
VEHICLE MAINTENANCE MINIMUM
REQUIREMENTS
VMMR B2007
Docklands Light Railway Ltd.
Castor Lane, Poplar
London, E14 0BL
CONTENTS
1.
Purpose ............................................................................................................................... 5
2.
Application ........................................................................................................................... 5
3.
Scope .................................................................................................................................. 6
4.
Definitions and Abbreviations .............................................................................................. 7
5.
Requirements for Light Maintenance ................................................................................... 7
6.
Star Chart ............................................................................................................................ 8
General Information ............................................................................................................. 8
Motor and Trailer Bogie ....................................................................................................... 9
Propulsion System ............................................................................................................. 11
Brake System .................................................................................................................... 13
Pneumatic Equipment........................................................................................................ 15
Underframe Equipment ...................................................................................................... 18
Coupler and Drawgear ....................................................................................................... 20
Articulation Area ................................................................................................................ 22
Windscreen Wiper ............................................................................................................. 23
Windows ............................................................................................................................ 23
Door System ...................................................................................................................... 23
Lighting .............................................................................................................................. 24
Monitoring and Safety Equipment ...................................................................................... 25
Emergency Equipment ...................................................................................................... 25
Heating and Ventilation System ......................................................................................... 25
Drive Control System ......................................................................................................... 26
Interior ............................................................................................................................... 27
7.
Requirements for Heavy Maintenance ............................................................................... 28
8.
Requirements for One-off Modification / Refurbishment / Upgrade .................................... 28
9.
Transport & Storage .......................................................................................................... 28
10.
Records and Reporting ...................................................................................................... 28
11.
Parts and Material Specifications ....................................................................................... 28
12.
References and Appendices .............................................................................................. 28

VEHICLE MAINTENANCE MINIMUM
REQUIREMENTS
VMMR B2007
Docklands Light Railway Ltd.
Castor Lane, Poplar
London, E14 0BL
12.
1
Reference Drawings ............................................................................................ 28
12.
2
Reference Documents ......................................................................................... 29
13.
Change Log ....................................................................................................................... 29

VEHICLE MAINTENANCE MINIMUM
REQUIREMENTS
VMMR B2007
Docklands Light Railway Ltd.
Castor Lane, Poplar
London, E14 0BL
1. Purpose
This document exists to support the requirements of rolling stock assets as set out in the
Franchise Agreement.
1.1.
DLR Vehicle Maintenance Minimum Requirements (VMMR) outline the requirements
for a Maintenance Plan. They set out what maintenance needs to be performed but
not how the maintenance is to be performed, unless best practice has already been
established. The intervals at which maintenance must be completed are not specified
either, except that some maximum limits are given and there is a requirement that the
interval should be set so as to ensure continued compliance to the essential
requirements. Further, as explained in MR-700, VMMR’s are neither exhaustive nor
prescriptive: suppliers meeting these are not guaranteed to deliver system safety or
performance; suppliers may apply to vary them.
1.2.
DLR VMMR focus on
output measures (not input ones), however some
essential
requirements are specified, such as:
• critical limits / backstop on how often certain activities must be carried out e.g.
bogies to be overhauled within x thousand Km, but not precisely when; and not
how to group different maintenance activities together efficiently
• critical processes of how to carry out particular activities e.g. where experience
has derived a best practice approach, which DLRL passes on as part of its
knowledge management role, in order to mitigate known DLRL reputational
risks.
1.3.
DLRL VMMR’s provide a baseline:
• against which DLRL audits of work done can be carried out to assess franchise
compliance;
• such that related documents can be assessed for compliance (e.g. suppliers’
maintenance recommendations); and
• which can be enhanced over time e.g. as best practice emerges from
investigations.
2. Application
This VMMR applies to DLRL’s Franchisee through the Maintenance Standard for Rolling
Stock, MR700.
