NHTSA ID Number: 10117318
Manufacturer Communication Number: SIL 3-EP-17 Rev
TSB/Document Date: 2017-09-14
Summary
Announces the availability of internal components for the DPIM2 and procedures for replacement.
Revisions to this document are noted
by a stripe in the lefthand margin
SUBJECT:
SIL 3EP17, Rev. B
June, 2017
Page 1 of 28
Replacing Gate Drive Cards Inside the Dual Power Inverter Module 2 (DPIM2)
MODELS AFFECTED:
H 40/50 EPTM System Equipped With DPIM2
Tools Required
• Electrostatic Discharge (ESD) Wrist Strap (refer to Figure 3)
• Pick or Small Flat Blade Screwdriver
• TorxPlus® T8 Bit
• TorxPlus® T10 Bit
• TorxPlus® T20 Bit
• TorxPlus® T25 Bit
• 8mm Hex Socket
• Loctite® 242
• Loctite® 425
Introduction:
This Service Information Letter (SIL) announces the availability of the Gate Drive Card (P/N 29559319) and
includes the procedure to replace the Gate Drive Cards located inside the DPIM2. The availability of this kit may
eliminate the need for a complete DPIM2 replacement under certain failure conditions.
Refer to Table 1 for related part numbers.
Table 1. DPIM2 Gate Drive Card Parts Information
Part Name
Part Number
Quantity (per DPIM2)
Gate Drive Card
29559319
6
NOTE: Perform the necessary diagnosis prior to ordering a Gate Drive Card(s) P/N 29559319. Contact
Allison Technical Assistance Center (TAC) at (800) 2525283 to confirm the failure.
ML / SL7968EN
3733331
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 2 of 28
Warranty Claim Information:
1. When a Gate Drive Card, P/N 29559319, is utilized to repair a failed DPIM under warranty, use Gate Drive
Card P/N 29546784 as the PFP and claim the P/N in the Service Parts subsection of the AWAARE claim.
Diagnosis:
A Gate Drive Card may become damaged in various ways but typically it is due to a boardlevel component failing,
either visually or internally. Visual examples include any of the tantalum capacitors (refer to Figure 1) or resistors
burning. Boardlevel components can fail internally without any physical signs of damage.
DTCs that can set due to a failed Gate Drive Card include 7358 and 7458. At this time, unless there is visual
damage to the card, there is no way to determine which of the three (3) Gate Drive Cards have failed. If there is no
visual indication of which card has failed, all three (3) Gate Drive Cards will need to be replaced.
Figure 1. Burnt Tantalum Capacitor on Gate Drive Card
WARNING: DO NOT rely on the High Voltage Interlock Loop (HVIL) or control systems to deenergize
the system. Always perform the Electrical Disconnect Verification Procedure to be sure the system is
discharged before servicing components.
DO NOT attempt to bypass any High Voltage Interlock for any reason. Tampering with the HVIL may result
in injury. Failure to follow proper safety procedures may result in serious personal injury or death.
NOTE: Allison Transmission, Inc. requires that the DPIM be removed from the vehicle prior to component
replacement. Prior to removal of the DPIM, refer to the H 40/50 EPTM System Troubleshooting Manual
(TS5812EN) and perform the Electrical Disconnect Verification Procedure.
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 3 of 28
NOTE: The Gate Drive Card replacement should NOT be performed if smoke and/or water damage
are present.
CAUTION: The spring pins (refer to Figure 2) located in the SKiM® module that contact the bottom of the
Gate Drive Card are NOT available for replacement if lost or damaged. Extreme caution must be used
during removal of any Gate Drive Cards to ensure no spring pins are damaged or lost.
Figure 2. SKiM® Module Spring Pin
The procedures contained in this SIL are organized into the following sections:
Section 1: Removal of Main Cover and HVIL Circuit Card
Section 2: Removal of BCA Card Mounting Shelf
Section 3: Removal of Gate Drive Card
Section 4: Installation of Gate Card Drive
Section 5: Installation of BCA Card Mounting Shelf
Section 6: Installation of Main Cover and HVIL Circuit Card
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 4 of 28
Section 1: Removal of Main Cover and HVIL Circuit Card
NOTE: All circuit cards in the DPIM2 are sensitive to ESD. ESD damage can be caused by voltage levels
that cannot be felt by humans. When working on the DPIM2, ALWAYS wear an ESD wrist strap to ground
any possible electrostatic charge. The strap should be worn around the wrist with the alligator clip securely
attached to the DPIM chassis (refer to Figure 3).
Figure 3. Electrostatic Discharge (ESD) Wrist Strap (Typical)
1. Using a TorxPlus® T25 bit, remove twentysix (26) M5 x 18mm machine screws that secure the Main
Cover to the DPIM Housing (refer to Figure 4). Set the screws aside for reassembly. Remove the Main
Cover. Discard the cover gasket.
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 5 of 28
Figure 4. DPIM Main Cover
2. Exercising care, cut one (1) wire tie at location shown in Figure 5. 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 5. HVIL Circuit Card – Wire Tie Location
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 6 of 28
3. Cut the two (2) wire ties at locations shown in Figure 6 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 6. 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 7).
