Replace the Jumpers, Contacts or Connector - VRS3500 [IAE]

TASK 73-22-35-300-010-A
Replace the Jumpers, Contacts or Connector - VRS3500

FIN: 1000EM1 ** ON A/C NOT FOR ALL
FIN: 1000EM2 ** ON A/C NOT FOR ALL

1. Reason for the Job
This task is for A1 and A5 basic (non SelectOne) engines, which have not SBE 72-0562 incorporated (SelectOne Production Standard).
This task gives the procedure for the replacement of the data entry plug jumpers, contacts or connector.
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	AR	ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE
No specific	AR	CAP - PROTECTION
No specific	AR	ELECTRICAL CONTACTS INSERTION TOOL
No specific	AR	PLIERS - NOSE, SOFT, LONG
No specific	AR	WARNING NOTICE(S)
No specific	AR	WRENCH - STRAP
No specific	Torque wrench: range to between 35.2 and 28.8 lbf.in (0.40 and 0.33 m.daN )
No specific	Torque wrench: range to between 58 and 53 lbf.in (0.66 and 0.60 m.daN )
IAE1P16271	1	FIXTURE-HOLDING
IAE1R19416	1	WRENCH-SPECIAL 4 AND 8 SLOT CONNECTOR, LIFTING
IAE2P16552	1	TESTER-EEC SOFTWARE LOADER AND DEP

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.V02-138)	lockwire

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
FOR [1000EM1] (ENGINE-1)
437AL, 438AR
FOR [1000EM2] (ENGINE-2)
447AL, 448AR

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
4	JUMPER	AIPC 73-22-35-80-070
5	JUMPER	AIPC 73-22-35-80-080
6	JUMPER	AIPC 73-22-35-80-090
7	JUMPER	AIPC 73-22-35-80-100
1	SEALING PLUGS	AIPC 73-22-35-80-110
2	CONTACTS	AIPC 73-22-35-80-130

E. Referenced Information

REFERENCE	DESIGNATION
TASK 70-23-11-911-013-A	General Torque Tightening Techniques
TASK 70-23-15-912-010-A	Connection of Electrical Connectors
TASK 70-40-11-911-014-A	Locking Devices General Information
TASK 71-13-00-010-010-A	Opening of the Fan Cowls 437AL(447AL),438AR(448AR)
TASK 71-13-00-410-010-A	Closing of the Fan Cowls 437AL(447AL),438AR(448AR)
TASK 73-22-34-710-040-A	Operational Test of the EEC
Data Entry Plug Assembly
Data Entry Plug Assembly Backshell
Data Entry Plug Assembly Jumpers, Contacts and Connector
Data Entry Plug Assembly Jumpers, Contacts and Connector Replacement Worksheet
Data Entry Plug Assembly Jumper and Contact Removal
Data Entry Plug Assembly Jumper, Contact and Sealing Plug Installation
EEC Data Entry Plug Tester, IAE2P16242

3. Job Set-up
Subtask 73-22-35-941-052-A ** ON A/C NOT FOR ALL

A. Safety Precautions
(1) On the center pedestal, on the ENG panel 115VU:
(a) Put a WARNING NOTICE(S) to tell persons not to start the engine.
(2) Make sure that the engine 1(2) shutdown occurred not less than 5 minutes before you do this procedure.
(3) On the overhead maintenance panel 50VU:
(a) Make sure that the ON legend of the ENG/FADEC GND PWR/1(2) pushbutton switch is off.
(b) Put a WARNING NOTICE(S) to tell persons not to energize the FADEC 1(2).

Subtask 73-22-35-010-052-A ** ON A/C NOT FOR ALL

B. Get Access
(1) Open the fan cowls (Ref. AMM TASK 71-13-00-010-010):
(a) FOR [1000EM1] (ENGINE-1)
437AL 438AR.
(b) FOR [1000EM2] (ENGINE-2)
447AL 448AR.
(2) Put the ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE in position.

Subtask 73-22-35-010-058-A ** ON A/C NOT FOR ALL

C. Disconnect the Data Entry Plug (DEP) from the Electronic Engine Control (EEC)

Data Entry Plug Assembly ** ON A/C NOT FOR ALL

(1) Disconnect the DEP (1) from EEC (2) connector with the IAE1R19416 WRENCH-SPECIAL 4 AND 8 SLOT CONNECTOR, LIFTING.
(2) Install a cap on to the EEC connector to give protection from unwanted fluids or materials.

