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

Cheek sheet of components

installation

- Number of speed sensor (TC1/TS1)

1 speed sensor miss to be checked

will be checked

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

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

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

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)

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)

Static test procedure

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

Test Procedure will be

added

Static test procedure

- Create separate folder for Test Record and Test

Procedure

will be created

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