NHTSA ID Number: 10082262
Manufacturer Communication Number: SIL 1-EP-15REVB
TSB/Document Date: 2016-10-13
Summary
SERVICE LETTER ANNOUNCING THE AVAILABILITY OF KITS TO REPLACE COMPONENTS OF THE DUAL POWER INVERTER MODULE 2 (DPIM2) AND ELIMINATING THE NEED TO REPLACE THE ENTIRE DPIM2. THE ANNOUNCEMENT INCLUDES SERVICING INSTRUCTIONS.
Figure 3. DPIM Main Cover
2. Exercising care, cut one (1) wire tie at location shown in Figure 4. Do NOT remove any wire ties that pass
through the HVIL Circuit Card. Leaving the severed wire ties in place will provide a visual aid for wire tie
locations during installation of the replacement circuit card.
Figure 4. HVIL Circuit Card – Wire Tie Location
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 8 of 52
3. Cut the two (2) wire ties at locations shown in Figure 5 and remove them from the mounts. The wire
tie mounts do NOT have to be removed from the DPIM Housing unless they interfere with the removal
or installation of the HVIL circuit card.
Figure 5. HVIL Circuit Card – Two (2) Wire Tie Locations
CAUTION: Do NOT pull on the wires when removing connectors, doing so may pull the pins out of the
connector.
4. When removing connectors, push down on the tab at Location 1 and push the harness out of the connector
at Location 2 (refer to Figure 6).
Figure 6. HVIL Circuit Card Connector Removal
5. Remove three (3) wire harness connectors from HVIL Circuit Card surface mount connectors by gently
depressing the retaining tab with a pick or small flat blade screwdriver. Refer to Figure 7.
NOTE: Use care to avoid bending or damaging the circuit card connectors.
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 9 of 52
Figure 7. HVIL Circuit Card – Three (3) Harness Connector Locations
WARNING: Any conductive material (i.e. screws, bolts, nuts, etc.) can cause a short inside the DPIM that
will result in permanent and irreversible DPIM damage. All hardware must be accounted for throughout
the service procedure.
6. Using an 8mm socket, remove the four (4) M5 nut/washer assemblies as shown in Figure 8. Disconnect the
two (2) wire ring terminals from the studs.
Figure 8. HVIL Circuit Card – Four (4) Mounting Nut/Washer Locations (M5)
7. Using a TorxPlus® T25 bit, remove the four (4) M5x30mm screws securing the HVIL Circuit Card as shown
in Figure 9.
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 10 of 52
Figure 9. HVIL Circuit Card – Four (4) Mounting Screw Locations (M5x30mm)
8. Using a TorxPlus® T25 bit, remove the two (2) M5x14mm screws securing the HVIL Circuit Card as shown
in Figure 10.
Figure 10. HVIL Circuit Card – Two (2) Mounting Screw Locations (M5x14mm)
9. Using a TorxPlus® T25 bit, remove the four (4) M5x22mm screws securing the HVIL Circuit Card as shown
in Figure 11.
Figure 11. HVIL Circuit Card – Four (4) Mounting Screw Locations (M5x22mm)
10. Lift the HVIL Circuit Card straight up and remove it from the DPIM Housing.
11. Verify that the choke is in place as shown in Figure 12.
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 11 of 52
NOTE: The choke may have adhered to the underside of the HVIL Circuit Card when it was removed. If
this has occurred, reinstall choke to its proper location as shown in Figure 12. The choke must be installed
with the arrow pointing toward the DC lug box.
(1)
–
Choke
Figure 12. Verification of Choke Installation
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 12 of 52
Section 2: Removal of BCA Card Mounting Shelf
1. Carefully cut and remove the wire ties retaining the wire harnesses (refer to Figure 13).
Figure 13. Wire Tie Locations
NOTE: Label the wires on connectors 2, 3, and 4 (refer to Figure 14) with the corresponding phase (A, B,
C) as indicated by the circuit card connector labels (CURR A, CURR B or CURR C) for reinstallation.
CAUTION: Failure to properly label the current sensor harnesses may lead to improper reinstallation
and cause the DPIM to not operate.
2. Remove five (5) wire harness connectors from circuit card surface mount connectors by gently depressing
the retaining tab with a pick or small flat blade screwdriver (refer to Figure 14 and Figure 15).
NOTE: Use care to avoid bending or damaging the circuit card connectors.