4. Procedure
Subtask 73-22-35-020-053-A ** ON A/C NOT FOR ALL

A. Remove the backshell assembly (1) from the data entry plug assembly.

Data Entry Plug Assembly Backshell ** ON A/C NOT FOR ALL

(1) Remove and discard the lockwire from the backshell assembly (1).
(2) Install the data entry plug assembly on the IAE1P16271 FIXTURE-HOLDING as follows:
(a) Align the main key (3) on the data entry plug connector (4) with the holding fixture receptacle main key-way (7).
(b) Use light hand pressure to engage the data entry plug assembly with the holding fixture receptacle and tighten it by hand.
(3) Remove the backshell assembly (1) from the data entry plug connector. Use a WRENCH - STRAP or equivalent, to loosen the backshell nut (6).
(4) Remove the anti-vibration rubber (2) from the jumper end(s) (5) or the backshell assembly (1).
(5) Remove the data entry plug connector (4) from the fixture.

Subtask 73-22-35-350-050-A ** ON A/C NOT FOR ALL

B. Remove the jumpers, the sealing plugs and the contacts from the connector.

Data Entry Plug Assembly Jumpers, Contacts and Connector ** ON A/C NOT FOR ALL

Data Entry Plug Assembly Jumpers, Contacts and Connector Replacement Worksheet ** ON A/C NOT FOR ALL

Data Entry Plug Assembly Jumper and Contact Removal ** ON A/C NOT FOR ALL

(1) Write the connector hole letters and the type of jumper that is to be removed on the worksheet. The number of contacts on the jumper is the type of jumper (2, 3, 4 or 5 contacts).
(a) If you replace the connector, you must write all the connector hole letters and the type of each jumper that is removed. Write the connector hole letters and the type of each jumper that is to be removed on the worksheet in the figure.

NOTE: This worksheet will be used during the installation and the test procedures.

(2) Remove the jumpers (4) thru (7) as necessary. Hold the connector (3) in your hand and use the ELECTRICAL CONTACTS INSERTION TOOL (8) or equivalent.

NOTE: If it is necessary, cut the jumper wires so that you can easily install the removal tool on to the jumper. Cut the wire 0.250 in. (6.35 mm) from the top of the connector rubber insert.

(3) Remove the sealing plugs (1) as necessary with your fingers or PLIERS - NOSE, SOFT, LONG.
(4) Remove the contacts (2) as necessary, use the ELECTRICAL CONTACTS INSERTION TOOL or equivalent.

NOTE: A small piece of straight wire will help in the removal of the contact.

NOTE: You can install the removed contacts, sealing plugs and jumpers if they were not damaged during the removal.

Subtask 73-22-35-350-051-A ** ON A/C NOT FOR ALL

C. Install the jumpers, the contacts and the sealing plugs in the connector.

Data Entry Plug Assembly Jumpers, Contacts and Connector ** ON A/C NOT FOR ALL

Data Entry Plug Assembly Jumpers, Contacts and Connector Replacement Worksheet ** ON A/C NOT FOR ALL

Data Entry Plug Assembly Jumper, Contact and Sealing Plug Installation ** ON A/C NOT FOR ALL

CAUTION: DO NOT USE THE REMOVAL TOOL TO INSTALL THE JUMPERS OR THE CONTACTS. IF THE REMOVAL TOOL IS USED, THE COLLET IN THE CONNECTOR CANNOT RETRACT AND LOCK THE JUMPER OR THE CONTACT.

CAUTION: DO NOT PUSH TOO HEAVILY ON THE INSERTION TOOL WHEN YOU PUT THE JUMPER OR THE CONTACT IN. IF YOU PUSH TOO HEAVILY YOU CAN CAUSE DAMAGE TO THE COLLET.

(1) Install the new AIPC 73-22-35-80-070 JUMPER (4), AIPC 73-22-35-80-080 JUMPER (5), AIPC 73-22-35-80-090 JUMPER (6) and AIPC 73-22-35-80-100 JUMPER (7) in the correct connector holes as written during the removal procedure. Use the ELECTRICAL CONTACTS INSERTION TOOL (9), or equivalent.

NOTE: Use the worksheet that you made when you removed the jumpers as an aid to make sure that you put all the jumpers in the correct connector holes.

(a) Hold the connector (3) in your hand.
(b) Push the jumper in to the connector hole until the shoulder of the contact is locked by the collet.

