SIL 4-EP-19
February, 2019
Page 1 of 11
SUBJECT:

Refresh Kit for Energy Storage System (ESS3)

MODELS AFFECTED:

H 40/50 EPTM with ESS3

Introduction:
A Refresh Kit P/N 29558119 is now available to service ESS3 battery packs.
The sub-packs within the ESS3 kit are unique and cannot be used for ESS1 or ESS2. For information on the ESS1
or ESS2 refresh kit, refer to SIL 10-EP-10.
Refer to Table 1 for proper refresh kit part number and warranty information.
WARNING: To help avoid electrocution, death, or bodily injury, only Allison approved technicians with
proper credentials for working with high voltage equipment may remove the top cover of the ESS. DO
NOT remove the top cover of the ESS unless you are properly trained and credentialed for working with
high voltage equipment. The ESS contains dangerous voltages even if an HVIL switch is open or the
vehicle ignition key is “OFF”.

CAUTION: To ensure proper operation of the Energy Storage System (ESS), all six battery sub-packs
must be replaced when refreshing the sub-packs.
The Nickel Metal Hydride (NiMH) battery refresh kit will extend the service life of the ESS3 unit. This SIL provides
information on the contents of the battery refresh kit and general installation information. Please refer to Table 2 for
a complete list of components used to refresh an ESS3.
Table 1. ESS3 Refresh Kit Part Number Identification
Refresh Kit P/N

Refresh Kit Installation
Instructions

Beginning Refresh Kit S/N

Parts Warranty

29558119

ESS Service Manual
SM4162EN

7010030001

2 Years

RL / SL8473EN

4454477

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SIL 4-EP-19
February, 2019
Page 2 of 11
Table 2. ESS3 Refresh Kit P/N 29558119 Components
Part Name

Allison P/N

Quantity

Package Assembly - Sub-Pack 1

29558170

1*

Package Assembly - Sub-Pack 2

29558171

1*

Package Assembly - Sub-Pack 3

29558172

1*

Package Assembly - Sub-Pack 4

29558173

1*

Package Assembly - Sub-Pack 5

29558174

1*

Package Assembly - Sub-Pack 6

29558175

1*

Fan Relay Assembly

29542854

3

Serviceable part

Bolt Assembly - M6 L30, w/Washer

29551891

60*

Sub-pack mounting
bolts

Nut Assembly - M5, w/Washer

29558176

6*

low and high-side
relays

Bolt Assembly - M6 L20, w/Flat &
Lock Washers

29551893

6*

HV fuse
connections

Bolt Assembly - M6 L20, w/Flat Washer

29551894

8*

Shield ground to
pipe support

Bolt Assembly - M8 L23, w/Washer

29551895

40*

Upper cover bolts

29558177

1*

Data Tag

Notes

* Parts cannot be ordered outside of this kit.

NOTE: Carefully inspect the ESS cover gasket for damage or deterioration. See SIL 2-EP-15 for more
details on inspection and replacement.

Packaging:
The cardboard boxes that contain the sub-packs are numbered 1 thru 6 for proper sub-pack identification. Refer to
Figure 4 for sub-pack identification, numbering and positioning.
The six ESS Refresh Kit sub-packs will be delivered on one complete wooden frame pallet. Refer to Figure 1
and Figure 2 for details.

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SIL 4-EP-19
February, 2019
Page 3 of 11

Figure 1. ESS Refresh Kit

Figure 2. ESS Refresh Kit Sub-Pack

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SIL 4-EP-19
February, 2019
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Figure 3. ESS Refresh Kit Sub-Pack Connectors

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SIL 4-EP-19
February, 2019
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Figure 4. ESS3 BCIM and Sub-Pack 1 – 6 Numbering Identification

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SIL 4-EP-19
February, 2019
Page 6 of 11

Service Installation Instructions:
WARNING: Failure to comply with the all safety information could result in serious personal injury or death.

