hr, 50 km/hr). What is the effect?

Completion of the Online test procedure (test at Jakarta)

√ (09082011)

49

Clarification of driver's procedure

- Add of additional test for Online test at Jakarta. Results are implemented at driver manual guide

Emergency door handle is activated when the train move (standstill, 5 km/hr, 50 km/hr). What is the effect?

Completion of the Online test procedure (test at Jakarta) /

√ (09082011)

50

Clarification of driver's procedure

- Simulation of the platform situation is to be added on Online test

Completion of the Online test

√ (22112012)

24 March 2011 51

Leveling of the train

- Procedure of leveling necessary

Add to the maintenance manual and sent preliminary formal letter to Dipo

- Procedure of lamp intensity test

Measurement condition (environment)

√ (09082011) update maintenance manual later

25 March 2011 52

Room lamp intensity test

335433966.xls

Page 3 of 7

update of the test procedure record sheet

√ (28032011)

22.11.2012

No

Audited Item

Open Item

Remark

53

Function test Air Conditioner

- Procedure of function test Air Conditioner

Add target value of humidity temperature

54

Function test Air Conditioner

- Measurement of Air Conditioner must be repeated on MC2

The humidity outside of tolerance

55

Pneumatic Static Test of braking sy

- Air supply equipment (item no 4), deviation between setting value and actual value

Confirmation/statement from KNORR request

Action by PT. INKA / Result update of the procedure and record sheet Will repeat the measurement and adjust the thermostat

Status Close √ (28032011)

thermostat has adjusted √ (07042011) & measurement repeated. Humidity inside the tolerance

Regarding to statement √ (29032011) from KNORR (dated 27 March 2011)

28 March 2011 56

List of standard

Will add to the Vehicle record book

√ (09082011)

57

Emergency Door opening cock

- protection cover not yet installed

protection against unauthorized installed according to PT INKA Door proposal

√ (07092011)

58

Driver Cabs equipment

- First Aid box not yet install for each cabin

install before start of dynamic test

√ (07062011)

59

Driver Cabs equipment

- Add in the check sheet (chapter "Safety Relegated Equipment")

60

List of safety relevant calculation & investigation

- Add summary of safety relevant calculation and investigation (FMECA) to type test folder

Amendment to the existing list, see list of deviations.

√ (09082011) will add the list to the folder type test

√ (22112012)

definition of solution

√ (07092011)

29 March 2011 61

Door lock from inside

- Function of each door is not given according to the technical specification point 9.4.2

safety operation is not given

62

Door lock from inside

- Label "Door Out Operation - Please use the next door")

63

Door switch on driver desk

- Push button for door system is not correct function

safety relegated issue

correction of installation

√ (07062011)

submit for information and file as safety related document

√ (22112012)

responsible by PT. KA

n.a.

Closed for PT. INKA

30 March 2011 64

Automatic Coupler

- certification of the absorption of the energy until 7 km/h without damage of the carbody structure is requested

result of first article inspection of coupler

65

Main lighting passenger room

- Type test of brightness of 200 lux at 200 mm above the aisle floor

compilation of the specification and measurement on train set 3

n.a.

√ (04042011)

31 March 2011 66

Pneumatic Static Test of the braking system

- Measurement of AW0 & AW3 outside of tolerance

repeat measurement & clarification of tolerance

67

Door emergency handle

- update of corresponding drawings

submission of change request no change request necessary

completion and identification of the change request

√ (16022012)

68

Ground contact

- ground contact cable are outside of the loading gauge

re-check of fitting and length correction

correction and check of loading gauge

√ (09082011)

69

Battery Box

- Lock system of the cover is too loose

Adjustment of the lock mechanism and check of the design

70

Car cover, rear ends

- aligning of the cover in the line

71

Filter box (door)

- draining hole missing

335433966.xls

√ (16022012)

√ (07062011) adjustment

water can not drain

Page 4 of 7

redesign

√ (07062011) modified

√ (12052011)

22.11.2012

No

Audited Item

Open Item

Remark

Action by PT. INKA / Result in progress

installed

Status Close √ (12052011)