NOTE: When the collet locks the contact, the collet makes a light click sound.

(c) Lightly pull back the jumper to make sure that the contact is locked in the collet. The contact is correctly locked if the jumper does not move rearward.
(d) Remove the insertion tool.
(2) Install the AIPC 73-22-35-80-130 CONTACTS (2) and the AIPC 73-22-35-80-110 SEALING PLUGS (1) in the open connector holes that remain. Use the ELECTRICAL CONTACTS INSERTION TOOL or equivalent.

NOTE: Make sure the contact is locked in the connector collet before you install the sealing plug.

(a) Install the sealing plugs (larger diameter down) in to the open connector holes with your fingers or soft nose pliers.

Subtask 73-22-35-210-051-A ** ON A/C NOT FOR ALL

D. Examine the Repair

Data Entry Plug Assembly Backshell ** ON A/C NOT FOR ALL

Data Entry Plug Assembly Jumper, Contact and Sealing Plug Installation ** ON A/C NOT FOR ALL

(1) Make sure that the jumper contacts and the contacts are straight and that the sealing plugs are installed correctly in all the open connector holes.
(2) Examine the data entry plug connector for damage.

Subtask 73-22-35-750-050-A ** ON A/C NOT FOR ALL

E. Do an electrical wiring test on the data entry plug assembly.
Use the IAE2P16552 TESTER-EEC SOFTWARE LOADER AND DEP.

Data Entry Plug Assembly Backshell ** ON A/C NOT FOR ALL

EEC Data Entry Plug Tester, IAE2P16242 ** ON A/C NOT FOR ALL

PRE SBE73-0029

(1) Turn the POWER switch to on. The red power light will not go on at this time.
(2) Push the LIGHT TEST switch. Make sure that all the lights on the panel come ON.
(3) Install the data entry plug connector (4) on the tester. Align the data entry plug main key with the tester main key-way and tighten it with your fingers.

Data Entry Plug Assembly Backshell ** ON A/C NOT FOR ALL

(4) set the letter Y on the selector switch and push the DEP TEST switch. Write the jumpered wire combination from the lights that are ON.
Example: If the lights C and X are written, the combination Y-C-X is a three contact jumper.
(5) Turn the selector switch clockwise and set each letter on the selector switch and push the DEP TEST switch. Write each jumpered wire combination from the lights that are ON for each letter on the selector.
(6) Compare each of the jumpered wire combinations you have written with the jumpered wire combinations you make on the work sheet.
(7) If the correct jumpered wire combination lights do not come on, do the steps that follows:
(a) Do a check of the DEP to jumper wire combinations that are written on the work sheet.
(b) Do the DEP electrical wiring test again for the correct jumper combination.

END OF PRE SBE73-0029

Subtask 73-22-35-750-053-A ** ON A/C NOT FOR ALL

F. Do an electrical wiring test on the data entry plug assembly.
Use the IAE2P16552 TESTER-EEC SOFTWARE LOADER AND DEP.

POST SBE73-0029

(1) Setup of the IAE2P16552 TESTER-EEC SOFTWARE LOADER AND DEP.

NOTE: Do not attach the Yellow Y cable connectors to the TDS Ranger or the IAE2P16552 TESTER-EEC SOFTWARE LOADER AND DEP until instructed to do so, or the DEP test will not be successful.

(a) Make sure the POWER switch for the IAE2P16552 TESTER-EEC SOFTWARE LOADER AND DEP is in the OFF position.
(b) Connect the IAE2P16552 TESTER-EEC SOFTWARE LOADER AND DEP to an external power source (110V/60Hz or 220V/50 Hz).
(2) Do a test of the DEP wiring.
(a) Follow the instructions in the table below:

NOTE: The center of the "D-Pad" and the "Enter" key can be used interchangeably throughout the following procedure.

