[C320-list] C320-list Digest, Vol 4708, Issue 1, fuel gauge malfunction?

Wed Aug 14 14:47:39 PDT 2024

Hello Mike, 

We have had a similar issue where the needle showed way over full. Before going into a lot of work changing the fuel tank sender, you might first check the meter itself. Ours appeared to have died, so replacing that was a lot easier and cheaper as well…!

Rob van Dorp en Annemiek Lambers
BONVIEVENT
Hull 534
The Netherlands
(Sent from my iPhone)

> Op 14 aug 2024 om 22:02 heeft c320-list-request at lists.catalina320.com het volgende geschreven:
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> Today's Topics:
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>   1. Fuel tank gauge malfuction (mmellon)
>   2. Re: Fuel tank gauge malfuction (Ferris Wills)
>   3. Re: Fuel tank gauge malfuction (Ferris Wills)
>   4. Re: Fuel tank gauge malfuction (Greg Flanagan)
>   5. Re: Fuel tank gauge malfuction (john at frostnet.net)
>   6. Re: Fuel tank gauge malfuction (Joe Grande)
>   7. Re: Fuel tank gauge malfuction (Joe Grande)
>   8. Re: Fuel tank gauge malfuction (Dave Hupe)
> 
> 
> ----------------------------------------------------------------------
> 
> Message: 1
> Date: Wed, 14 Aug 2024 11:07:13 -0700
> From: mmellon <mmellon at cruzio.com>
> To: c320-list at lists.catalina320.com
> Subject: [C320-list] Fuel tank gauge malfuction
> Message-ID: <1723658844-540418 at mid.hostedemail.com>
> Content-Type: text/plain; charset=utf-8
> 
> Hi all. My cockpit fuel gauge spontaneously started reading full (actually above full, completely to the extreme right full scale) when i know the tank is not actually full.Removing the pink lead from the gauge results in a zero reading (needle at extreme left. I haven't gotten any further with testing at this point but will. The resistance measured from the disconnected pink lead to ground is 23 ohms, corresponding approximately to a full tank I think.I am suspicious that the float in the tank is either mechanically stuck in full tank position or is defective.1996 Hull number 324. 19-20 gal tank.Does anyone have comment on this? How difficult is it to replace the entire sender unit, leak-free?? If i just remove the sender from the tank, is the gasket reusable? If not, are replacement gaskets available? Is the entire replacement sender from catalina direct compatible?Thanks in advance.MikeSent from my Galaxy:Mike Mellon?
> 
> ------------------------------
> 
> Message: 2
> Date: Wed, 14 Aug 2024 11:27:02 -0700
> From: Ferris Wills <ferriswills707 at gmail.com>
> To: C320-List at catalina320.com
> Cc: c320-list at lists.catalina320.com, mmellon <mmellon at cruzio.com>
> Subject: Re: [C320-list] Fuel tank gauge malfuction
> Message-ID: <32C235EB-E95D-4C74-AFE1-230197D86E96 at gmail.com>
> Content-Type: text/plain;    charset=utf-8
> 
> Hi,
> 
> After running through the fuel gauge diagnostics described on the c320 site, I replaced the fuel sender on Argo(#505) with one ordered from Catalina Direct.
> 
> Removal of the old one required some contortionist moves from within the port lazarette but wasn?t too bad. Kit came with the required seal. Works well now, but I still maintain a written fuel log ???
