Smartcraft System-Fuel Gauge

Discussion in 'General Discussion' started by secret agent, May 21, 2009.

  1. secret agent

    secret agent Member

    49
    Dec 28, 2008
    Harrison Township MI
    1999 Sundancer 310
    Island Time
    Twin 5.7 Mercruiser Magnum MPI
    :smt100Ok, I need the power of the board to help me through this.

    2004 Sea Ray Sundancer 280
    Brand new motors 2008 due to improper winterizing prior year.
    Smartcraft system in which all gauges seem to be working.
    getting fault message Fuel Fault.
    Fuel gauge(small 2inch gauge) not working. Only 1 of the link wires is connected.
    I ve checked mercury and got wiring diagrams for tach/speedo
    only.
    Can't find any linking diagrams for fuel.

    Boat mech says that there is not wiring from the fuel tank???
    How could Sea Ray not have any wiring to the fuel gauge??:smt021

    Is there something else I should be looking for.
    Found a Fuel gauge wiring harness online but its for a 2 tank
    system. We only have 1 tank.

    Any suggestion would be greatly appreciated and thank you in advance for your help.

    Secret Agent
     
  2. Henry Boyd

    Henry Boyd Well-Known Member PLATINUM Sponsor

    Apr 24, 2007
    Newburyport, on the peaceful and serene Merrimack
    02' 280 DA
    496 w BIII
    Secret Agent,

    The original fuel gauge was wired directly into the boat's wiring harness. The Smartcraft gauge goes through the engine harness and ECM. You need the two tank harness from Mercury. You will only use one lead for fuel. If you want to add a sender to your freash water tank in the future, you can plug it into the other tank wire and calibrate SC to show fresh water volume. But for now just seal the end and wrap it up.

    Next you need to find the wire that goes from the old fuel gauge to the the gas tank sending unit. I seem to recall it is pink. There will also be very small lettering on it that says 'fuel'. You then have to cut that wire, and splice the end that goes to the fuel tank to the proper wire on the new SC tank harness.

    You MUST get the correct end. For this reason when I retrofitted our 280 with SC, I found the easiest place to get to the pink wire was under the dash at the helm. I then ran a splice from there to the tank harness in the engine compartment.

    Then you need to calibrate the fuel tank. There are two methods, 'default' and one where you fill the tank in increments. I went with default and it seems to have worked out pretty well. The 280 tanks are pretty symetrical, so the same vertical travel of the float on the sender corresponds to a uniform change in volume.

    Henry
     
  3. secret agent

    secret agent Member

    49
    Dec 28, 2008
    Harrison Township MI
    1999 Sundancer 310
    Island Time
    Twin 5.7 Mercruiser Magnum MPI
    Thanks Henry for the input.
    This boat came with Smartcraft and don't understand
    how the fuel guage could not have ever worked.
    It just frustrates me how the mechanic can't figure it out.
     
  4. Henry Boyd

    Henry Boyd Well-Known Member PLATINUM Sponsor

    Apr 24, 2007
    Newburyport, on the peaceful and serene Merrimack
    02' 280 DA
    496 w BIII
    Is the fuel gauge Smartcraft? I got the impression that the Smartcraft was installed because your new engines had it. Did the boat have Smartcraft from the beginning?

    Henry
     
  5. secret agent

    secret agent Member

    49
    Dec 28, 2008
    Harrison Township MI
    1999 Sundancer 310
    Island Time
    Twin 5.7 Mercruiser Magnum MPI
    Yes the gauge has the smartcraft links on it.

    Boat came with the SC system.
     
  6. STIHLBOLTS

    STIHLBOLTS New Member TECHNICAL Contributor PLATINUM Sponsor

    Oct 3, 2006
    Panama City Beach Fl/ South Ga
    2004 - 220 Sundeck
    5.0L w/Bravo 3 Drive
    2004 all the sport boats and sport cruisers came with gages that were smart craft ready.
     