STEP	ACTION	RESULT	ADDITIONAL INFORMATION
(a)	Move the main power switch which is labeled "AC POWER INPUT" on the IAE2P16552 TESTER-EEC SOFTWARE LOADER AND DEP, to the ON position.	The orange "AC PWR ON" light will be on.	The orange light means the equipment is powered and ready for use.
(b)	Push and hold the green power button on the TDS Ranger until the word "Booting" appears at the bottom of the screen next to an arrow.	The "V2500 Front End Program" screen will be displayed.	If the unit was already on, a count down screen will appear after approximately three seconds. Wait for the countdown to reach zero. Continue to hold the green power button until the word "Booting" appears. If the unit was off, the word "Booting" will appear after approximately two seconds.
(c)	When the "V2500 Front End Program" screen is shown, connect the Yellow Y cable to the IAE2P16552 TESTER-EEC SOFTWARE LOADER AND DEP and TDS Ranger as labeled.		The system setup is complete. NOTE: If the Yellow Y cable was already connected to the TDS Ranger before step (b), the DEP test will not be successful. Disconnect the Yellow Y cable from the TDS Ranger and go back to step (b).
(d)	1. Use the "D-Pad" on the TDS Ranger and highlight "Go to Engine Support Program". 2. Push the ENTER key.	The "V2500 Engine Support Programs" screen will be displayed.	At this screen, there will be three options: 1. V2500 Loader 2. DEP Tester 3. Administrative Functions.
(e)	1. Use the "D-Pad" on the TDS Ranger and select DEP Tester. 2. Push the ENTER key.	The "Data Entry Plug Tester" screen will be displayed.	At this screen, there will be two options: 1. Test Data Entry Plug 2. Data Entry Plug Tester Self Test.
(f)	1. Use the "D-Pad" on the TDS Ranger and select "Test Data Entry Plug". 2. Push the ENTER key.	The Document Property Rights Notice will be displayed.	NOTE: You must agree to the terms and conditions or it is not permissible to use this device.
(g)	1. If you agree to the terms and conditions, use the "D-Pad" to highlight the check box, and push the ENTER key. 2. Use the "D-Pad" to highlight "Continue", and push the ENTER key.	The "Data Entry Plug Tester" screen will be displayed with instructions to 1. Install the Data Entry Plug and 2. Select Continue.
(h)	1. Install the DEP on the panel marked "Data Entry Plug Tester Interface" on the IAE2P16552 TESTER-EEC SOFTWARE LOADER AND DEP. 2. Use the "D-Pad" on the TDS Ranger, and select "Continue". 3. Push the ENTER key.	The "Data Entry Plug Tester" screen will be displayed with radio buttons to select the applicable engine model.
(i)	1. Use the "D-Pad" and "Key Pad" on the TDS Ranger to highlight the applicable engine model. 2. Push the ENTER key to turn the radio button black next to the appropriate engine model. 3. Use the "D-Pad" on the TDS Ranger, and select "Continue".	The detected configuration of the DEP will be displayed.	If the DEP wiring configuration is not recognized, "Unknown DEP jumper connection" will be displayed. Use the "D-Pad" on the TDS Ranger to select "Continue" and push the ENTER key. Continue with step (l). Otherwise, go to step (j).
(j)	1. If the configuration displayed is the setting you want, use the "D- Pad" on the TDS Ranger to select "Yes". 2. If the configuration displayed is not the setting you want, use the "D-Pad" on the TDS Ranger to select "Yes". 3. Push the ENTER key.	1. If "Yes" is selected, the DEP configuration will be displayed. Go to step (k). 2. If "No" is selected, you will be asked to enter the DEP configuration you want. Go to step (l).
(k)	1. Use the "D-Pad" on the TDS Ranger to select "Finish". 2. Push the ENTER key.	The "V2500 Engine Support Programs" menu will be displayed.	You should be at step (k) if the DEP was wired correctly, and you selected "Yes" at step (j). Otherwise, go to step (l).
(l)	1. If an unknown DEP jumper connection was detected, or if the configuration you detected was not the configuration you wanted, the words "Enter Desired" will be displayed, followed by several empty boxes. 2. Use the "D-Pad" ENTER key, TAB key, and keypad to enter the configuration you want. 3. Use the "D-Pad" to select "Continue".	The results you wanted will be displayed alongside the results you got.	When you enter the Engine Serial Number, enter the number without a "V" before it.
(m)	1. Remove the DEP from the panel that says "Data Entry Plug Tester Interface" on the IAE2P16552 TESTER-EEC SOFTWARE LOADER AND DEP. 2. For each row on the TDS Ranger that show "Fail" in the right column, correct the wiring as necessary. 3. Install the DEP on the panel that says "Data Entry Plug Tester Interface" on the IAE2P16552 TESTER-EEC SOFTWARE LOADER AND DEP. 4. Use the "D-Pad" on the TDS Ranger to select "Continue". 5. Push the ENTER key.	The words "Do you want to retest this plug?" will be displayed.	It is possible to go back to the wiring display screen by using the "D-Pad" on the TDS Ranger to select "Back" and pushing the ENTER key.
(n)	1. Use the "D-Pad" on the TDS Ranger to select "Yes". 2. Push the ENTER key.	A screen will be displayed with instructions to select "DEP P/N to be tested". Go back to step (i) for instructions to continue with the DEP test.	If you selected "No", the "V2500 Engine Support Programs" menu will be displayed.