72

Fitting of the main air pipe on the car

- retrofit of an additional bracket

73

Driver's desk

- door panel description, command left on the right side of the panel, command right on the left side of the panel

Design according to the drawing,

agreement and acceptance changed by PT. KAI necessary (deviation of Indonesia regulations)

√ (12052011)

74

Main switch box

- Isolated stick

Fitting in the box or definition another location

definition of fitting location

√ (07092011)

75

Main switch box

- Isolated stick

Add in the list of safety related equipment

compilation of the check sheet of components installation for TS1 as amendment (see also point 59)

√ (09082011)

- Loading gauge inspection

Check sheet of loading gauge move from complete to incomplete

- Paint fixed up the complete roof

Prepared surface too smooth or not rough

01 April 2011 76

Vehicle Record Book

please see point 68

√ (04042011)

04 April 2011 77

78

Roof : TC2, M2, M1, TC1

Roof : M2, M1

- Brake resistor

repainted (surface preparation with sand blasting according to the surface sample)

√ (07092011)

NCR missing (must add at vehicle record book) √ (07092011)

washer of the protection cover rusted clean, fitting screws and anti corrosion protection

79

Roof

- AC units

rusted location on the roof

clean, sealing and anti corrosion protection

√ (07092011)

check and repair

√ (21092012)

06 April 2011 80

Door TC2

- Right door (number 3) has noise when moving

81

Air Conditioner

- change request by Konvekta is requested

Currently, Konvekta exchange all fans. Konvekta has to notify the reason of measurement

requirement of changing request by Konvekta

Engineering

Dynamic test on 15.05.2011 (first test run) 82

Articulation area M1 - M2

- Tapping noise from the articulation area

surmise: ungreased joint of the permanent coupler

Check of the area and grease of the articulated joints and recheck of the noise

√ (07092011)

83

Emergency light

- function of the emergency light is not given.

Regarding to the Indonesia rules one lamp of each door must be also switched on in the emergency case. So in the KRL train must be switched on 6 lamps per car.

Investigation of the caution and re-inspection.

√ (16022012)

84

Condensed water in the passenger rooms

- Strong water condensation on the ceiling

check of the AC control system and adjust of the cooling curve. Monitoring during the dynamic tests.

√ (21092012)

85

Test of the thermal capacity on the brake pads

- Investigation of the influence of the brake temperature of the brake pads and the wheels is requested.

335433966.xls

The microstructure of the wheels may not change.

Page 5 of 7

Agreement with KNORR and evaluation of the results in the record sheets

22.11.2012

No

Audited Item Handrails and connection pieces of the stanchion

86

Open Item

Remark

Action by PT. INKA / Result

- edge particles and peeled surface film

Cleaning and exchange of damaged parts

- M1 middle door right: water drops via the door mechanism in the passenger room

investigation of the reason of strong water flow and optimize of the AC controlling.

Status Close √ (16022012)

Dynamic test on 16.05.2011 87

Condensed water on door mechanism

√ (03052012) monitoring during dynamic test (see point 105)

88

Journey time check

- Objective for the type test: to verify the ability of the vehicle to meet the specified running schedules and energy consumption

Recommendation: Carrying out during the multiple operation test

Implementation in to the type test procedure, carrying out and evaluation.

√ (07092011)

89

Air systems – compressor duty cycle

- Objective according to the vehicle specification point 11.1.3: to verify that the installed compressor/s can deliver the required amount of air to meet all system requirements

Recommendation: Carrying out during the type test of TS2

Implementation in to the type test procedure, carrying out and evaluation.

√ (07092011)

21 May 2011 90 Under frame area near the movable step.

- Using of overlong screws.

Regarding to the remarks during the inspection on Check the function and 31st of May, see also Email 110420-MZ-INKA-Anti_Skid screw material, shorten the repairing progress. screw and protect the surface.

√ (07092011)

91

Movable Step

- Corrosion of the shims (leveling of the steps).

Regarding to the remarks during the inspection on Repair. 31st of May, see also Email 110420-MZ-INKA-Anti_Skid repairing progress.

√ (07092011)

92

Inspection and Test plan

- Add the quality measures for the Anti Skid Painting on the roof.

