UNIVERSAL JOINT GP 8X5005 - Caterpillar

3208 (1Z) Marine EnginesReference: Engine News, June 1990, "Testing The Starter On The Engine."Under some conditions the BATTERY contact in the starter solenoid may corrode and cause intermittent cranking or no cranking at all. This symptom is exactly the same as butt engagement between the starter pinion and engine ring gear. See the reference article. When this fault is present (starter "clicks" but will not crank), the solenoid coils draw full current. This can cause the solenoid coils to overheat if the start switch is held in the crank position.
The cause of battery contact corrosion is condensation, which can be a result of temperature changes within the solenoid. This moisture does not enter from leaking seals, but enters from slow breathing of the contact cavity as a hot solenoid cools. The frequent, shorter operating cycles of a pleasure craft can accelerate the problem and result in a low hour failure.
The accumulation of moisture and the resulting corrosion has only been a problem on 3T2648 Starting Motor Groups with the 8C3646 consist number. See the identification tag on the starting motor. This starting motor group includes the 8T8818 Solenoid. Do not replace the solenoid. If the 8C3646 consist number is found, order a Remanufactured 0R2188 or new 3T2648 Starting Motor Group. The 0R2188 and 3T2648 Starting Motor Groups now include the 7T2266 Starting Motor Group. The 7T2266 Starting Motor Group is not serviced separately.