MR700 sets out management requirements on the franchisee, and mandates
Vehicle Maintenance Minimum Requirements (VMMR) which set out the requirements for
the Maintenance Plan, specifying what standards are to be maintained and giving limits on
by when critical activities must be performed.
Each VMMR section may call up
Maintenance Specification (MS) which are discrete self-
contained documents for use by overhaul contractors, consistent with best practice (i.e. for
traction motors, bogies, couplers, compressors and wheelsets). VMMR may also call up
VMMR B2007
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VEHICLE MAINTENANCE MINIMUM
REQUIREMENTS
VMMR B2007
Docklands Light Railway Ltd.
Castor Lane, Poplar
London, E14 0BL
Project Specifications (PS) which set out specifications to which the rolling stock is
modified/ refurbished / upgraded.
3. Scope
This Vehicle Maintenance Minimum Requirements document applies to DLR’s B2007 fleet. It
specifies what minimum requirements are to be maintained (mandating CMS and referencing
BT Manuals as required) and gives limits on by when critical activities must be performed
(e.g. gearbox overhaul must be carried out prior to a certain number of vehicle miles run,
brake pads must be renewed such that minimum limits are not exceeded in service).
Fundamentally, VMMR’s specify what is to be done, with some key limits on when. They do
not generally set out how maintenance is to be performed or grouped together logically into
exam block cards or whether activities should be primarily scheduled by miles run or time
VMMR B2007
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VEHICLE MAINTENANCE MINIMUM
REQUIREMENTS
VMMR B2007
Docklands Light Railway Ltd.
Castor Lane, Poplar
London, E14 0BL
passed or operating hours; nor whether regimes should be balanced or cumulative; nor yet
the level of granularity of maintenance by individual component.
For new vehicles, the VMMR is essentially a shell document, fundamentally referencing OEM
material such as the BT Manual. The intention going forward is for the BT Manual to provide
a knowledge repository, such that it is updated whenever changes are made to maintenance
(or indeed, to vehicles – through Project Specifications). Records of why the change was
made, together with what the pre-change situation was, should also be retained in the BT
Manual. Where ‘’As Required’’ is within the star chart documented evidence of the periodicity
chosen will be required to demonstrate the decision / justification.
Each VMMR:-
•
Lists MS in a star chart, specifying the limits when each overhaul is to be undertaken
•
In the absence of a MS, identifies the best documentation available – typically an
extract from the OEM maintenance manual, applied at the periodicity specified therein
•
Specifies requirements of where data is to go in the asset management system (i.e.
electronic records), even where work is undertaken according to a MS, since overhaul
providers may be supply chain partners who may not have access the asset
management system, whereas the Franchisee who delivers the VMMR does. See
also Section 10 Records below.
4. Definitions and Abbreviations
Please see
MR1000 and
MR700 for definitions and abbreviations
5. Requirements for Light Maintenance
The requirements for maintenance are set out in the BT Maintenance Manual B2007. The
maximum maintenance interval is currently specified for each maintenance activity as
follows:-
F1 – 13,000 km
F3 – 54,000 km
F5 – 216,000 km
F7 – 1,080,000 km
F2 – 27,000 km
F4 – 108,000 km
F6 – 540,000 km
S – Special Interval
All periodicities are in km. A tolerance exists on each exam of 900km (an average of 3 days
duty service), the tolerance is not cumulative and is applied to an exam but does not change
the original drop dead position of the next exam, i.e. if the 900km tolerance is used on a an
exam past the 13,500 km point the next exam is due in 13,500km minus the 900km overrun.
The period of time is specified when the activity must be carried out at regular time intervals
or distances travelled, as set out in:-
•
“maintenance_schedule_v_1_9_revI-Entwurf_2012-08-17.xls” which is part of BT
Maintenance Manual B2007, and repeated here (pages 7 - 20 of this VMS).
VMMR B2007
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VEHICLE MAINTENANCE MINIMUM
REQUIREMENTS
VMMR B2007
Docklands Light Railway Ltd.