> 
> Ferris
> Typos by iPhone
> 
>> On Aug 14, 2024, at 11:07?AM, mmellon via C320-list <c320-list at lists.catalina320.com> wrote:
>> 
>> ?Hi all. My cockpit fuel gauge spontaneously started reading full (actually above full, completely to the extreme right full scale) when i know the tank is not actually full.Removing the pink lead from the gauge results in a zero reading (needle at extreme left. I haven't gotten any further with testing at this point but will. The resistance measured from the disconnected pink lead to ground is 23 ohms, corresponding approximately to a full tank I think.I am suspicious that the float in the tank is either mechanically stuck in full tank position or is defective.1996 Hull number 324. 19-20 gal tank.Does anyone have comment on this? How difficult is it to replace the entire sender unit, leak-free?  If i just remove the sender from the tank, is the gasket reusable? If not, are replacement gaskets available? Is the entire replacement sender from catalina direct compatible?Thanks in advance.MikeSent from my Galaxy:Mike Mellon
> 
> 
> ------------------------------
> 
> Message: 3
> Date: Wed, 14 Aug 2024 11:27:02 -0700
> From: Ferris Wills <ferriswills707 at gmail.com>
> To: C320-List at catalina320.com
> Cc: c320-list at lists.catalina320.com, mmellon <mmellon at cruzio.com>
> Subject: Re: [C320-list] Fuel tank gauge malfuction
> Message-ID: <32C235EB-E95D-4C74-AFE1-230197D86E96 at gmail.com>
> Content-Type: text/plain;    charset=utf-8
> 
> Hi,
> 
> After running through the fuel gauge diagnostics described on the c320 site, I replaced the fuel sender on Argo(#505) with one ordered from Catalina Direct.
> 
> Removal of the old one required some contortionist moves from within the port lazarette but wasn?t too bad. Kit came with the required seal. Works well now, but I still maintain a written fuel log ???
> 
> Ferris
> Typos by iPhone
> 
>> On Aug 14, 2024, at 11:07?AM, mmellon via C320-list <c320-list at lists.catalina320.com> wrote:
>> 
>> ?Hi all. My cockpit fuel gauge spontaneously started reading full (actually above full, completely to the extreme right full scale) when i know the tank is not actually full.Removing the pink lead from the gauge results in a zero reading (needle at extreme left. I haven't gotten any further with testing at this point but will. The resistance measured from the disconnected pink lead to ground is 23 ohms, corresponding approximately to a full tank I think.I am suspicious that the float in the tank is either mechanically stuck in full tank position or is defective.1996 Hull number 324. 19-20 gal tank.Does anyone have comment on this? How difficult is it to replace the entire sender unit, leak-free?  If i just remove the sender from the tank, is the gasket reusable? If not, are replacement gaskets available? Is the entire replacement sender from catalina direct compatible?Thanks in advance.MikeSent from my Galaxy:Mike Mellon
> 
> 
> ------------------------------
> 
> Message: 4
> Date: Wed, 14 Aug 2024 12:34:17 -0600 (MDT)
> From: Greg Flanagan <greg.flanagan at shaw.ca>
> To: C320-List at catalina320.com
> Subject: Re: [C320-list] Fuel tank gauge malfuction
> Message-ID:
>    <1823342020.99159616.1723660457992.JavaMail.zimbra at cds216.dcs.int.inet>
>    
> Content-Type: text/plain;    charset=utf-8
> 
> Please keep apprised of what you learn. My fuel gauge (always a bit iffy) has recently locked on 1/4 full when I know the tank is full. I always fill on the basis of consumption ~ 1.75 litres/hr (.5 gals/hr) but it was nice that the fuel gauge was approximately close.
> 
> Thanks,
> 
> Greg
> Hoop Dancer #1076
> Sidney, BC
> 
>> On Aug 14, 2024, at 11:07?AM, mmellon via C320-list <c320-list at lists.catalina320.com> wrote:
>> 
>> ?Hi all. My cockpit fuel gauge spontaneously started reading full (actually above full, completely to the extreme right full scale) when i know the tank is not actually full.Removing the pink lead from the gauge results in a zero reading (needle at extreme left. I haven't gotten any further with testing at this point but will. The resistance measured from the disconnected pink lead to ground is 23 ohms, corresponding approximately to a full tank I think.I am suspicious that the float in the tank is either mechanically stuck in full tank position or is defective.1996 Hull number 324. 19-20 gal tank.Does anyone have comment on this? How difficult is it to replace the entire sender unit, leak-free?  If i just remove the sender from the tank, is the gasket reusable? If not, are replacement gaskets available? Is the entire replacement sender from catalina direct compatible?Thanks in advance.MikeSent from my Galaxy:Mike Mellon
> 
> ------------------------------
> 
> Message: 5
> Date: Wed, 14 Aug 2024 14:20:33 -0500
> From: <john at frostnet.net>
> To: <C320-List at Catalina320.com>
> Subject: Re: [C320-list] Fuel tank gauge malfuction
> Message-ID: <8df101daee7f$0902d9d0$1b088d70$@frostnet.net>
> Content-Type: text/plain;    charset="utf-8"
> 
> Mine has done the same since new. My memory is that Frank Buttler suggested the sender unit was put in 180 degrees from proper alignment. The sender hole pattern allows that. That puts the float in a position that it hits the wall before going all the way up. I never fixed mine because it is under the A/C unit and hard to reach.