WARNING: When installing the six sub-packs from the refresh kit, DO NOT connect the Service
Disconnect connectors until all other procedures have been completed. Connection of the six Service
Disconnect connectors will be the final procedure before the ESS cover is attached. To help avoid serious
bodily injury including death, electrocution, and burns, follow approved electrical safety procedures.
Refer to H 40/50 EPTM Energy Storage System (ESS) Service Manual (SM4162EN) for Removal and Replacement
instructions of the sub-packs and attaching components.
The H 40/50 EPTM uses potentially hazardous electrical energy. All hybrid propulsion components are identified
with warning labels or symbols (refer to figures 2-1, 2-2, and 2-3 in the H 40/50 EPTM Service Manual (SM4162EN).
NOTE: DO NOT attempt to service components containing potentially hazardous electrical energy if
you are not trained to do so.
All persons working with potentially hazardous electric energy should familiarize themselves with safe electrical
work practices. References to publicly available documentation that can assist a technician with the safe electrical
work practices required to service the H 40/50 EPTM electrical system are in Section 2, Paragraph F of the
H 40/50 EPTM Service Manual (SM4162EN).
Normal Energy Storage System (ESS) Operating Conditions:
ESS Voltage Range: 432-780 VDC
DPIM Amperage Range: -350 to +350A
DO NOT rely on the High Voltage Interlock Loop (HVIL) or control systems to de-energize the system. Always
perform the appropriate tests to be sure the system is discharged before servicing components.
WARNING: DO NOT attempt to bypass any High Voltage Interlock for any reason. Tampering with the
High Voltage Interlock Loop (HVIL) may result in serious personal injury or death. Failure to follow proper
safety procedures may result in serious personal injury or death.

WARNING: The ESS contains hazardous electrical energy. To help avoid serious bodily injury including
death, electrocution, and burns, follow approved electrical safety procedures. ALWAYS follow the Electrical
Disconnect Verification Procedure and Electrical Safe Work Practices procedures in ELECTRICAL
SAFETY of the H 40/50 EPTM ESS Service Manual before servicing any ESS connector or component.
Appropriate safety equipment includes, but is not limited to, safety glasses, safety shoes, and J-50090-2 Class 0
high voltage isolation gloves with J-50090-1 leather outer gloves (both included in the J-50090 kit). Please follow
all warnings and instructions provided by the safety equipment manufacturer.

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SIL 4-EP-19
February, 2019
Page 7 of 11
To help avoid personal injury or equipment damage, ensure that the work table or other supporting device can
safely support the Energy Storage System (ESS). The ESS weighs approximately 454 kg (1000 lbs).
To help avoid personal injury, use appropriate lifting devices to lift the sub-pack assemblies. Each sub-pack
assembly weighs approximately 62 kg (137 lbs).

Sub-Pack Removal:
WARNING: ALWAYS follow the Electrical Disconnect Verification Procedure and Electrical Safe Work
Practices procedures in ELECTRICAL SAFETY of the H 40/50 EPTM ESS Service Manual before servicing
any ESS connector or component. To help avoid serious bodily injury including death, electrocution, and
burns, follow approved electrical safety procedures.

NOTE: Refer to H 40/50 EPTM ESS Service Manual (SM4162EN) for a complete description of ESS
service procedures.
All bolts removed during the sub-pack refresh procedure will be replaced with new bolts. Note the bolt type, size
and length identification during the removal procedure to assist with the assembly procedure. Refer to SM4162EN
for proper installation torque specifications.
WARNING: The ESS contains hazardous electrical energy. To help avoid serious bodily injury including
death, electrocution, and burns, follow approved electrical safety procedures. ALWAYS follow the Electrical
Disconnect Verification Procedure and Electrical Safe Work Practices procedures in ELECTRICAL
SAFETY of the H 40/50 EPTM ESS Service Manual before servicing any ESS connector or component.
1. Refer to the H 40/50 EPTM Energy Storage System (ESS) Service Manual (SM4162EN) for “Safety
Information”.
2. Perform the Electrical Disconnect Verification Procedure and Electrical Safe Work Practices procedures
in ELECTRICAL SAFETY of the H 40/50 EPTM ESS Service Manual (SM4162EN) before servicing any
ESS connector or component.
3. Remove the ESS upper cover. Refer to the H 40/50 EPTM ESS Service Manual (SM4162EN) for complete
details.
NOTE: The six battery sub-pack service connectors must be clean prior to disconnecting. Carefully clean
these connectors to avoid possible connection failure due to dust or foreign matter contamination.
4. Disconnect all six of the battery sub-pack service connectors. Protect the connectors by completely wrapping
each connector with black electrical tape. Wrap the taped connector in a clear, non-conductive plastic
bag and secure the plastic bag with a rubber band.
5. Mark and label all Battery Control Interface Modules (BCIM)s numbers one, two and three as shown in
Figure 4. The sub-pack wiring harnesses are labeled for proper identification. Identifying the BCIMs will
ensure proper sub-pack connection and ESS operation.

