Proportions In 2015, the project reached a $1.1 billion blowout due to modifications that were required for the design of the train, changing proportions from almost identical to the
V sets to the standard suburban double decker proportions. In October 2016, it was announced that the D sets would be wide and wider than the V sets they would replace. This required works to provide additional clearance on several sections of the
Blue Mountains Line between
Springwood,
Katoomba and
Lithgow, including the heritage-listed
Ten Tunnels Deviation. The increased length of the trains also required platform extensions at
Linden and
Warrimoo.
Union opposition and safety concerns In 2018, it was announced that the trains would have a maximum of two staff members on board, suggesting that the train guard be either replaced by a customer service role or merged with a customer service role, ruling out Driver Only Operation. The
Rail Tram and Bus Union (RTBU) welcomed any announcement regarding safety and retaining train guards. However, in 2019 it was announced that
Driver Only Operation would be implemented, with the driver viewing the side of the train via several
CCTV cameras. The RTBU criticised this move as being "unsafe", due to the lack of
microphones on the train. In February 2020, the RTBU announced that members would refuse to staff the New Intercity Fleet over safety and employment concerns. On 27 November 2020, a strike in protest of the safety concerns was performed by the RTBU, shutting down all intercity services effective immediately until 7am. A confidential 2018 report to the NSW government revealed that the doors could easily fail when opened at speed, which was only announced to the public in 2021. On 5 February 2021, an incident where a commuter fell between a train and the platform at Hornsby station in January was highlighted by the RTBU as a potentially fatal situation if it had occurred with a D set. On 2 March 2021, the Customer Service Guard position was not recognised by the
Fair Work Commission. In November 2021, an 18 month delay of entry into service was announced due to the union standoff and the
COVID-19 pandemic. Throughout December 2021, the RTBU carried out a series of industrial actions in protest. On 22 March 2022,
Nine News revealed that the RTBU regarded the CCTV cameras as unsafe, highlighting the lack of microphones, viewing blackspots, and poor vision quality, especially in the rain.
Approval by the Office of the National Safety Regulator In July 2021, the independent Office of the National Rail Safety Regulator (ONRSR) deemed the fleet to be safe. Sue McCarrey, CEO of the ONRSR, outlined that they had worked with the operator since design stage right through to testing, pledging that ongoing safety audits would continue through to their operation. Additionally, McCarrey concluded that there was no greater risk than the current older fleet and in fact the use of technology on the new fleet would make them even safer, saying: "We believe that risk is being managed through the technology on the train. The operating model we have approved for the NIF includes the use of a driver, a guard and the use of CCTV cameras at each door providing both the guard and the driver a view down the entire platform. Both the driver and the guard have access to screens to show them what is actually happening along the entire platform". McCarrey made it clear that as an independent regulator she is not part of the current negotiations between the RTBU and the train operator (NSW Trains) and nor should she be, however if those negotiations resulted in a change to the operating model, then the ONRSR would have to relitigate those proposed changes and once again complete that independent check to ensure that the changes proposed to the train operations continue to effectively manage the risks. On 26 November 2024, the D sets were given approval to operate in passenger service with modifications on only the
Central Coast & Newcastle Line from the ONRSR. On 30 September 2025, it was announced that the ONRSR approved the introduction of services on the
Blue Mountains Line.
Fair Work Commission On 18 February 2022, Sydney Trains and Transport for NSW lodged an application to the Fair Work Commission seeking to suspend or terminate any further industrial action from the RTBU regarding the D sets, the
Transport Asset Holding Entity, wages and any other cause. After the February shutdown the Fair Work action was suspended.
Maintenance In September 2017, the
Central Coast Express Advocate opposed the
Kangy Angy Maintenance Centre citing issues of noise and flooding. In December 2021, it was announced that only 20 out of 300 jobs at the Kangy Angy Maintenance Centre, had been filled locally, which was heavily criticised by several
Labor MPs including
Chris Minns.
Lowering of permitted service speed The train is specified and designed by
Hyundai Rotem to be able to operate to a maximum service speed of . However, their maximum service speed has been limited to , despite previous strategic planning assuming a service speed of 160 km/h. == Services ==