33816-92D00 Suzuki MAGNETO LEADS GUIDE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
The Electronic Control Module (ECM) contains no moving parts. Replacement of the ECM can be costly. Replacement can also be a time consuming task. Follow the troubleshooting procedures in this manual in order to be sure that replacing the ECM will correct the problem. Verify that the suspect ECM is the cause of the problem.Note: Ensure that the ECM is receiving power and that the ECM is properly wired to the negative battery circuit before a replacement of the ECM is attempted. Refer to Troubleshooting, "Electrical Power Supply Circuit - Test".A test ECM can be used to determine if the ECM is faulty. Install a test ECM in place of the suspect ECM. Flash program the correct flash file into the test ECM. Program the parameters for normal operation. The parameters must match the parameters in the suspect ECM. Refer to the following test steps for details. If the use of a test ECM resolves the problem, reconnect the suspect ECM in order to verify that the problem returns. Replace the ECM only if the test ECM resolves the problem and the problem returns with the suspect ECM.Note: When a new ECM is not available, you may need to remove an ECM from an engine that is not in service. The interlock code for the replacement ECM must match the interlock code for the suspect ECM. Be sure to record the parameters from the replacement ECM on a "Parameters Worksheet" for the engine. Use the "Copy Configuration/ECM Replacement" feature that is found under the "Service" menu on the Caterpillar Electronic Technician (ET).
If the flash file part number and the and engine application are not matched, engine damage may result.
Perform the following procedure in order to replace the ECM.
Record the configuration data:
Connect Cat ET to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools".
Print the parameters from the "Configuration" screen on Cat ET. If a printer is unavailable, record all of the parameters on the "Parameter Worksheet". Record any logged diagnostic codes and logged event codes for your records.
Use the "Copy Configuration/ECM Replacement" feature that is found under the "Service" menu on Cat ET. Select "Load from ECM" in order to copy the configuration data from the suspect ECM.Note: If the "Copy Configuration" process fails and the parameters were not obtained in Step 1.a, the parameters must be obtained elsewhere. Some of the parameters are stamped on the engine information plate. Most of the parameters must be obtained from the factory.
Remove the ECM:
Turn the keyswitch to the OFF position.
Disconnect the P1 and P2 ECM connectors.
Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel immediately.
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.
Remove the fuel lines from the ECM.
Disconnect the ECM ground strap.
Remove the mounting bolts from the ECM.
If you are flash programming, go to Step 5. If you are physically replacing the personality module, proceed to Step 3.Note: Flash programming is the preferred method for replacing the ECM software. The personality module can be physically removed if flash programming is unsuccessful.
Moisture entry into the ECM from improper servicing can result in ECM failure.
Remove the personality module chip from the old ECM.
Remove the tag wire from the back cover of the ECM.
Illustration 1 g01132254
Back side of the ECM (1) Cover screws
Remove cover screws (1) from the back cover of the ECM.
Remove the O-ring seal from the cover.
Remove the personality module (EPROM chip) by squeezing the tabs on the ends of the blue plastic case (EPROM carrier). Pull the module straight out of the ECM.
Improper O-ring placement could result in moisture damage from improper sealing. Do not over tighten screws! This could result in damaged threads and moisture damage from improper sealing.
Install the personality module into the new ECM.
Carefully seat the personality module into the personality module socket.Note: Do not use excessive force to insert the module into the socket. The socket will accept the personality module if the personality module is oriented correctly. A audible click is heard when the personality module is seated into the socket.
Install the O-ring seal for the cover of the personality module.
Install the access cover for the personality module on the ECM. Tighten the cover screws for the personality module to a torque of 2.25 0.25 N m (20 2 lb in).
Install the replacement ECM.
Use the old mounting hardware to install the replacement ECM.
Connect the fuel lines (if equipped).
Verify that the fuel lines are installed correctly. The fuel lines must not put tension on the ECM. Rubber grommets are used to protect the ECM from excessive vibration. The ECM should move slightly in the rubber grommets. If the ECM cannot be moved sli