> 
> 
> 
> John
> 2007 C320MKII
> Hull  #1118
> Lake Guntersville, AL
> 
> 
> 
> 
> -----Original Message-----
> From: C320-list <c320-list-bounces at lists.catalina320.com> On Behalf Of Greg Flanagan via C320-list
> Sent: Wednesday, August 14, 2024 1:34 PM
> To: C320-List at catalina320.com
> Cc: Greg Flanagan <greg.flanagan at shaw.ca>
> Subject: Re: [C320-list] Fuel tank gauge malfuction
> 
> Please keep apprised of what you learn. My fuel gauge (always a bit iffy) has recently locked on 1/4 full when I know the tank is full. I always fill on the basis of consumption ~ 1.75 litres/hr (.5 gals/hr) but it was nice that the fuel gauge was approximately close.
> 
> Thanks,
> 
> Greg
> Hoop Dancer #1076
> Sidney, BC
> 
>> On Aug 14, 2024, at 11:07?AM, mmellon via C320-list <c320-list at lists.catalina320.com> wrote:
>> 
>> ?Hi all. My cockpit fuel gauge spontaneously started reading full (actually above full, completely to the extreme right full scale) when i know the tank is not actually full.Removing the pink lead from the gauge results in a zero reading (needle at extreme left. I haven't gotten any further with testing at this point but will. The resistance measured from the disconnected pink lead to ground is 23 ohms, corresponding approximately to a full tank I think.I am suspicious that the float in the tank is either mechanically stuck in full tank position or is defective.1996 Hull number 324. 19-20 gal tank.Does anyone have comment on this? How difficult is it to replace the entire sender unit, leak-free?  If i just remove the sender from the tank, is the gasket reusable? If not, are replacement gaskets available? Is the entire replacement sender from catalina direct compatible?Thanks in advance.MikeSent from my Galaxy:Mike Mellon
> 
> 
> 
> ------------------------------
> 
> Message: 6
> Date: Wed, 14 Aug 2024 19:26:02 +0000
> From: Joe Grande <joe_grande at msn.com>
> To: "C320-List at catalina320.com" <C320-List at catalina320.com>
> Cc: Ferris Wills <ferriswills707 at gmail.com>,
>    "c320-list at lists.catalina320.com" <c320-list at lists.catalina320.com>
> Subject: Re: [C320-list] Fuel tank gauge malfuction
> Message-ID:
>    <BL1PR11MB597898C5A0504C4B8A9308C8E1872 at BL1PR11MB5978.namprd11.prod.outlook.com>
>    
> Content-Type: text/plain; charset="utf-8"
> 
> My experience on Whisper #772 with fuel readings over 21 years, has twice been the gauge. Getting continuity from the sending unit confirmed gauge problem.
> Joe Grande
> 2000 #772 Whisper
> Currently motoring up San Juan Channel in Washington State.
> 
> Sent from my T-Mobile 5G Device
> Get Outlook for Android<https://aka.ms/AAb9ysg>
> ________________________________
> From: C320-list <c320-list-bounces at lists.catalina320.com> on behalf of Ferris Wills via C320-list <c320-list at lists.catalina320.com>
> Sent: Wednesday, August 14, 2024 11:27:02 AM
> To: C320-List at catalina320.com <C320-List at catalina320.com>
> Cc: Ferris Wills <ferriswills707 at gmail.com>; c320-list at lists.catalina320.com <c320-list at lists.catalina320.com>
> Subject: Re: [C320-list] Fuel tank gauge malfuction
> 
> Hi,
> 
> After running through the fuel gauge diagnostics described on the c320 site, I replaced the fuel sender on Argo(#505) with one ordered from Catalina Direct.
> 
> Removal of the old one required some contortionist moves from within the port lazarette but wasn?t too bad. Kit came with the required seal. Works well now, but I still maintain a written fuel log ???
