NHTSA ID Number: 10156735
Manufacturer Communication Number: SIL 22-EP-16
TSB/Document Date: 2019-04-08
Summary
Service information announcing the availability of a service kit for the DPIM2 current sensor and replacement procedure
SIL 22EP16
April, 2016
Page 14 of 58
Figure 17. BCA Mounting Shelf (GATE Drive Card Cable Connectors Shown Circled)
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).
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).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 15 of 58
Figure 19. Releasing the GATE Drive Card 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) Current Sensors.
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 16 of 58
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 Torx PlusTM T25 bit, remove the six (6) M5x22mm screws (refer to Figure 21).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 17 of 58
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 22EP16
April, 2016
Page 18 of 58
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 22EP16
April, 2016
Page 19 of 58
Section 4: Removal/Installation of Current Sensor (Inverter A Phase C and Inverter B Phase A)
Current Sensor Removal
1. Using a Torx PlusTM T25 bit, remove the two (2) M5x22mm screws (refer to Figure 25).
Figure 25. Location of Two (2) M5x22mm Screws
2. Using a Torx PlusTM T25 bit, remove the two (2) M5x18mm screws (refer to Figure 26).
Figure 26. Location of Two (2) M5x18mm Screws
3. Shift the AC terminal Block farther into the AC Lug Box (refer to Figure 27).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 20 of 58
NOTE: Relocating the AC terminal Block will provide access for the removal of the AC Busbar Support.
Figure 27. Relocating the AC Terminal Block
4. Using an 11mm hex socket, remove the one (1) M5 BCA Standoff (refer to Figure 28).
CAUTION: Do not break the threaded portion of the BCA standoff into the DPIM housing. The BCA
standoffs are M5 thread and have Loctite applied.
WARNING: There is no Allison approved repair for broken standoffs in the DPIM housing. Drilling the
broken thread out presents a risk of drilling through the DPIM or into the coolant channel.
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 21 of 58
Figure 28. Location of M5 BCA Standoff
5. Using a Torx PlusTM T20 bit, remove the two (2) M4x22mm screws (refer to Figure 29).
Figure 29. Location of Two (2) M4x22mm Screws
6. Remove the AC Busbar Support by sliding it out from under the AC Busbar (refer to Figure 30).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 22 of 58
Figure 30. Removal of AC Busbar Support
7. Using a Torx PlusTM T20 bit, remove the one (1) M4x19mm screw (refer to Figure 31).
Figure 31. Location of One (1) M4x19mm Screw
8. Remove the nonmagnetic spacer located between the bottom of the Current Sensor and the underside
of the AC Busbar (refer to Figure 32).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 23 of 58
Figure 32. NonMagnetic Spacer Location
9. Remove the Current Sensor by sliding it off the end of the AC Busbar (refer to Figure 33).
Figure 33. Removal of Current Sensor
CAUTION: Ensure that the screw, spacer and nut have not been left in the DPIM after removing the
Current Sensor (refer to Figure 34).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 24 of 58
Figure 34. Current Sensor Fasteners
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.
CAUTION: Ensure that the electrostatic discharge wrist strap is properly connected to the DPIM chassis
while using the vacuum.
Current Sensor Installation
1. Apply one drop of NyoGel® 760G Synthetic Lubricant to each of the new Current Sensor (P/N 29557481 or
P/N 29557482) pins (refer to Figure 35) and one drop to each of the mating harness terminals.
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 25 of 58
Figure 35. Applying NyoGel® 760G Synthetic Lubricant to Current Sensor Pins
2. Connect the new Harness Assembly to the new current sensor ensuring the latch is secure.
NOTE: The Wiring Harness MUST be replaced along with the Current Sensor.
3. Lift the AC terminal block and install the current sensor by sliding it over the end of the AC Busbar (refer to
Figure 36).
Figure 36. Installation of Current Sensor
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 26 of 58
4. Align the holes in the bracket to the mounting holes in the DPIM chassis and start two M4x16 screws
included in the service kit. (refer to Figure 37).
Figure 37. Location of Mounting Holes
5. Insert the alignment tool (P/N 29558018) into the plate side of the current sensor so that the tool is against
the sensor housing and sitting on top of the AC busbar (refer to Figure 38).