(3) Shut down the IAE2P16552 TESTER-EEC SOFTWARE LOADER AND DEP.
(a) Make sure the power switch for the IAE2P16552 TESTER-EEC SOFTWARE LOADER AND DEP is in the OFF position.
(b) Disconnect the power cable.
(c) Shut down the TDS Ranger as follows:
1 Push the green power button on the TDS Ranger and hold it until the countdown starts.
2 When the countdown starts, let the power button go.

NOTE: It will take approximately three seconds for the countdown to start. If you push the power button for too long time, the TDS Ranger will reset itself.

(d) Disconnect the Yellow Y cable from the IAE2P16552 TESTER-EEC SOFTWARE LOADER AND DEP and TDS Ranger.
(e) Disconnect the Data Entry Plug from the panel that says "Data Entry Plug Interface" on the IAE2P16552 TESTER-EEC SOFTWARE LOADER AND DEP.
(f) At the "Power Menu", use the "D-Pad" on the TDS Ranger to highlight "Shutdown".
(g) Push the ENTER key to shut down the TDS Ranger.

END OF POST SBE73-0029

Subtask 73-22-35-420-053-A ** ON A/C NOT FOR ALL

G. Install the backshell assembly on to the data entry plug connector.

Data Entry Plug Assembly Backshell ** ON A/C NOT FOR ALL

(1) Install the data entry plug connector (4) on to the IAE1P16271 FIXTURE-HOLDING.
(a) Align the main key (3) on the data entry plug connector (4) with the holding fixture receptacle main key-way (7).
(b) Use light hand pressure to engage the data entry plug connector with the holding fixture receptacle and tighten it by hand.
(2) Align and install the anti-vibration rubber (2) on to the jumper end(s) (5) or in to the backshell (1) of the data entry plug.
(3) Install the backshell assembly (1) on the connector (4) and tighten the backshell nut by hand.
(4) TORQUE the backshell nut (6) to between 58 and 53 lbf.in (0.66 and 0.60 m.daN )

. Use a strap wrench, TG-70 or equivalent (Ref. AMM TASK 70-23-11-911-013).
(5) Safety the backshell assembly (1) to the backshell nut (6) with lockwire (Material No.V02-138) (Ref. AMM TASK 70-40-11-911-014).
(6) Remove the data entry plug assembly from the holding fixture.
(7) Install a CAP - PROTECTION on the data entry plug assembly.

5. Close-up
Subtask 73-22-35-410-056-A ** ON A/C NOT FOR ALL

A. Connect the data entry plug assembly (1) to the EEC (2).

Data Entry Plug Assembly ** ON A/C NOT FOR ALL

(1) Remove the protective cap or bag from the data entry plug assembly (1).
(2) Remove the cap from the EEC (2) connector.
(3) Align the main key on the data entry plug assembly (1) with the EEC (2) receptacle main key-way (Ref. AMM TASK 70-23-15-912-010).
(4) Use light hand pressure to engage the data entry plug assembly with the EEC receptacle and tighten it by hand.
(5) TORQUE the data entry plug connector to between 35.2 and 28.8 lbf.in (0.40 and 0.33 m.daN )

. Use the EEC harness wrench, IAE1R19416 (Ref. AMM TASK 70-23-11-911-013).

Subtask 73-22-35-410-052-A ** ON A/C NOT FOR ALL

B. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Close the fan cowls (Ref. AMM TASK 71-13-00-410-010):
(a) FOR [1000EM1] (ENGINE-1)
437AL 438AR.
(b) FOR [1000EM2] (ENGINE-2)
447AL 448AR.
(3) Remove the access platform(s).
(4) Remove the WARNING NOTICE(S).

Subtask 73-22-35-730-052-A ** ON A/C NOT FOR ALL

C. Do an operational test of the EEC (Ref. AMM TASK 73-22-34-710-040).

[Rev.10 from 2021] 2026.04.01 03:00:58 UTC