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SIL 4-EP-19
February, 2019
Page 8 of 11

NOTE: Multiple ground straps and wiring connections are located within the ESS. Note the locations of
grounding straps and wiring connections during the battery sub-pack removal to assist with sub-pack
reassembly.
6. To avoid confusion, and for ease of installation when performing the ESS battery sub-pack refresh procedure,
sub-packs 4, 5, and 6 should be replaced first. Sub-packs 1, 2, and 3 will be removed and replaced in a
later step. Refer to Figure 4 for sub-pack identification, numbering and positioning. Remove the 30 sub-pack
mounting bolts from sub-packs 4, 5, and 6.
7. Remove the ESS battery sub-packs numbered 4, 5 and 6 only. Refer to the H 40/50 EPTM ESS Service
Manual (SM4162EN) for complete details.
8. Note the locations of the three fan relays. Remove and discard the three fan relays. Refer to the
H 40/50 EPTM ESS Service Manual (SM4162EN) for complete details. Three new fan relays are supplied
in the ESS Refresh Kit.

Refresh Kit Installation:
CAUTION: To prevent H 40/50 EPTM operational issues, recheck ALL connections and re-torque ALL
bolts. Failure to properly attach wiring and connectors will result in improper H 40/50 EPTM operation
and H 40/50 EPTM component damage.

WARNING: When installing the six sub-packs from the refresh kit, DO NOT connect the Service
Disconnect connectors until all other procedures have been completed. Connection of the six Service
Disconnect connectors will be the final procedure before the ESS cover is attached. To help avoid serious
bodily injury including death, electrocution, and burns, follow approved electrical safety procedures.

NOTE: For bolt identification refer to Table 2 ESS3 Refresh Kit P/N 29558119 Components. For bolt
torque specifications refer to the H 40/50 EPTM ESS Service Manual (SM4162EN).
1. Install three new fan relays. Refer to the H 40/50 EPTM ESS Service Manual (SM4162EN) for complete
details.
NOTE: The lower case must be clean prior to battery sub-pack installation. Carefully clean the lower case
to allow proper installation of battery sub-packs. Refer to the end of Section 4. Removal, Testing and
Replacement in the H 40/50 EPTM ESS Service Manual (SM4162EN) for cleaning details
2. Remove four (4) gray circular retaining tabs from the sub-packs.
3. Insert J-48779, lifting device into holes previously occupied by the gray circular retaining tabs. Install the
battery sub-packs following the Service Manual (SM4162EN) procedures.
NOTE: Be sure the J-48779, lifting device, is inserted through both the plastic cover and metal case to
avoid damage to the sub-pack.
4. Install new ESS battery sub-packs 4, 5 and 6 from the ESS Refresh Kit. Refer to the H 40/50 EPTM ESS
Service Manual (SM4162EN) for complete details, including proper torque specifications.

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SIL 4-EP-19
February, 2019
Page 9 of 11

NOTE: When connecting the high voltage wiring eyelet terminals, be sure to use new supplied bolts.
Torque all bolts to specifications. Refer to the H 40/50 EPTM ESS Service Manual (SM4162EN) for details.
5. Repeat the general removal and installation steps above for sub-packs 1, 2, and 3. Refer to the H 40/50 EPTM
ESS Service Manual (SM4162EN) for complete instructions.
CAUTION: To prevent H 40/50 EPTM operational issues, recheck ALL connections and retorque ALL
bolts. Failure to properly attach wiring and connectors will result in improper H 40/50 EPTM operation
and H 40/50 EPTM component damage.

WARNING: When the ESS service disconnect connectors are connected, the ESS will be completely
live. To help avoid serious bodily injury including death, electrocution, and burns, follow approved
electrical safety procedures.
6. Install the BCIMs in the locations they were removed from based on the identification marks one, two
and three as shown in Figure 4
7. When all of the ESS3 sub-packs and BCIMs have been installed, all connections have been made and all
bolts torqued, unwrap the six service disconnect connectors. Connect all six service disconnect connectors.
Refer to the H 40/50 EPTM ESS Service Manual (SM4162EN) for complete instructions.
8. Install the ESS upper cover using new bolts and torque the bolts to specifications. Refer to the H 40/50 EPTM
ESS Service Manual (SM4162EN) for complete details.
9. Install the data tag to a clean surface in the area shown in Figure 5. Remove the double-sided tape from the
serial number data tag, align the bolt holes and attach the serial number data tag.

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SIL 4-EP-19
February, 2019
Page 10 of 11

Figure 5. Data Tag

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SIL 4-EP-19
February, 2019
Page 11 of 11
10. For ESS3 Refresh Kit installation you are not required to update the SID; the original should work with the
refresh kit.

Activities:
The customer must note the Refresh Kit Serial Number and contact the Technical Assistance Center (TAC) to
record the updated information.
1. When a Refresh Kit is installed, record the serial number of the Refresh Kit.
2. Record original ESS serial number.
3. Record DPIM serial number.
4. Record System Identification Number (SID).
5. Record the amp hour throughput.
6. Contact TAC at 1-800-252-5283.

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