Connector Identification, Removal, Disassembly, Reassembly, and Installation for All Cat® Products Equipped with BR Series Connectors {1408} Caterpillar

Caterpillar Products

All Machines

Introduction

This Special Instruction covers the Tyco Electronics (TE) BR Series Connectors used as part of the next generation electronic architecture that includes Ethernet Data Link. This Special Instruction will discuss the connectors, removal procedure, and connector disassembly for repair. Troubleshooting will be covered in each machine service manual.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

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Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Turn the battery disconnect switch to the OFF position and lockout the battery disconnect switch with a safety lock. Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the start switch and battery disconnect location to inform personnel that the machine is being worked on.

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Improper operation of an access platform could result in injury or death. Operators must carry out their duties properly and follow all instructions and guidelines given for the machine and access platform.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

Associated Parts

Illustration 1	g06246619
490-0571 Connector Plug As

Table 1

BR Series 2 Position 490-0571 Connector Plug As for "A" Key or 490-0578 Connector Plug As "B" Key
Associated Parts
Quantity	Part Number	Description
2	169-0705	Seal
1	490-0586	Backshell
	or
	490-0587	Backshell

Illustration 2	g06246629
490-0572 Receptacle As

Table 2

BR Series 2 Position 490-0572 Receptacle As for "A" Key or 490-0582 Receptacle As "B" Key
Associated Parts
Quantity	Part Number	Description
2	169-0705	Seal
1	490-0586	Backshell
	or
	490-0587	Backshell

Illustration 3	g06247265
44 Pin Cavity Connector Plug As

Table 3

BR Series 44 Pin Cavity 483-2761 Connector Plug As, 483-2762 Connector Plug As, or 483-2763 Connector Plug As
Associated Parts
Quantity	Part Number	Description
1	483-2775	Connector Cover
1	483-2765	Terminal As
1	483-2767	Terminal As
2	483-2768	Connector Socket

Illustration 4	g06247279
49 Pin Cavity Connector Plug As

Table 4

BR Series 49 Pin Cavity 483-2772 , 483-2773 Connector Plug As, and 483-2774 Connector Plug As
Associated Parts
Quantity	Part Number	Description
1	483-2775	Connector Cover
1	483-2768	Seal Plug
1	483-2765	Terminal As
1	483-2767	Terminal As

Table 5

BR Series 40 and 81 Pin Cavity 453-5339 Connector Plug As or 442-7945 Connector Plug As
Associated Parts
Quantity	Part Number	Description
1	431-2102	Connector Socket
1	453-6479	Socket Terminal
1	483-2768	Seal Plug
1	456-0574	Terminal As
1	456-0575	Terminal As
1	Patch Cable

Required Tools

Table 6

Required Diagnostic Tools
Quantity	Part Number	Description
1	538-8729	Extraction Tool
1	290-9703	Extraction Tool
1	147-6456	Wedge Removal Tool
1	509-3833	Extraction Tool

Connector Removal, Disassembly, Reassembly, and Installation Procedure

Perform the following procedure for servicing the connectors:

442-7945 Connector Plug As Removal, Disassembly, Reassembly, and Installation Procedure

Note: A CWS login is required to access Caterpillar Channel1. Scan the QR code below with a QR enabled device or copy the link below.

Illustration 5	g06253073

Reference: For more information, refer to a video for this procedure on Caterpillar Channel1.

https://channel1.mediaspace.kaltura.com/media/40-81++Position+Connector+Terminal+Removal+Overview/1_mz21dsov

Removal

Note: The Following steps are applicable for the 81 Position and 40 Position Connector. The illustrations below shows 442-7945 Connector Plug As.

Illustration 6	g06213246
(1) Connector Lock Slide (2) Full Lock Stop (3) Lever Lock Tab (4) Backshell (5) Backshell Lever (6) Full Unlock Stop (7) Backshell Locking Hooks (8) Connector Housing (9) MQS (Micro Quadlok System)

Illustration 7	g06219148
(10) Junior Power Terminal (JPT) Retainer

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Illustration 8	g06200247

1. Press and hold the lever lock tab (3) down on the backshell (4).
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   Illustration 9	g06199127

2. Rotate backshell lever (5) to the full unlock stop (6).

   Note: The backshell lever lifts connector off the ECM pins.

