0384427 JOHNSON STARTER ASSEMBLY COMPLETE

Table 1
Event Code    
Description    Default Conditions which Generate this Code    System Response    
E035(1) Loss of Coolant Flow Warning     The coolant flow switch opens.     The code is active and the code is logged.    The coolant flow switch is a reed switch that is used to detect the flow of coolant in the engine's cooling system.
Illustration 1 g01249790
Coolant flow switch (1) Flow switch assembly (2) PaddleThe coolant flow switch is a normally open switch. The contacts of flow switch assembly (1) close as coolant flow from the engine flows across paddle (2) of the switch. The Electronic Control Module (ECM) monitors the status of the coolant flow switch during engine operation. If the ECM detects a loss of coolant flow in the engine during operation, a signal will be sent in order to alert the operator of the condition.The status of the "Engine Coolant Flow" can be monitored using Caterpillar Electronic Technician (ET) in order to determine the state of the coolant flow switch.
Illustration 2 g01393020
Schematic for the coolant flow switchTest Step 1. Verify that the Coolant Level is Correct
Ensure that the coolant level for the engine is correct.Expected Result:The coolant level is OK.Results:
OK - The coolant level is OK. Proceed to Test Step 2.
Not OK - The coolant level is low.Repair: Diagnose the reason for a low coolant level.Refer to Systems Operation/Testing and Adjusting, "Cooling System" for additional information.Verify that the repair eliminates the problem.STOPTest Step 2. Inspect the Electrical Connectors and the Wiring
Remove electrical power from the ECM.
Illustration 3 g01393380
ECM (3) J1/P1 connectors (4) J2/P2 connectors
Illustration 4 g01827133
Component locations (5) Coolant flow switch
Thoroughly inspect connectors (3) and (4). Thoroughly inspect connector (5) for the coolant flow switch. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Illustration 5 g01394770
Terminal locations at the P1 ECM connector for the coolant flow switch (P1-26) Coolant flow switch (P1-29) Sensor return
Illustration 6 g01155187
Terminal locations at the connector for the coolant flow switch (Terminal 1) Switch signal (Terminal 2) Return
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
Check the allen head screw for each of the ECM connectors for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.Expected Result:All connectors, pins, and sockets are completely inserted and coupled. The harness and wiring are free of corrosion, of abrasion, and of pinch points. All connections and grounds are tight and free of corrosion.Results:
OK - The harness and wiring are OK. Proceed to Test Step 3.
Not OK - There is a problem in the connectors and/or wiring.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem.STOPTest Step 3. Use Cat ET to Monitor the Switch Status
Connect Cat ET to the service tool connector.
Restore electrical power to the ECM.
Observe the status for "Engine Coolant Flow" on the Cat ET.
Start the engine.
Observe the status for "Engine Coolant Flow" on the Cat ET.
Remove electrical power from the ECM.Expected Result:Cat ET indicates "No Flow" while the engine is not running. Cat ET indicates "Flow" while the engine is running.Results:
OK - Cat ET indicates "No Flow" while the engine is not running. Cat ET indicates "Flow" while the engine is running.Repair: The switch is operating correctly at this time. There may be an intermittent problem with the switch or the switch circuit. If an intermittent problem is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - Cat ET does not indicate "No Flow" while the engine is not running. Cat ET does not indicate "Flow" while the engine is running. Cat ET does not indicate the correct status for the coolant flow switch. Proceed to test step 4.Test Step 4. Create a Short at the Connector for the Coolant Flow Switch
Disconnect the connector for the coolant flow switch.
Fabricate a jumper wire that is long enough to create a short at the harness connector for the coolant flow switch. Crimp connector pins to each end of the jumper wire.
Install the jumper wire to the terminals of the harness connector of the coolant level switch.
Restore electrical power to the ECM.
Observe the status of "Engine Coolant Flow" on Cat ET.
Remove electrical power from the ECM. Restore the wiring to the original configuration.Expected Result:The status indicates "Flow" with the jumper wire in place.Results:
OK - The status indicates "Flow" with the jumper wire in place. The ECM and the wiring are operating correctly. Proceed to Test Step 5.
Not OK - The status indicates "No Flow" with the jumper wire in place. There is a problem in the harness between the ECM and the connector for the coolant flow switch. There may be a problem with the ECM. Proceed to Test Step 6.Test Step 5. Check the Coolant Flow Switch