  7. Woody

    Woody Well-Known Member PLATINUM Sponsor

    Nov 20, 2007
    N. Wisconsin/Lk Superior
    2005 420DA
    Cummins 6CTA8.3
    Didn't you just have them put this gauge in about a month ago? Your mechanic says there are no wires from the tank. Check for yourself, pull the round access plate for the sending unit in the aft berth floor and see what you find.
     
  8. flflatrate

    flflatrate New Member

    305
    May 21, 2009
    pompano florida
    2003 240 sundeck
    5.o MPI
    if you installed new motors in 08 compared to your old motors there should be a 2 pin plug behind the stb. motor that isn't hooked up. In that 3 pin plug should be only 1 wire that is pink and I think it should be the center pin. On the new motor there isn't a 3 pin hook up for the fuel you have to buy an adapter harness because the new motor is a ( i think 6 pin) transom harness and it will have a spot to hook it up to.
     
  9. CJ Martin

    CJ Martin Member

    762
    Oct 4, 2006
    Great Mills, MD
    2002 320DA
    350MAG Horizons / V-drives
    Concur with flflaterate - it sounds like the plug at the engine isn't connected. Might have been missed when the engines were swapped.

    -CJ
     
  10. secret agent

    secret agent Member

    49
    Dec 28, 2008
    Harrison Township MI
    1999 Sundancer 310
    Island Time
    Twin 5.7 Mercruiser Magnum MPI
    Thank you everyone for your input. Will check to see what
    we have going on and will report back.
     
  11. secret agent

    secret agent Member

    49
    Dec 28, 2008
    Harrison Township MI
    1999 Sundancer 310
    Island Time
    Twin 5.7 Mercruiser Magnum MPI
    When we purchased the boat it had a fuel gauge with a cracked bezel.
    Dealer made good and replaced with new fuel gauge but can't figure how to connect it properly.
    Both motors were replaced with brand new 2008 motors so I am sure they had some difficulties with 2004 SC systems

    Will check to see the wiring connections are all set.
     
  12. flflatrate

    flflatrate New Member

    305
    May 21, 2009
    pompano florida
    2003 240 sundeck
    5.o MPI
    there is an additional harness needed for the newer style motor to hook it up to the old wiring. If needed pm me and I can get you part number
     
  13. secret agent

    secret agent Member

    49
    Dec 28, 2008
    Harrison Township MI
    1999 Sundancer 310
    Island Time
    Twin 5.7 Mercruiser Magnum MPI
    Ok found the pink and blue wire. Not connected
    to anything.
    I think that the boat mech is having trouble getting the
    right harness for the engine connection.

    Hopefully we will get this figured out soon. Not liking
    no fuel guauge.
     
  14. flflatrate

    flflatrate New Member

    305
    May 21, 2009
    pompano florida
    2003 240 sundeck
    5.o MPI
    behind motor should just be 1 pink wire from the boat. If your mechanic is merc certified and is a dealer tell him to call merc tech and talk to steve pavey. He is a great connection and will help. He will get the correct part number for him in a few seconds
     
  15. flflatrate

    flflatrate New Member

    305
    May 21, 2009
    pompano florida
    2003 240 sundeck
    5.o MPI
    here is a pic of the plug that should be on your motor. [​IMG]
    and here is the part number of the harness you need to hook up to the pink sender wire 84-865891t02 $83.25 list price
     
  16. secret agent

    secret agent Member

    49
    Dec 28, 2008
    Harrison Township MI
    1999 Sundancer 310
    Island Time
    Twin 5.7 Mercruiser Magnum MPI
    Thanks for all your help flflatrate:thumbsup:
     
  17. flflatrate

    flflatrate New Member

    305
    May 21, 2009
    pompano florida
    2003 240 sundeck
    5.o MPI
    no problem. I would go crazy without a fuel gauge.
     

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