Copyright © 2016 Allison Transmission
, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 13 of 52
Figure 14. Wire Harness Connector Removal (4 Locations)
Figure 15. Wire Harness Connector Removal
TorxPlus®
3. Using a
T25 bit, remove the seven (7) M5x14mm screws securing the BCA Mounting Shelf
(refer to Figure 16).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 14 of 52
Figure 16. BCA Mounting Shelf Fastener Locations
4. Carefully lift the BCA Mounting Shelf and set in on the side of the chassis as shown in Figure 17.
NOTE: Three (3) harnesses are still connecting the BCA Card to the GATE Drive Cards. Do NOT relocate
the BCA Mounting Shelf any farther than as shown in Figure 17.
Figure 17. BCA Mounting Shelf Relocation
5. Remove three (3) ribbon cable connectors from the GATE Drive Cards (refer to Figure 17) as follows:
a. Use the handle of Tab Bending Tool J51586 to disengage and remove the cable strain relief cap
(refer to Figure 18).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 15 of 52
Figure 18. Cable Strain Relief Cap Removal (BCA Cable Card Connector Shown for Clarity)
b. Press the tabs down on both sides of the GATE Drive Card Connector to release the ribbon cable
connector (refer to Figure 19).
Figure 19. Releasing the Ribbon Cable Connector (BCA Cable Card Connector Shown for Clarity)
6. Remove the BCA Mounting Shelf from the DPIM to gain access to the three (3) Gate Drive Cards.
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 16 of 52
Section 3: Removal of the AC Busbar Assembly
NOTE: Refer to Figure 20 for DPIM2 Phase Locations.
Figure 20. DPIM2 Phase Locations
1. Using a TorxPlus® T25 bit, remove the six (6) M5x22mm screws (refer to Figure 21).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 17 of 52
Figure 21. Mounting Screw Locations
2. Using a 6mm hex key, remove the three (3) M8 AC lug bolts (refer to Figure 22).
Figure 22. AC Lug Bolts
3. Remove the HVIL switch connector (refer to Figure 23).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 18 of 52
Figure 23. HVIL Switch Location
4. Carefully remove the AC Busbar Assembly by slightly lifting upward then outward from the AC Lug Box
(refer to Figure 24).
CAUTION: Do not allow the AC Busbar Assembly to strike the HVIL Switch during the removal process.
Figure 24. Removal of AC Busbar Assembly
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 19 of 52
Section 4: Removal of GATE Drive Card
NOTE: Refer to Figure 25 for DPIM2 Phase Locations.
Figure 25. DPIM2 Phase Locations
1. Using a TorxPlus® T8 bit, remove the twelve (12) M3x8mm (coarse thread) screws from the GATE Drive
Card (refer to Figure 26).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 20 of 52
Figure 26. GATE Drive Card Fastener Locations (M3x8mm Coarse Thread – Quantity 12)
2. Using a TorxPlus® T10 bit, remove the four (4) M3x8mm (fine thread) screws from the GATE Drive Card
(refer to Figure 27). Set the two (2) grounding brackets aside.
Figure 27. GATE Drive Card Fastener Locations (M3x8mm Fine Thread) – Quantity 4
3. Carefully pry back the ten (10) white locking tabs (refer to Figure 28) to release the GATE Drive Card from its
mounting location and gently lift the card straight up. Take care to not drop the spring pins (refer to Figure 29)
that may stick to the solder pads on the underside of the card.
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 21 of 52
Figure 28. GATE Drive Card Locking Tab Locations
NOTE: If the spring pin sticks to the underside of the card, do not attempt to dislodge the spring from
the card until the card has been completely removed. No loose pins should be left in the DPIM during
disassembly.
Figure 29. Spring Pins
4. Using a 4mm hex key, remove the six (6) M6x10mm screws from the SKiM Module (refer to Figure 30).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 22 of 52
Figure 30. SKiM Module Fastener Locations
5. Using a 4mm hex key, remove the three (3) M6x12mm screws from the SKiM Module (refer to Figure 31) and
remove the three capacitors.
Figure 31. SKiM Module Capacitor Removal
6. Using a TorxPlus® T20 bit, remove the four (4) M4x14mm screws retaining the Encoder Module (refer to
Figure 32) and carefully remove the Encoder Module.