NOTE: The plate side of the sensor references the side of the sensor with a thin plate that completes the
sensor housing.
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 27 of 58
Figure 38. Alignment Tool in Plate Side of Current Sensor
6. Using a Torx PlusTM T20 bit and with the alignment tool still installed, torque the two (2) M4x16 sensor
mounting screws to 1.21.5 N∙m (10.613.3 lb in.).
7. Remove the alignment tool and verify that the AC busbar is not touching the sensor housing.
8. Route the harness assembly ensuring adequate wire bend radius and secure it to the sensor with a new
zip tie ensuring no relative movement of the harness to the sensor housing. Clip excess zip tie length as
required (refer to Figure 39).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 28 of 58
Figure 39. Harness Tied to Sensor Housing
9. Label the harness with the appropriate phase (“A” or “C”) on the BCA connector end of the harness
to assist during reassembly.
10. Install the AC Busbar Support by sliding it under the AC Busbar (refer to Figure 40).
Figure 40. Installation of AC Busbar Support
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 29 of 58
11. Using a Torx PlusTM T20 bit, apply a drop of Loctite® 242 thread locking compound and install the two (2)
M4x22mm screws (refer to Figure 41). Torque the two (2) M4x22mm screws to 1.21.5 N∙m (10.613.3 lb in.).
Figure 41. Location of Two (2) M4x22mm Screws
12. Apply one drop of Loctite® 242 thread locking compound to the end of the external threads of the M5
BCA Standoff. Using an 11mm hex socket, install the one (1) M5 BCA Standoff (refer to Figure 42 ). Torque
the one (1) M5 BCA Standoff to 3.13.5 N∙m (27.430.9 lb in.).
Figure 42. Location of M5 BCA Standoff
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 30 of 58
13. Slide the AC terminal Block back into its proper location. Apply one drop of Loctite® 425 or 242 thread
locking compound to the ends of the external threads of the two (2) M5x18mm screws. Using a Torx PlusTM
T25 bit, install the two (2) M5x18mm screws (refer to Figure 43). Torque the two (2) M5x18mm screws to
3.13.5 N∙m (27.430.9 lb in.).
Figure 43. Location of Two (2) M5x18mm Screws
14. Using a Torx PlusTM T25 bit, install the two (2) M5x22mm screws (refer to Figure 44). Torque the two (2)
M5x22mm screws to 3.13.5 N∙m (27.430.9 lb in.).
Figure 44. Location of Two (2) M5x22mm Screws
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 31 of 58
Section 5: Removal/Installation of Current Sensor (Inverter A Phases A and B, and Inverter
B Phases B and C)
Current Sensor Removal
1. Using an 11mm hex socket, remove the one (1) M5 BCA Standoff (refer to Figure 45).
CAUTION: Do not break the threaded portion of the BCA standoff into the DPIM housing. The BCA
standoffs are M5 thread and have Loctite applied.
WARNING: There is no Allison approved repair for broken standoffs in the DPIM housing. Drilling the
broken thread out presents a risk of drilling through the DPIM or into the coolant channel.
Figure 45. Location of M5 BCA Standoff
2. Using Torx PlusTM T20 and T25 bits, remove the two (2) M4x22mm screws and two (2) M5x18mm screws
securing the AC busbar support for the phase nearest the current sensor being replaced (refer to Figure 46).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 32 of 58
Figure 46. Location of M4 and M5 AC Busbar Support Screws
3. Using a Torx PlusTM T20 bit, remove the two (2) M4x22mm screws securing the AC busbar support for the
phase which the current sensor is being replaced (refer to Figure 47).
Figure 47. Location of Two (2) M4x22mm Screws
4. Slide the two (2) AC busbar supports under the AC busbar towards the AC lug box end of the chassis
(refer to Figure 48).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 33 of 58
Figure 48. Location of AC Busbar Supports
TM
5. Using a Torx Plus
T20 bit, remove the one (1) M4x19mm screw (refer to Figure 49).
Figure 49. Location of One (1) M4x19mm Screw
6. Remove the nonmagnetic spacer located between the bottom of the Current Sensor and the underside
of the AC Busbar (refer to Figure 50).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 34 of 58
Figure 50. NonMagnetic Spacer Location
7. Remove the Current Sensor by sliding it off the end of the AC Busbar (refer to Figure 51).
Figure 51. Removal of Current Sensor
CAUTION: Ensure that the screw, spacer and nut have not been left in the DPIM after removing the
Current Sensor (refer to Figure 52).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 35 of 58
Figure 52. Current Sensor Fasteners
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.