Castor Lane, Poplar
London, E14 0BL
7. Requirements for Heavy Maintenance
Overhauls for the following equipment shall take place in advance of the backstop limits set
out below and the content of them will be outlined in self-contained Maintenance
Specifications (MS) in order to facilitate knowledge flows along the contractual chain:-
•
Wheelsets shall be overhauled in accordance with DLR-CMS 752 Maintenance
Specification Wheelsets, such that they remain within all limits specified.
All components of the vehicles shall be overhauled prior to the maximum intervals between
overhauls specified, generally in the ‘remark’ column, of:-
•
“
maintenance_schedule_v_1_9_revI-Entwurf_2012-08-17.xls” which is part of BT
Maintenance Manual B2007, and repeated here (pages 7 - 20 of this VMS).
8. Requirements for One-off Modification / Refurbishment / Upgrade
No PS (Project Specifications) apply at present.
9. Transport & Storage
See
BT Manual B2007 and
DLR-ENG-SPC- MS 752 -Wheelsets.
10. Records and Reporting
See BT Manual B2007, in addition to the requirements set out in MR-700 / MR-1000
11. Parts and Material Specifications
See BT Manual B2007 and relevant DLR Specifications (CMS and PS).
12. References and Appendices
Reference to drawings for a modification in a PS, reference to OEM manuals in a VMMR or
CMS, updates to BT Manuals when a PS is applied.
VMMR’s are not required to contain or reference all relevant information and are not
expected to duplicate OEM material. However, they should state that all limits and processes
which relate to essential requirements i.e. that impact on the purpose of DLRL’s Rolling stock
standards / VMMR’s (see particularly section 1 Purpose above) must be explicitly defined by
the Franchisee or another DLRL supply chain partner.
12.
1 Reference Drawings
Section /
Drawing Number
Drawing Title
Job No.
VMMR B2007
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VEHICLE MAINTENANCE MINIMUM
REQUIREMENTS
VMMR B2007
Docklands Light Railway Ltd.
Castor Lane, Poplar
London, E14 0BL
12.
2 Reference Documents
Reference
Section /
Document Title
Number
Job No.
13. Change Log
All changes Major or Minor must be captured via the change log
VMMR B2007 Change Log
Author of
Section
Page
Reason for Change
Date
Change
5
Document Hierarchy chart updated following
12/04/2013
J. Glover
review ilop & software configuration folders
added.
6.43
12
Gearbox oil sampling added at 54,000Km
24/06/2013
J. Glover
6.44
12
Gearbox mag plug particle inspection added at
24/06/2013
J. Glover
54,000Km
6.3
9
Sealing Joint visual inspection added
03/01/2014
J. Glover
6.4
9
Sealing Joint visual inspection added
03/01/2014
J. Glover
6.123
17
Power convertor visual inspection added
03/01/2014
J. Glover
6.124
17
Power convertor / main fan visual inspection
03/01/2014
J. Glover
added
6.183
22
Data recorder Test download removed
03/01/2014
J. Glover
VMMR B2007
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VEHICLE MAINTENANCE MINIMUM
REQUIREMENTS
VMMR B2007
Docklands Light Railway Ltd.
Castor Lane, Poplar
London, E14 0BL
Issue 4
•
Text in
italics has been quoted from the VMMR.