Recommendation: Add the chapter 5.

PI-295-003-002, rev. B

√ (09082011)

At each track joint, the coupler head spring up (additional noise).

Recheck of the design.

√ (07092011)

Investigation of the function (check in procedure testing)

√ (09082011)

Dynamic test on 07.06.2011 93

Automatic Coupler

Vertical movement of the coupler head is very smooth-running.

94

Crawl Mode (Train Washing)

Reset function not clear described. (at switch off of the train washing button the function will be not released).

95 96

Functional Label (train washing) Passenger room

"i" letter Missing

97 98

Passenger room Passenger door

Door cover (TV)

99 100 101

Passenger room Passenger room Windows

102 103

Driver Cabs Door handle

104 105

lock of driver door roof

106

Cable isolation

Baggage rack

Sealing rubbers of the door windows are deformed ( e.g. M1, TC2) Inside the train

Change the label re-adjustment of the baggage racks are necessary in all adjusting the Level, repair cars crack and repainting short the screw could be serial failure surmise: high temperature variation

Change repainting

windows in TC2 sealing rubber is not correct installed Paint crack on door and at door panel

investigation and repairing

TC1 screw of handle missing Hole on the roof at M1 near pantograph

√ (16022012) √ (22112012)

monitoring, investigation (repair or change)

M1 door number 4 (LCD cover screws lost) door of panel in each car is crack (painting)

M1, M2 and TC2 rusted (screw and washer)

√ (16022012) √ (16022012)

√ (07092011) √ (16022012) √ (21092012)

repainting Change screw and washer

√ (16022012) √ (21092012)

Add screw Monitoring and Repainting

√ (07092011) √ (07092011)

Sealing and repair

√ (07092011)

Repair

√ (07092011)

Cable isolation in M1 damaged (on the roof) 107

Cable protection

335433966.xls

Shrinking hose of two cables are deformed and broken, near pantograph (M1) damage Page 6 of 7

22.11.2012

No

Audited Item

Open Item

Remark

Action by PT. INKA / Result

Status

Missing paint

exchange / repair roughness and re-painting

Close √ (07092011) √ (07092011)

110 Ground contact 03 August 2011 111 destination indicator (Tc1& TC2)

Retrofit of the brackets according to TS2

Modification

√ (16022012)

112

dynamic type test

add spec. Requirement 3.6.3: 8 car unit must push/pull away another 8 car unit

113

Check Sheet of Component Installation

equipment for manual lifting/lowering of pantograph is not mentioned and not install

114

Check Sheet of Component Installation

116

108 109

Cable brackets Roof driver's cab

Corrosion of the brackets

condense water inside

open item from Depok (June 2011)

investigation & monitor, NCR - add requirement in dynamic type test plan - add instructions to driver's manual

√ (07092011)

Spec. Chapter 10.1.2 INKA installed additional tank to lower / lift pantograph

tested on TS3

√ (07092011)

equipment for manual release of mechanical brake is not mentioned and not install

device available at each parking brake cylinder. Device on first and last bogie is mounted outside drivers cab

installation according specification

√ (22112012)

Complete Train

all pneumatic valves must be protected against unauthorized use

according to specification not necessary

protect with wire

√ (16022012)

117

preventive maintenance schedule

not available to consultant

submit preventive maintenance schedule

√ (11082011)

118

maintenance records

not available to consultant

submit existing maintenance records

√ (07092011)

Water from Aircon (and rain) is going uncontrolled down from roof. The existing rain gutter covers door only and is far too small for conditions in Indonesia

re-design rain drain

√ (03052012)

incoming water cannot go out because 1 (one) drainage tube (right side) is missing

check all trains and install missing drainage tube

√ (07092011)

the standard driver's key is too big to operate mechanical door lock

revise design or talk to PT KAI / KRL about using another key

defect

replace

04 November 2011 119 carbody TC2 and drivers cab

120

carbody TC2 door 3

13. February 2012 121 mechanical door lock

122

indicator lamp of parking brake

Open Item Train Open Item TOTAL Open Item closed/deleted open items

335433966.xls

√ (07092011)

122 69 191 117

Page 7 of 7

22.11.2012