3. Remove connector from ECM.

Removal of Backshell

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Illustration 10	g06218937
Backshell in Locked Position (4) Backshell (5) Backshell Lever (7) Backshell Locking Hooks (8) Connector Housing

1. Position the backshell lever in the lock position to retain connector slide locks (1) in the connector housing (8).

2. Squeeze the backshell locking hooks (7) while lifting the rear of the backshell (4).

   Note: Lifting with a small screwdriver under the hooks, will help the backshell release from connector housing.

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   Illustration 11	g06199194
   Backshell Removal (4) Backshell (8) Connector Housing

3. Rotate the backshell (4) from the connector housing (8).

   Note: If connector slide locks (1) fall out, reinsert into the housing (8) (after the backshell has been removed).

   Note: The slide locks are interchangeable.

MQS Contact Removal

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Illustration 12	g06199203
(8) Connector Housing (9) Small Gauge Terminal Position Assurance (TPA) (10) Junior Power Terminal (JPT) Retainer

1. Release the MQS Retainer Terminal Position Assurance (TPA) (9) from the connector housing (8) by sliding the TPA from the housing with the extraction tool.

2. Slide out the Junior Power Terminal (JPT) assurance lock (9) from connector housing (8) to unlock all the wire terminals.

   Note: Unlocking the terminals will allow the wires to be removed from the connector housing.

   Note: The MQS (TPA) (10) cannot be removed from connector housing (8). Moving 10 mm (0.39 inch) unlocks the terminals.

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   Illustration 13	g06247301
   (11) Retention Finger (12) Terminal Extraction Tool

3. Insert 538-8729 Extraction Tool (12) into socket side of connector when removing Ethernet Cables. Refer to Illustration 11.

   Note: The 509-3833 Extraction Tool can be used when extracting only 1 wire.

4. Press against retention finger (11) of the connector.

   Note: Retain pressure on the retention finger (11) while performing the following step.

5. Remove both Ethernet wires simultaneously out of the back of the connector.

   Note: Removing both wires simultaneously will prevent unneeded wire strain.

JPTS Contact Removal

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Illustration 14	g06219264
(10) Junior Power Terminal (JPT) Retainer

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Illustration 15	g06219266
Junior Power Terminal (JPT) Retainer in Locked position

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Illustration 16	g06219269
Junior Power Terminal (JPT) Retainer in Unlocked position

1. Unlatch the JPT TPA from the locked position.

   Note: The unlocked position is only 1 mm (0.04 inch) of movement.

2. Insert the 290-9703 Extraction Tool in the face side of the connector.

3. Remove both Ethernet wires simultaneously from the connector.

Assembly

1. Insert both Ethernet wires simultaneously into the connector.

   Note: Inserting both wires simultaneously will prevent unneeded wire strain.

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   Illustration 17	g06199203
   (8) Connector Housing (9) MQS Retainer Terminal Position Assurance (TPA) (10) MQS Retainer Terminal Position Assurance (TPA)

2. Place MQS Retainer (TPA) (9) in the connector housing (8).

   Note: The MQS Retainer (TPA) will only insert in one direction.

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   Illustration 18	g06199248
   (9) MQS Retainer Terminal Position Assurance (TPA)

3. Engage the MQS (TPA) to the lock position to secure the wires.
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   Illustration 19	g06199243
   Lock Position of Backshell (5) Backshell Lever

4. Position the backshell lever (5) in the lock position.

   Note: If connector slide locks (1) are removed from connector housing (8), insert slides to the full inserted position in the housing (8). The slides will have the retaining clips on the following edge and fingers facing up when inserting the slides into the connector housing (8).

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   Illustration 20	g06199261
   (3) Lever Lock Tab (4) Backshell (5) Backshell Lever (6) Full Unlock Stop (8) Connector Housing (13) Front Tabs of the Backshell

5. Insert the front tabs (13) of the backshell (4) in the connector housing (8). Rotate the backshell (4) into the connector housing (8) to the lock position.

Installation

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Illustration 21	g06199127
(1) Connector Slide Lock (5) Backshell Lever (6) Full Unlock Stop

1. Rotate backshell lever (5) to the full unlock stop (6).

   Note: The connector slide locks will be in the unlocked position.

2. Install connector over ECM.
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   Illustration 22	g06199123
   (3) Lever Lock Tab (4) Backshell (5) Backshell Lever

3. Rotate the backshell lever (5) until the lever lock tab (3) is engaged.

   Note: Rotating the backshell lever (5) will lower the connector (8) and engage the sockets onto the pins.