•
Text highlighted in YELLOW has been added
•
Text that is struck through has been deleted
VMMR B2007 Change Log
Author of
Section
Page
Reason for Change
Date
Change
6.18.1
10
Replace traction rod bushes at F6 & F7 added
19/01/2014
J. Glover
as agreed through CNRS 2014-61
6.18.2
10
Horizontal (lateral) stops assessments added
19/01/2014
J. Glover
as agreed through CNRS 2014-61
6.33.1
11
Rotate slewing ring through 90° added as
19/01/2014
J. Glover
agreed through CNRS 2014-61
6.33.2
11
Condition assess slewing rings from 3 vehicles
19/01/2014
J. Glover
to determine the next maintenance activity
(1,080,000km) added as agreed through CNRS
2014-61
6.91
15
Assess 1 vehicle at 630,000Km added as
19/01/2014
J. Glover
agreed through CNRS 2014-61
6.96
15
Through assessment changed to F7 depending
19/01/2014
J. Glover
further assessment required at 630,000Km
added as agreed through CNRS 2014-61
6.96.1
15
Replace Overflow valve at F6 & F7 added, as
19/01/2014
J. Glover
agreed through CNRS 2014-61
6.98
15
Changed to F7 from F6 depending on
19/01/2014
J. Glover
assessment required at 630,000Km added as
agreed through CNRS 2014-61
6.98.1
16
Replace artic hose on F6 & F7 added, as agreed
19/01/2014
J. Glover
through CNRS 2014-61
6.103
16
Assess 1 vehicle at 630,000Km as agreed
19/01/2014
J. Glover
through CNRS 2014-61
6.106
16
No longer required at F6 as agreed through
19/01/2014
J. Glover
CNRS 2014-61
6.118.1
17
Battery torques / cleaning added as agreed
19/01/2014
J. Glover
through CNRS 2014-61
6.127.1
18
Replace power convertor contactor added as
19/01/2014
J. Glover
agreed through CNRS 2014-61
VMMR B2007
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VEHICLE MAINTENANCE MINIMUM
REQUIREMENTS
VMMR B2007
Docklands Light Railway Ltd.
Castor Lane, Poplar
London, E14 0BL
VMMR B2007 Change Log
Author of
Section
Page
Reason for Change
Date
Change
6.127.2
18
Replace power convertor contactor relay ,
19/01/2014
J. Glover
depending on condition assessments at
630,000Km and 720,000Km, as agreed through
CNRS 2014-61
6.131.1
18
Clean brake resistors as agreed through CNRS
19/01/2014
J. Glover
2014-61
6.17
21
Door connection cable removed from F6, as
19/01/2014
J. Glover
agreed through CNRS 2014-61
6.184
22
Removed from F6 and added to F5 , as agreed
19/01/2014
J. Glover
through CNRS 2014-61
General
All defective hyperlinks removed.
02/08/2016
S.E. Taylor
General
General formatting changes
02/08/2016
S.E. Taylor
Section 5
900km tolerance added for maintenance
02/08/2016
periodicity
Star Chart
In the
Notes the key for
Incl. utilities and tools
02/08/2016
S.E. Taylor
corrected from ** to ***
Star Chart
Redundant red highlighting removed from blank
02/08/2016
S.E. Taylor
cells.
Star Chart
Assessment 630,000km column removed and
02/08/2016
Assessment 900,000km column added.
6.2
Maintenance periodicity changed to reflect
02/08/2016
S.E. Taylor
actual maintenance. Removed from S and
included in F6 and F7.
Changed from
Every 3 years to
Approximately 6
years.
6.10
Motor and Trailer Bogie – Shock Absorbers
02/08/2016
S.E. Taylor
changed to
Motor and Trailer Bogie – Primary
Suspension.
Check horizontal and vertical shock absorbers
changed to Check horizontal and vertical
dampers.
6.20
After 5 years initially then at (DLRL) agreed
02/08/2016
S.E. Taylor
appropriate intervals and undertake axlebox
bearing condition assessments with the OEM to
identify the optimum overhaul interval.
annually,
check 4 randomly selected axle bearings (of the
fleet) thorough internal test by manufacturer.
6.21
Check 4 randomly selected axle bearings (of
02/08/2016
S.E. Taylor
the fleet) thorough internal test by manufacturer.
VMMR B2007
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VEHICLE MAINTENANCE MINIMUM
REQUIREMENTS
VMMR B2007
Docklands Light Railway Ltd.
