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Old 10-12-2021, 07:16 AM   #1
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Cat 3208 stays running

So I was very happy that my 3208 started yesterday after a long time idle. It's a new boat to me so I am still working on issues but I did start up the cat yesterday. It sounds pretty good. I only wanted to run briefly to verify operational since I bought it without seeing it run. It started in about 10 seconds of cranking so that was great. It ran smoothly so I was satisfied until I turned off the key and it kept running. It doesn't have a stop button so I just disconnected the fuel solenoid. I must say the wiring diagrams in my manual is a bit rough to follow.
Any thoughts?
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Old 10-12-2021, 07:39 AM   #2
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Congrats on getting it fired up, that must be a relief. Is there a stop button at one station and and not the other? Seems like an odd thing to not connect at all.
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Old 10-12-2021, 07:51 AM   #3
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Turning off the key can damage alternator on some boats. What boat do you have? If no pull out to stop handle there must be a stop switch. Sometimes if the start switch is a rocker switch, pushing the bottom half stops it. A pic of your controls would help.
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Old 10-12-2021, 08:09 AM   #4
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I believe the 3208 fuel solenoid is normally closed, power to open.

So it is either sticking or you might have a bad ignition switch.

Assuming normal wiring...any post OEM wiring could mean anything is possible.
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Old 10-12-2021, 08:16 AM   #5
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The boat is a 79 Mainship Mark 1 repowered with the cat. It still has a stop button but that does not look to be connected anymore. The solenoid does seem to work fine without the engine running so I am not sure why yet.
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Old 10-12-2021, 08:22 AM   #6
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Cheap ignition switches go bad fairly quick....

Do you have an upper station with start, run,, stop key?

If the solenoid works perfectly when jumper wired, it is getting power from someplace. Some setups may have a relay between ignition key and engine parts....that could be sticking as well.
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Old 10-12-2021, 08:22 AM   #7
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On shut down solenoids that are powered (closed circuit) to stop, the switch need to be on when you push the stop button or nothing will happen.
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Old 10-12-2021, 08:45 AM   #8
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Originally Posted by Gdavid View Post
On shut down solenoids that are powered (closed circuit) to stop, the switch need to be on when you push the stop button or nothing will happen.
It was a repower, so I am guessing the stop switch was disconnected but stayed as a hole filler.

3208 solenoids I am almost sure (just researched it a bit) are power to stay open (listed as 1 amp).

If there is a 3 position key switch and no start button.... probably a power to open solenoid.
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Old 10-12-2021, 08:45 AM   #9
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Without a stop button it sounds like your 3208 is rigged energize to run, the same way it would be set up in a truck. Shutting down by disconnecting the fuel solenoid seems to confirm that. I'm thinking you have a problem with the key switch.

Try starting it up, let it run for a bit and then turning the key off. If the engine keeps running check voltage at the solenoid to see if it is still powered up.

If the solenoid is not still powered up then you may have a faulty solenoid though I can't see disconnecting the wires would shut it down.

Another way to verify energize to run vs energize to shut down is look for a push button on top of the solenoid. Energize to run will NOT have the button.
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Old 10-12-2021, 09:23 AM   #10
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If alternator is wired up wrong, it can backfeed power through ignition wire that also feeds fuel solenoid. That can drive you nuts sorting it out.

Put a meter on fuel solenoid wire. See if it has power with ign sw off. Start engine, then turn ign sw off. See if power remains on. That will point to alternator if that is the issue.

If solenoid stayed on all the time, it would be warm/hot to the touch.
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Old 10-12-2021, 09:29 AM   #11
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Quote:
Originally Posted by psneeld View Post
......... power to stay open (listed as 1 amp).....
I've not researched the spec on the fuel solenoid. I have meausred mine with a clamp meter at 7 AMPs. If OP has the Cat OEM alternator(s) at 55 AMPs max and a more realistic 25 - 27 AMPs output at cruise speed then 7 AMPs plus the normal running loads there isn't much left to charge the house bank.

Back to the OPs engine not shutting down. If he has the same 7 AMP solenoid draw I have observed that's a pretty heavy load on the key switch if it wasn't designed for that load.
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Old 10-12-2021, 09:33 AM   #12
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Its definitely an energize to run solenoid. I don't know if there may be a relay powering it or not.
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Old 10-12-2021, 09:45 AM   #13
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No solenoid would draw 7 amps continuously while running. You would be able to cook food on it for a little while until it smoked. On DC solenoids the whole coil is energized only to reposition the slug then most of the coils are cut out with an internal contact to a small fraction of the current to maintain the position. So 7 amps to move it to Run position then 1 or less to hold it there.
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Old 10-12-2021, 10:21 AM   #14
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On the 3126 Cats the fuel solenoid receives power from a little relay that is located on the junction box mounted on the engine. I believe it's a pretty common Bosch relay about 8 bucks at an auto parts store... It may be that that may be applicable to the 3208 also...
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Old 10-12-2021, 10:48 AM   #15
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Originally Posted by Ka_sea_ta View Post
On the 3126 Cats the fuel solenoid receives power from a little relay that is located on the junction box mounted on the engine. I believe it's a pretty common Bosch relay about 8 bucks at an auto parts store... It may be that that may be applicable to the 3208 also...
It does have a smaller relay near the oil filters that I don't know what it does yet
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Old 10-12-2021, 02:36 PM   #16
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Google 3208 fuel solenoid wiring diagram...look under images.
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Old 10-12-2021, 04:48 PM   #17
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Well i think i may have figured it out.
I have a 3" manual and i got better answers here..
It has a relay between the ignition and the fuel solenoid that seems to be the issue.
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Old 10-18-2021, 01:04 PM   #18
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Quote:
Originally Posted by Doodie99 View Post
So I was very happy that my 3208 started yesterday after a long time idle. It's a new boat to me so I am still working on issues but I did start up the cat yesterday. It sounds pretty good. I only wanted to run briefly to verify operational since I bought it without seeing it run. It started in about 10 seconds of cranking so that was great. It ran smoothly so I was satisfied until I turned off the key and it kept running. It doesn't have a stop button so I just disconnected the fuel solenoid. I must say the wiring diagrams in my manual is a bit rough to follow.
Any thoughts?
There is likely a switch you have to leave on to turn off the engine (I have one). If it is off, the engine will not turn off. Secondly, there is a button on top of the engine that you can press to turn engine off. Not sure where you're is located but it is likely located on top.....look around and you're likely to locate it. I have 3208's too.
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Old 10-18-2021, 05:09 PM   #19
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On my 3208, you must leave the key "on". Turn off engine by pressing the "stop" button. Engine shuts down, you get oil, over heat alarms until you turn the key "off."Click image for larger version

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Old 10-18-2021, 05:52 PM   #20
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One thing that can happen and people rarely notice is a stuck Stop switch. Make sure the Stop switch fully returns to the normal position after pushing. I find my Stop switches hang occasionally. I have learned that if my engine cranks for more than 3 seconds to double check the Stop switch.
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