Fuel sender troubleshooting

CJ Martin

Member
Oct 4, 2006
762
Great Mills, MD
Boat Info
2002 320DA
Engines
350MAG Horizons / V-drives
I have a problem with my starboard fuel guage reading empty even with a full tank. It worked fine all last year, so something must have happened during layup.

I hooked up an ohmmeter at the guage side and read 256 on the starboard and 30 on the port side (port side is also fine, and works). Disconnected the starboard tank sender and read 256 ohms directly at the sender. That would seem to rule out the wiring to the guage and the guage itself. I pulled the sender out of the tank but didn't see anything obviously wrong, so I put it all back together.

Right now I'm guessing the sender is bad. Am I missing anything else? Doesn't seem much else it could be. :smt017

I am "lucky" in that this is the starboard sender - it's pretty easy to get to and there is ample room above the tank to pull the sender out. The port tank and sender are buried with very little room above the sender - the only ways I see to change that sender would be to either remove all the vaccuflush tanks, hot water heater and water manafold, then slide the tank aft OR cut an access hole under the starboard forward seat. :smt013

-CJ
 
Chris,

The easiest way to check the sender/wiring is to connect a jumper from the sender terminal to the tank ground. The gauge should read full deflection, like way past full, if the wiring and gauge is ok. If it does, you have found the problem. Order a sender from Sea Ray.
 
Frank,
Well that should be easy enough. Thanks!

Assuming it is the sender, any tips on installing the new one?

-CJ
 
Nope........I'm sure you've already guess that the hardest part is getting access. The senders usually have an elbow or bend about 1/2 way up to let he float swing, so access only needs to be a portion of the tank height. On some DA's it is easier to get access by removing the hull vents on the side of the boat than fishing the sender out of of the tank in the bilge.

Sorry I'm not more help...............
 
CJ Martin said:
I hooked up an ohmmeter at the guage side and read 256 on the starboard and 30 on the port side (port side is also fine, and works). Disconnected the starboard tank sender and read 256 ohms directly at the sender. That would seem to rule out the wiring to the guage and the guage itself. I pulled the sender out of the tank but didn't see anything obviously wrong, so I put it all back together.

Right now I'm guessing the sender is bad. Am I missing anything else? Doesn't seem much else it could be. :smt017

-CJ

When you had the sender out, did you vary the position of the swing arm and check that the resistance from the electrical terminal to the unit body varies from 256 ohms to about 30 ohms, or just stays at 256 ohms? It if varies as it should, then it would indicate that the arm is not being operated by the float. Is the float intact? If it does not vary, then it has an electrical problem.

This thread belongs in the electrical section.
 
When I had the sender out I wasn't able to get a meter on it as I was trying not to get gas everywhere. I was able to verify the arm was not stuck and the float was not full of gas.

Today at lunch I tried Frank's trick and the gauge went to above full. New sender ordered, hopefully it will be here by the weekend.

-CJ
 
Update - got the new sender installed Friday afternoon. If only every problem were this easy to troubleshoot & repair! Went very smoothly and the analog guage works again.

Next project - hooking up both tank senders to the Smartcraft system...

-CJ
 

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