NOTE: Removal of the Encoder Module is required ONLY if Inverter A Phase A SKiM® Module or Inverter
B Phase C SKiM® Module and GATE Drive Cards are being replaced (refer to Figure 25).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 23 of 52
Figure 32. Encoder Module Removal
7. Using a TorxPlus® T25 bit, remove the two (2) M5x18mm mounting screws from the AC Busbar. If the
DPIM has busbarmounted current sensors installed, remove the AC Busbar and Current Sensor Assembly
together (refer to Figure 33). If the DPIM has chassismounted current sensors installed, perform Step 8
below prior to removing the AC Busbar and Current Sensors Assembly.
Figure 33. AC Busbar Mounting Screw Locations
8. If the DPIM has chassismounted current sensors installed, use a TorxPlus® T20 bit to remove the two (2)
M4x16mm mounting screws from the current sensor mounting bracket. Remove the AC busbar and current
sensor assembly together (refer to Figure 34).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 24 of 52
Figure 34. ChassisMount Current Sensor Screw Location
Section 5: Measure Baseline DPIM Cooler Circuit Leak Rate
NOTE: The DPIM Leak Tester (J51673) is used to verify that the SKiM® Module ORing is not damaged
during the installation of the SKiM® Module (refer to Section 7: Installation of SKiM® Module). Damage
to this ORing will allow lube oil to enter the DPIM cavity, permanently damaging internal electrical
components and making the DPIM inoperative. Prior to removing the original SKiM® Module, a baseline
leak rate must be recorded to account for any system leaks that are not associated with the SKiM®
Module and ORing being replaced. After the new SKiM® Module has been installed, the leak rate must be
within 0.5 psi of the baseline leak rate.
1. Slightly raise the AC lug box end of the DPIM and allow the DPIM cooler circuit to fully drain through the
cooler ports at the DC lug box end.
2. After the fluid has fully drained, lower the AC lug box end of the DPIM until it is level.
3. Thread the No. 8 Plug and No. 8 Quick Disconnect Fitting (provided with J51673 ) into the DPIM cooler
ports (refer to Figure 35). Torque the fittings to 3036 N∙m (2227 lb ft.).
NOTE: The No. 8 Plug and No. 8 Quick Disconnect Fitting may be installed in either cooler port.
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 25 of 52
Figure 35. Installation of Cooler Port Fittings
NOTE: Ensure that the Pressure Regulator is adjusted to the lowest setting prior to connecting J51673
to shop air.
4. Connect the hose end of J51673 to the Quick Disconnect Fitting and connect shop air to the Pressure
Regulator end of J51673 (refer to Figure 36).
Figure 36. Connecting DPIM Leak Tester J51673
5. Open the J51673 Flow Valve and adjust the Pressure Regulator until the pressure stabilizes at 25 psi (refer
to Figure 37).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 26 of 52
Figure 37. DPIM Leak Tester J51673
6. Close the Flow Valve and start Stop Watch.
7. After five (5) minutes elapses, record the pressure.
NOTE: A properly sealed cooler system should have a pressure drop of no more than 12.5 psi over a five
(5) minute period. If the pressure drop exceeds 2.5 psi, there may be a sealing problem with the port
Plug, port Quick Disconnect Fitting, or DPIM Leak Tester J51673.
8. Proceed to Step 10 if the pressure drop is no more than 12.5 psi over the five (5) minute period.
9. If the pressure drop exceeds 2.5 psi, check and correct the sealing integrity of all test equipment and repeat
steps 57 until the pressure drop is less than 2.5 psi from 25 psi over a five (5) minute period.
10. Disconnect J51673 at the Quick Disconnect Fitting on the DPIM and allow the cavity to depressurize.
NOTE: Leave all other pressure testing equipment in place while removing the old SKiM® Module (refer to
Section 6: Removal of SKiM® Module) and installing the new SKiM® Module (refer to Section 7: Installation
of SKiM® Module). Doing so will ensure the that only change to the sealing of the DPIM cooler circuit
occurs at the SKiM® Module and ORing that are being replaced.
Section 6: Removal of SKiM® Module
1. Slide Tab Bending Tool J51586 over the DC busbar terminal tab.
NOTE: The terminal tab MUST be fully inserted in the tool groove in order to control the location of
the bend (refer to Figure 38).
CAUTION: Improper use or failure to use Tab Bending Tool J51586 could result in overbending of the
DC busbar tab, potentially causing unrepairable damage to the DC busbar.
