MUFFLER AS 1099323 - Caterpillar

System Operation Description:Use this procedure under the following conditions:Use this procedure if any of the following diagnostic codes are active:
0526-05 Turbo Wastegate Drive current below normal
0526-06 Turbo Wastegate Drive current above normal
0526-07 Turbo Wastegate Drive not responding properlySome engine models will have a turbocharger with an electronically controlled wastegate. Typically, the wastegate is a mechanical valve that is used in the turbocharger in order to regulate the intake manifold pressure to a set value.The control system for the electronically controlled wastegate precisely regulates the intake manifold pressure by using a wastegate regulator to control the wastegate.The required intake manifold pressure is calculated by the software that is contained in the Electronic Control Module (ECM). The ECM uses the wastegate regulator to control the wastegate in order to provide the precise value of intake manifold pressure. The solenoid in the wastegate regulator is controlled by a PWM signal from the ECM.
Table 1
Pin Connections
Sensor Pin Function P2 Pin Connection
1 Ground 44
2 Signal 17
Illustration 1 g01806857
Schematic for the wastegate regulator
Illustration 2 g01806859
Typical view of the pin locations on the P1 connector for the wastegate regulator
(17) Wastegate pulse width modulation (PWM) signal
(44) Wastegate return
Illustration 3 g01806858
Connector for the wastegate regulator
(1) Ground (GND)
(2) Signal (SIG)
Illustration 4 g01806873
Wastegate regulator
(1) Wastegate regulator Test Step 1. Check for Diagnostic Codes
Turn the keyswitch to the OFF position.
Connect the electronic service tool to the diagnostic connector.
Turn the keyswitch to the ON position. Start the electronic service tool.
Monitor the electronic service tool for active diagnostic codes and/or logged diagnostic codes. Expected Result:One or more diagnostic codes are active or logged.Results:
526-xx diagnostic codes are active and/or logged - Proceed to Test Step 2.
No Codes - The fault seems to be resolved.Repair: For intermittent faults, refer to Troubleshooting, "Electrical Connectors - Inspect".STOPTest Step 2. Inspect Electrical Connectors and Wiring
Thoroughly inspect the P2/J2 ECM connector and the P511 connector for the wastegate regulator. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the wastegate solenoid.
Check the screw for the ECM connector for the correct torque of 5.0 N m (44 lb in). Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted and the harness is free of corrosion, abrasion, and pinch points.Results:
OK - The harness is OK. Proceed to Test Step 3.
Not OK - There is a fault in the connectors and/or the harness.Repair: Repair the connectors or the harness and/or replace the connectors or the harness. Ensure that all of the seals are correctly in place and ensure that the connectors are completely coupled.Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.STOPTest Step 3. Determine the Diagnostic Code that is Active
Turn the keyswitch to the ON position. Access the "Diagnostics Tests" on the electronic service tool. Activate the "Turbo Wastegate Solenoid Test". Wait at least 30 seconds in order for the result to be displayed.
Determine if the fault is related to either of the