CAUTION: Ensure that the electrostatic discharge wrist strap is properly connected to the DPIM chassis
while using the vacuum.
Current Sensor Installation
1. Apply one drop of NyoGel® 760G Synthetic Lubricant to each of the new Current Sensor (P/N 29557481 or
P/N 29557482) pins (refer to Figure 53) and one drop to each of the mating harness terminals.
Figure 53. Applying NyoGel
®
760G Synthetic Lubricant to Current Sensor Pins
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 36 of 58
2. Connect the new harness assembly to the new current sensor ensuring the latch is secure.
NOTE: The Wiring Harness MUST be replaced along with the Current Sensor.
3. Install the new current sensor by rotating it down between the AC busbars and then sliding it over the end
of the AC busbar (refer to Figure 54).
Figure 54. Installation of Current Sensor
4. Align the holes in the bracket to the mounting holes in the DPIM chassis and start two (2) M4x16 screws
included in the service kit (refer to Figure 55).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 37 of 58
Figure 55. Location of Mounting Holes
5. Insert the alignment tool (P/N 29558018 ) into the plate side of the current sensor so that the tool is against
the sensor housing and sitting on top of the AC busbar (refer to Figure 56).
NOTE: The plate side of the sensor references the side of the sensor with a thin plate that completes the
sensor housing.
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 38 of 58
Figure 56. Alignment Tool in Plate Side of Current Sensor
PlusTM
6. Using a Torx
T20 bit and with the alignment tool still installed, torque the two (2) M4x16 sensor
mounting screws to 1.21.5 N∙m (10.613.3 lb in.)
7. Remove the alignment tool and verify that the AC busbar is not touching the sensor housing.
8. Route the harness assembly ensuring adequate wire bend radius and secure it to the sensor with a new
zip tie ensuring no relative movement of the harness to the sensor housing. Clip excess zip tie length as
required. (refer to Figure 57).
Figure 57. Harness Tied to Sensor Housing
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 39 of 58
9. Label the harness with the appropriate phase (“A” or “B”) on the BCA connector end of the harness to
assist during reassembly.
10. Install both AC busbar supports by sliding them back in place under the AC busbars.
11. Using Torx PlusTM T20 and T25 bits and Loctite® 242 thread locking compound, install the two (2) M4x22mm
screws and two (2) M5x18mm screws to secure the AC busbar support (refer to Figure 58). Torque the two
(2) M4x22mm screws to 1.21.5 N∙m (10.613.3 lb in.) and the two (2) M5x18mm screws to 3.13.5 N∙m
(27.430.9 lb in.).
Figure 58. Location of M4 and M5 AC Busbar Support Screws
12. Using a Torx PlusTM T20 bit, install the two (2) M4x22mm screws (refer to Figure 59). Torque the two (2)
M4x22mm screws to 1.21.5 N∙m (10.613.3 lb in.).
Figure 59. Location of Two (2) M4x22mm Screws
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 22EP16
April, 2016
Page 40 of 58
13. Apply one drop of Loctite® 242 thread locking compound to the end of the external threads of the M5
BCA Standoff (refer to Figure 60). Using an 11mm hex socket, install the one (1) M5 BCA Standoff . Torque
the one (1) M5 BCA Standoff to 3.13.5 N∙m (27.430.9 lb in.).
Figure 60. Location of M5 BCA Standoff
Section 6: Removal/Installation of Inverter B Phase C Current Sensor
Current Sensor Removal
1. Using an 11mm hex socket, remove the one (1) M5 BCA standoff (refer to Figure 61).
CAUTION: Do not break the threaded portion of the BCA standoff into the DPIM housing. The BCA
standoffs are M5 thread and have Loctite applied.
WARNING: There is no Allison approved repair for broken standoffs in the DPIM housing. Drilling the
broken thread out presents a risk of drilling through the DPIM or into the coolant channel.
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TSB/Document ID: SIL 22-EP-16
Replacement Service Bulletin Number:
MFR Communication Date: 2016-04-25
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT ADAPTIVE/MOBILITY
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