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 27 of 52
Figure 38. Inserting J51586 Over DC Busbar Terminal Tab
2. Bend the DC busbar terminal tab up until tool J51586 contacts the DC busbar (refer to Figure 39). The
resulting bend of the tab will be approximately 45 degrees.
Figure 39. Bending DC Busbar Terminal Tab
3. Using a TorxPlus® 6in T25 bit, remove the fourteen (14) M5x14mm screws (refer to Figure 40).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 28 of 52
CAUTION: Do not damage the white insulation on the DC busbar while removing the screws securing the
SKiM® module in place. Damage to insulation can cause permanent damage to the DPIM.
Figure 40. SKiM® Module Fastener Locations
4. Lift the front of the SKiM® module to a 45 degree angle or until it is flush with the terminal tabs (refer to
Figure 41). Pull the SKiM® module outward from the DPIM at a 45 degree angle.
Figure 41. SKiM® Module Removal
5. Remove the SKiM® Module ORing (refer to Figure 42).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 29 of 52
Figure 42. SKiM® Module ORing
Section 7: Installation of SKiM® Module
WARNING: Inspect all reuse components for damage or corrosion, clean or replace any components as
necessary. A vacuum may be used to clean any debris inside the DPIM chassis. Debris or excessive
corrosion can cause isolation faults.
1. Lubricate NEW SKiM® Module ORing with clean transmission fluid and install in groove (refer to Figure 42).
2. Remove the plastic shipping cover from the SKiM® Module (refer to Figure 43).
Figure 43. SKiM® Module Plastic Shipping Cover
3. Ensure that no spring pins have been removed along with the plastic shipping cover and that all spring pins
are sitting slightly above the SKiM® Module surface (refer to Figure 44).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 30 of 52
Figure 44. SKiM® Module Spring Pins
NOTE: When installing the NEW SKiM® Module, do not allow the threaded bosses (location “A”) to contact
the SKiM® Module ORing (location “B”). The threaded bosses (location “A”) will insert into the locating
holes (location “C”) after the SKiM® Module has been positioned properly (refer to Figure 45).
Figure 45. Installation of SKiM® Module
WARNING: Damage to the SKiM® Module ORing can allow a transmission fluid leak that will result in
permanent and irreversible DPIM damage.
4. Position the SKiM® module at a 45 degree angle (flush with the bent terminal tabs) and apply pressure
towards the DC busbar as the front of the SKiM® module is lowered into final position (refer to Figure 46).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 31 of 52
Figure 46. SKiM® Module Installation
NOTE: Do NOT allow the SKiM® Module thread boss (location “A”) to come in contact with the SKiM®
Module ORing (location “B”) (refer to Figure 47).
Figure 47. SKiM® Module Thread Boss
5. Verify that all four (4) sides of the SKiM® Module are flush with the DPIM chassis to ensure that the SKiM®
Module ORing has not been pinched.
6. Verify that all fifteen (15) spring pins are in place (refer to Figure 48).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 32 of 52
Figure 48. SKiM® Module Spring Pins (Quantity 15)
7. Using a TorxPlus® 6in T25 bit, install the fourteen (14) M5x14mm screws (refer to Figure 49). Torque the
screws to 3.13.5 N∙m (27.431.0 lb in.).
CAUTION: Do not damage the white insulation on the DC busbar while installing the screws to secure the
SKiM® module. Damage to insulation can cause permanent damage to the DPIM.
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 01EP15, Rev. B
July, 2016
Page 33 of 52
Figure 49. SKiM® Module Fastener Locations
Section 8: Measure DPIM Cooler Circuit Leak Rate After SKiM® Module Installation
NOTE: All DPIM Leak Testing equipment should still be in place (refer to Section 5: Measure Baseline
DPIM Cooler Circuit Leak Rate).
1. Connect the hose end of J51673 to the Quick Disconnect Fitting on the DPIM.
2. Open the J51673 Flow Valve and adjust the Pressure Regulator until the pressure stabilizes at 25 psi (refer
to Figure 50).
Figure 50. DPIM Leak Tester J51673
3. Close the Flow Valve and start Stop Watch.
4. After five (5) minutes elapse, record the pressure.
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
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TSB/Document ID: SIL 1-EP-15REVB
Replacement Service Bulletin Number:
MFR Communication Date: 2016-07-26
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN
MFR Component System:
MFR Component Subsystem:
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