Figure 7. 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 8).
NOTE: Use care to avoid bending or damaging the circuit card connectors.
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 7 of 28
Figure 8. 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 9. Disconnect the
two (2) wire ring terminals from the studs.
Figure 9. HVIL Circuit Card – Four (4) Mounting Nut/Washer Locations (M5)
7. Using a TorxPlus® T25 bit, remove the four (4) M5 x 30mm screws securing the HVIL Circuit Card as
shown in Figure 10.
Figure 10. HVIL Circuit Card – Four (4) Mounting Screw Locations (M5 x 30mm)
8. Using a TorxPlus® T25 bit, remove the two (2) M5 x 14mm screws securing the HVIL Circuit Card as
shown in Figure 11.
Copyright © 2017 Allison Transmission
, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 8 of 28
Figure 11. HVIL Circuit Card – Two (2) Mounting Screw Locations (M5 x 14mm)
9. Using a TorxPlus® T25 bit, remove the four (4) M5 x 22mm screws securing the HVIL Circuit Card as
shown in Figure 12.
Figure 12. HVIL Circuit Card – Four (4) Mounting Screw Locations (M5 x 22mm)
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 13.
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 13. The choke must be installed
with the arrow pointing toward the DC lug box.
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 9 of 28
(1)
–
Choke
Figure 13. Verification of Choke Installation
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 10 of 28
Section 2: Removal of BCA Card Mounting Shelf
NOTE: Only the BCA Card Mounting Shelf corresponding to the inverter (A or B) needing repairs needs
to be removed.
1. Carefully cut and remove the wire ties retaining the wire harnesses (refer to Figure 14).
Figure 14. Wire Tie Locations
NOTE: Label the wires on connectors 2, 3, and 4 (refer to Figure 15) 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 15 and Figure 16).
NOTE: Use care to avoid bending or damaging the circuit card connectors.
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 11 of 28
Figure 15. Wire Harness Connector Removal (4 Locations)
Figure 16. Wire Harness Connector Removal
TorxPlus®
3. Using a
T25 bit, remove the seven (7) M5 x 14mm screws securing the BCA Mounting Shelf
(refer to Figure 17).
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 12 of 28
Figure 17. BCA Mounting Shelf Fastener Locations
4. Carefully lift the BCA Mounting Shelf and set it on the side of the chassis as shown in Figure 18.
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 18.
Figure 18. BCA Mounting Shelf Relocation
5. Remove three (3) ribbon cable connectors from the Gate Drive Cards (refer to Figure 18) as follows:
a. Use the handle of Tab Bending Tool J51586 to disengage and remove the cable strain relief cap
(refer to Figure 19).
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 13 of 28
Figure 19. 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 20).
Figure 20. 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 © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 14 of 28
Section 3: Removal of Gate Drive Card
NOTE: Refer to Figure 21 for DPIM2 Phase Locations.
Figure 21. DPIM2 Phase Locations
1. Using a TorxPlus® T8 bit, remove the twelve (12) M3 x 8mm (coarse thread) screws from the Gate Drive
Card (refer to Figure 22).
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 15 of 28
Figure 22. Gate Drive Card Fastener Locations (M3 x 8mm Coarse Thread – Quantity 12)
2. Using a TorxPlus® T10 bit, remove the four (4) M3 x 8mm (fine thread) screws from the Gate Drive Card
(refer to Figure 23). Set the two (2) grounding brackets aside.
Figure 23. Gate Drive Card Fastener Locations (M3 x 8mm Fine Thread) – Quantity 4
3. Carefully pry back the ten (10) white locking tabs (refer to Figure 24) to release the Gate Drive Card from its
mounting location and gently lift the card straight up and away from the DPIM.
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 16 of 28
Figure 24. 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.
4. Verify that all fifteen (15) spring pins are still present in the SKiM® module (refer to Figure 25).
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 17 of 28
Figure 25. SKiM® Spring Pins Locations
5. If any spring pins are stuck to the bottom of the card (refer to Figure 26), remove them from the solder pad
taking care not to bend or lose the pin. Reinstall the spring pin into the corresponding hole in the SKiM®
module (refer to Figure 25).
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 18 of 28
Figure 26. Spring Pins Stuck to Gate Drive Card Solder Pads
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 19 of 28
Section 4: Installation of Gate Card Drive
1. Position the Gate Drive Card over the locating hubs on the SKiM® module (refer to Figure 27). Carefully
press the new Gate Drive Card straight down over the ten (10) white locking tabs (refer to Figure 28) so
the card is fully seated.
NOTE: There are 6 locating hubs on the SKiM® module; two (2) on each end of the SKiM® module and
two (2) in the center.
CAUTION: Failure to mount the card on the locating hubs correctly can prevent the card from seating
completely causing the card to flex which can cause damage.