483-2761 and 483-2762 Removal, Disassembly, Reassembly, and Installation Procedure

Note: A CWS login is required to access Caterpillar Channel1. Scan the QR code below with a QR enabled device or copy the link below.

Illustration 23	g06253079

Reference: For more information, refer to a video for this procedure on Caterpillar Channel1.

https://channel1.mediaspace.kaltura.com/media/44-49+Position+Connector+Terminal+Removal+Overview/1_qd8qb5qf

Illustration 24	g06247309
(14) Connector Lever Lock (15) Connector Housing (16) Backshell (17) Lever Lock

Removal

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Illustration 25	g06247323
(14) Lever Lock

1. Press and hold the lever lock (14) down on the backshell.
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   Illustration 26	g06247334
   (14) Connector Lever Lock (18) Full stop Position

2. Rotate connector lever lock (14) to the full stop position (18).

   Note: Lever lifts connector off the ECM pins.

3. Remove connector from ECM.

Disassembly

Note: Position the connector lever lock in the lock position to remove the backshell from the connector housing.

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Illustration 27	g06247350
(19) Wiring Lock (20) Wiring Retainer

1. Release the wiring retainer (20) on the backshell.
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   Illustration 28	g06247375

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   Illustration 29	g06200392
   (16) Backshell (21) Backshell Lock Tabs

2. Disengage the back shell lock tabs (21) from the back shell (16) while lifting the rear of the back shell.

3. Rotate the back shell (16) from the connector housing.
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   Illustration 30	g06200403
   (22) TPA (23) locked Position

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   Illustration 31	g06200795
   (23) TPA (24) unlocked Position

4. Press the lower portion of the TPA inward to the center of the connector to disengage from the connector sockets. Refer to the direction of the arrow.

   Note: TPA cannot be removed from housing.

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   Illustration 32	g06241094

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   Illustration 33	g06241107
   (12) Extraction Tool (25) Wire Retaining Finger

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   Illustration 34	g06241113
   (12) Extraction Tool (25) Wire Retaining Finger

5. Insert extraction tool into the socket side of connector. Press against the wire retaining finger of the connector.

   Note: Retain pressure on the tabs to perform the following step.

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   Illustration 35	g06219540

6. Remove both Ethernet wires simultaneously out of the back of the connector.

   Note: Removing both wires simultaneously will prevent unneeded wire strain.

Assembly

Illustration 36	g06241134

The exterior rows use a different contact and wire size than the interior rows. Refer to Illustration 36.

1. Insert wires into the connector at the same time.

   Note: Inserting both Ethernet wires simultaneously will prevent unneeded wire strain.

2. Engage the retention finger of the wires into the connector.
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   Illustration 37	g06241094

3. Engage the wire retainer to lock position to secure Ethernet wire.
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   Illustration 38	g06241140

4. Position the backshell over the tabs of the connector.

5. Rotate backshell into the connector housing to the locked position.

6. Engage the wire wrap around the wires and on the backshell.

Installation

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Illustration 39	g06247323
(17) Lever Lock

1. Install the backshell over the connector plug.
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   Illustration 40	g06247334
   (14) Connector Lever Lock (18) Full stop Position

2. Rotate the connector lever lock to the Unlocked position.

3. Install connector over ECM plug.

4. Rotate the connector lever lock until the lock tab is engaged.

   Note: Rotating the lever will lower the connector and engage the sockets onto the pins.

Removal, Disassembly, Reassembly, and Installation Procedure for 490-0571 Connector Plug As and 490-0578 Connector Plug As.

Note: A CWS login is required to access Caterpillar Channel1. Scan the QR code below with a QR enabled device or copy the link below.