Castor Lane, Poplar
London, E14 0BL
VMMR B2007 Change Log
Author of
Section
Page
Reason for Change
Date
Change
6.22
Every 540,000 km 2 randomly selected
02/08/2016
S.E. Taylor
horizontal and vertical shock absorbers to be
checked by the supplier. Assess 5% (of the
fleet) of horizontal and vertical shock absorbers
at 630,000 km.
Assess 5% (of the fleet) of horizontal and
vertical shock absorbers at 900,000 km to
identify the optimum overhaul interval.
Requirement added Assessment 900,000 km
6.25
Requirement removed from F6
02/08/2016
S.E. Taylor
6.26
Requirement removed from F6
02/08/2016
S.E. Taylor
6.36
Maintenance out of sync due to current return
02/08/2016
S.E. Taylor
damage to original bearings, now replaced
during slip coupling mod. Revised maintenance
guidance required.
6.41
Oil sample from gearbox to be used as a
S.E. Taylor
comparator for condition. Photographic evidence
of all samples are to be recorded in the AMS
with time, date, gearbox location. Sample
reports should be stored electronically by KAD
and shared with DLRL as required.
6.42
Remove the magplug and inspect for particles
S.E. Taylor
Sample reports should be stored electronically
by KAD and shared with DLRL as required.
Photographic evidence of all samples are to be
recorded in the AMS with time, date, gearbox
location.
6.50
Visual inspection of the colour coding. Check
S.E. Taylor
torque witness marks of the screws and nuts as
well as coupling parts, if necessary, new
fastening screw and nut with torque attract and
colour coding renew, spacer and adapter
sleeves for damage, elastic sleeves for changes
to the rubber surfaces and abrasion (before
cleaning the coupling)
6.54
Overhaul whenever the drive coupling is parted
S.E. Taylor
for overhaul of the gearbox or traction motor.
During general inspection.
Requirement removed from F7 and added to S
6.61
Condition assess at 900,000km to identify the
S.E. Taylor
optimum overhaul interval.
Removed requirement from F6 and F7 and
added to Assessment 900,000km.
VMMR B2007
Issue 4
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VEHICLE MAINTENANCE MINIMUM
REQUIREMENTS
VMMR B2007
Docklands Light Railway Ltd.
Castor Lane, Poplar
London, E14 0BL
VMMR B2007 Change Log
Author of
Section
Page
Reason for Change
Date
Change
6.64
Check air supply and brake system for leakage,
S.E. Taylor
Function check. of current collector equipment.
6.70
EP-Compact (B05, B06) To be condition
assessed to determine if this can be moved to
the F7.
6.89
Requirement added to Assessment 900,000km
S.E. Taylor
6.94
Requirement added to Assessment 900,000km
S.E. Taylor
6.95
Requirement added to Assessment 900,000km
S.E. Taylor
6.96
Requirement added to Assessment 900,000km
6.101
Requirement added to Assessment 900,000km
6.103
Requirement added to F7.
6.104
Replace as required.
Requirement removed from F7
6.107.1
Compressor Piston Rings entire line added.
6.115
Once after 6 months fill up with water –
applicable to new vehicle only.
6.116
Top fill up with water
6.124
Every 4 years: dDevice fan
Requirement added to F6 and F4 and removed
from S
6.125
Every 8 years: main fan, DCU back up battery
6.125.2
Replace for overhauled item. Condition assess 3
relays at 900,000 km and a further 3 relays at
720,000 km to determine future overhaul /
replacement.
Requirement added to Assessment 900,000km.
6.131
Requirement removed from S and added to F7.
6.146
4 couplers to be condition assessed during 2016
with a view to move overhaul to F7.
6.160
Note: there is no information describing how to
test this function
6.176
Checking condition of the reflector
6.178
Check the functional status of the recorder (the
five green LEDs of fault lights)
VMMR B2007
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