Figure 27. Locating Hub Identification on SKiM® Module
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 20 of 28
Figure 28. Gate Drive Card Locking Tab Locations
2. Place the two (2) grounding brackets into position of the SKiM® module. Using a TorxPlus® T10 bit, install
the four (4) M3 x 8mm (fine thread) screws to the Gate Drive Card (refer to Figure 29). Torque all four (4) M3
x 8mm (fine thread) screws to 0.60.8 N∙m (5.37.1 lb in).
Figure 29. Gate Drive Card Fastener Locations (M3 x 8mm Fine Thread) – Quantity 4)
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 21 of 28
3. Using a TorxPlus® T8 bit, install the twelve (12) M3 x 8mm (coarse thread) screws to the Gate Drive Card
(refer to Figure 30). Torque all twelve (12) M3 x 8mm (coarse thread) screws to 0.30.6 N∙m (2.75.3 lb in).
Figure 30. Gate Drive Card Fastener Locations (M3 x 8mm Coarse Thread – Quantity 12)
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 22 of 28
Section 5: Installation of BCA Card Mounting Shelf
1. Feed all tie wraps through the BCA Card Mounting Shelf (refer to Figure 31).
Figure 31. BCA Card Mounting Shelf Tie Wrap Location
2. Place the BCA mounting shelf onto the side of DPIM chassis and connect three (3) Gate Drive Card
Connectors to three (3) Gate Drive Cards (refer to Figure 32) and install the cable strain relief caps.
Figure 32. Gate Drive Card Cable Connector Installation (BCA Card Cable Connector Shown for Clarity)
3. Move the BCA Mounting Shelf to its final location. Using a TorxPlus® T25 bit, install the seven (7) M5 x
14mm screws that secure the BCA Mounting Shelf (refer to Figure 33). Torque the seven (7) M5 x 14mm
screws to 3.13.5 N∙m (27.431.0 lb in).
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 23 of 28
Figure 33. BCA Mounting Shelf Fastener Locations
4. Install five (5) wire harness connectors to circuit card surface mount connectors (refer to Figure 34,
Figure 35, and Figure 36).
Figure 34. Wire Harness Connector (4 Locations)
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 24 of 28
Figure 35. Current A, Current B, and Current C Locations
Figure 36. Wire Harness Connector Installation
NOTE: Each current sensor phase (A, B, and C) MUST be plugged into the appropriate connector
(CURR A, CURR B, CURR C).
CAUTION: Permanent damage to the H 40/50 EPTM System Drive Unit or DPIM can occur if the current
sensor harnesses are plugged into the wrong connectors.
5. Install new wire ties to retain the wire harnesses (refer to Figure 37).
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 25 of 28
Figure 37. Wire Tie Locations
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 26 of 28
Section 6: Installation of Main Cover and HVIL Circuit Card
1. Insert one (1) new wire tie into the HVIL Circuit Card at the same location as shown in Figure 38.
NOTE: To ease assembly, the new wire tie must be inserted through the hole in the circuit card prior to
installation in the DPIM Housing.
Figure 38. HVIL Circuit Card – Wire Tie Location
2. Install HVIL Circuit Card into the DPIM Housing.
NOTE: Ensure that the wire harnesses and individual wires are NOT pinched under the circuit card
during installation.
3. Connect the three (3) wiring harness connectors at locations shown in Figure 39.
Figure 39. HVIL Circuit Card – Three (3) Harness Connector Locations
4. Using a TorxPlus® T25 bit, install and finger tighten the ten (10) M5 screws that secure the HVIL Circuit
Card to the DPIM Housing. Torque all M5 screws to 3.13.5 N∙m (2731 lb in). Refer to Figure 40 for
fastener sizes and locations.
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 27 of 28
Figure 40. HVIL Circuit Card – Fastener Sizes/Locations
5. Install the two (2) wire ring terminals onto the studs at locations shown in Figure 41. Using an 8mm socket,
install four (4) M5 nut/washer assemblies onto the studs as shown in the same figure. Torque the nuts
to 3.13.5 N∙m (2731 lb in).
Figure 41. HVIL Circuit Card – Four (4) Mounting Nut/Washer Locations (M5)
6. Secure wiring with new wire ties and clip excess length as required. Refer to Figure 38 and Figure 42 for
wire tie locations.
Figure 42. HVIL Circuit Card – Two (2) Wire Tie Locations
7. Install new Cover Gasket P/N 29540714. Using a TorxPlus® T25 bit, install and finger tighten the twentysix
(26) M5 x 18mm machine screws that secure the Main Cover to the DPIM Housing as shown in Figure 43.
Torque the screws to 3.13.5 N∙m (2731 lb in).
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP17, Rev. B
June, 2017
Page 28 of 28
NOTE: For additional information refer to H 40/50 EPTM System Service Manual SM3602EN.
Figure 43. DPIM Main Cover
8. Complete the DPIM check sheet again to verify the repair before installing the DPIM on the bus.
Copyright © 2017 Allison Transmission, Inc. All Rights Reserved.
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TSB/Document ID: SIL 3-EP-17 Rev
Replacement Service Bulletin Number:
MFR Communication Date: 2017-06-22
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL
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