Illustration 41	g06253061

Reference: For more information, refer to a video for this procedure on Caterpillar Channel1.

https://channel1.mediaspace.kaltura.com/media/2+Position+Connector+Terminal+Removal+Overview/1_i35xttux

Perform the following procedure for servicing the connectors:

Illustration 42	g06241164
(26) Connector Plug (27) Connector Receptacle

Illustration 43	g06247481
Connector Plug (26) Connector Plug (28) Ethernet Wire (29) Wire Seal (30) CPA (Connector Position Assurance) (31) Connector Seal (32) Socket Contact (33) TPA (Terminal Position Assurance)

Removal

Illustration 44	g06241167
(30) Connector Position Assurance (CPA) Closed (34) Release Lever

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Illustration 45	g06241173
(30) Connector Position Assurance (CPA) open

1. Slide the Connector Position Assurance (CPA) (30) to the open position.
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   Illustration 46	g06241176
   (34) Release Lever

2. Press and hold the release lever (34) in the down position.

3. Remove connector from adapter.

Disassembly

Illustration 47	g06241178
TPA Locked Position (33) TPA

Illustration 48	g06241412
TPA unLocked Position (33) TPA

1. Release the TPA (33) from around the terminal housing of the connector.
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   Illustration 49	g06241419
   (12) Terminal Removal Tool

2. Insert wire terminal removal tool (12) into face side of connector.
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   Illustration 50	g06241423
   (35) Terminal Retention Finger

3. Press against retention finger (35) of the connector.

   Note: Retain pressure on the retention fingers to perform the following step.

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   Illustration 51	g06241424

4. Remove both Ethernet wires simultaneously out of the back of the connector.

   Note: Removing both wires simultaneously will prevent unneeded wire strain.

Assembly

1. Confirm that the TPA is in the open position
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   Illustration 52	g06241429
   Lock Tab Released (30) Lock Tab

2. Insert both Ethernet wires simultaneously into the connector at the same time.

   Note: Inserting both wires simultaneously will prevent unneeded wire strain.

3. Engage the retention fingers of the wires into the connector.
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   Illustration 53	g06241178
   TPA Locked (33) TPA

4. Engage the wire retainer to lock position to secure Ethernet wire.

Installation

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Illustration 54	g06241176
(28) Release Lever

1. Press connector to adapter until the release lever clicks.

2. Slide the CPA to the Locked position.

Disassembly and Reassembly Procedure for 490-0572 Receptacle As and 490-0582 Receptacle As.

Illustration 55	g06247611
Connector Receptacle (28) Ethernet Wire (36) Pin Contact (37) Wire Seal (38) TPA (Terminal Position Assurance)

Perform the following procedure for servicing the connectors:

Disassembly

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Illustration 56	g06241449
Receptacle with TPA Installed (38) TPA (39) TPA Removal Slot

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Illustration 57	g06241454
Receptacle with Locking Wedge Removed

1. Insert 147-6456 Wedge Removal Tool into the connector receptacle (39) and remove the TPA.
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   Illustration 58	g06241474
   (40) 538-8729 Extraction ToolRemoval Tool (41) Retention Finger

2. Insert 538-8729 (40) to release retention fingers (41).
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   Illustration 59	g06241479
   (41) Retention Finger

3. Press against retention fingers of the connector.

   Note: Retain pressure on the fingers to perform the following step.

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   Illustration 60	g06241491

4. Remove both Ethernet wires simultaneously out of the back of the connector.

   Note: Removing both wires simultaneously will prevent unneeded wire strain.

Assembly

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Illustration 61	g06241495

1. Insert both Ethernet wires simultaneously into the connector at the same time.

   Note: Inserting both wires simultaneously will prevent unneeded wire strain.

2. Insert wires until the retention fingers of the contact engage in the connector.
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   Illustration 62	g06241449
   Receptacle With TPA Installed (38) TPA (39) TPA Removal Slot

3. Insert locking wedge in the connector, aligning the removal slot and push to the lock position to engage the lock in the receptacle.

4. Press connector to adapter.

Reference Section

Backshell - An attached part to the wire entry side of a connector which may attach to the harness covering. Provides wash protection and provides some strain relief benefit.

Cavity - Area in a connector for terminals, plug, seal, and so forth.

Connector - A coupling device that provides an electrical and mechanical junction between two wires or between a wire and an electrical component. Also provides electrical insulation between circuits.

Connector Plug - The connector containing the coupling ring or active retention device of the mating pair. The connector plug contains socket contacts

Connector Receptacle - The connector containing the static retention device of the mating pair. The connector receptacle contains pin terminals.

Contact - An electrically conductive device attached to a wire to facilitate connection to an electrical component or wire.

Pin - Male Electrical Contact

Strain Relief - Any method or part that provides a gradual wire transition from a rigid member (connector or support) to unsupported wire. Support is so that the wire will not kink or have a high stress at the exit from the connector or support.

Socket - Female Electrical Contact