> 
> Ferris
> Typos by iPhone
> 
>> On Aug 14, 2024, at 11:07?AM, mmellon via C320-list <c320-list at lists.catalina320.com> wrote:
>> 
>> ?Hi all. My cockpit fuel gauge spontaneously started reading full (actually above full, completely to the extreme right full scale) when i know the tank is not actually full.Removing the pink lead from the gauge results in a zero reading (needle at extreme left. I haven't gotten any further with testing at this point but will. The resistance measured from the disconnected pink lead to ground is 23 ohms, corresponding approximately to a full tank I think.I am suspicious that the float in the tank is either mechanically stuck in full tank position or is defective.1996 Hull number 324. 19-20 gal tank.Does anyone have comment on this? How difficult is it to replace the entire sender unit, leak-free?  If i just remove the sender from the tank, is the gasket reusable? If not, are replacement gaskets available? Is the entire replacement sender from catalina direct compatible?Thanks in advance.MikeSent from my Galaxy:Mike Mellon
> 
> ------------------------------
> 
> Message: 7
> Date: Wed, 14 Aug 2024 19:26:02 +0000
> From: Joe Grande <joe_grande at msn.com>
> To: "C320-List at catalina320.com" <C320-List at catalina320.com>
> Cc: Ferris Wills <ferriswills707 at gmail.com>,
>    "c320-list at lists.catalina320.com" <c320-list at lists.catalina320.com>
> Subject: Re: [C320-list] Fuel tank gauge malfuction
> Message-ID:
>    <BL1PR11MB597898C5A0504C4B8A9308C8E1872 at BL1PR11MB5978.namprd11.prod.outlook.com>
>    
> Content-Type: text/plain; charset="utf-8"
> 
> My experience on Whisper #772 with fuel readings over 21 years, has twice been the gauge. Getting continuity from the sending unit confirmed gauge problem.
> Joe Grande
> 2000 #772 Whisper
> Currently motoring up San Juan Channel in Washington State.
> 
> Sent from my T-Mobile 5G Device
> Get Outlook for Android<https://aka.ms/AAb9ysg>
> ________________________________
> From: C320-list <c320-list-bounces at lists.catalina320.com> on behalf of Ferris Wills via C320-list <c320-list at lists.catalina320.com>
> Sent: Wednesday, August 14, 2024 11:27:02 AM
> To: C320-List at catalina320.com <C320-List at catalina320.com>
> Cc: Ferris Wills <ferriswills707 at gmail.com>; c320-list at lists.catalina320.com <c320-list at lists.catalina320.com>
> Subject: Re: [C320-list] Fuel tank gauge malfuction
> 
> Hi,
> 
> After running through the fuel gauge diagnostics described on the c320 site, I replaced the fuel sender on Argo(#505) with one ordered from Catalina Direct.
> 
> Removal of the old one required some contortionist moves from within the port lazarette but wasn?t too bad. Kit came with the required seal. Works well now, but I still maintain a written fuel log ???
> 
> Ferris
> Typos by iPhone
> 
>> On Aug 14, 2024, at 11:07?AM, mmellon via C320-list <c320-list at lists.catalina320.com> wrote:
>> 
>> ?Hi all. My cockpit fuel gauge spontaneously started reading full (actually above full, completely to the extreme right full scale) when i know the tank is not actually full.Removing the pink lead from the gauge results in a zero reading (needle at extreme left. I haven't gotten any further with testing at this point but will. The resistance measured from the disconnected pink lead to ground is 23 ohms, corresponding approximately to a full tank I think.I am suspicious that the float in the tank is either mechanically stuck in full tank position or is defective.1996 Hull number 324. 19-20 gal tank.Does anyone have comment on this? How difficult is it to replace the entire sender unit, leak-free?  If i just remove the sender from the tank, is the gasket reusable? If not, are replacement gaskets available? Is the entire replacement sender from catalina direct compatible?Thanks in advance.MikeSent from my Galaxy:Mike Mellon
> 
> ------------------------------
> 
> Message: 8
> Date: Wed, 14 Aug 2024 19:27:39 +0000 (UTC)
> From: Dave Hupe <hoopdtwo at yahoo.com>
> To: C320-List at Catalina320.com
> Subject: Re: [C320-list] Fuel tank gauge malfuction
> Message-ID: <814361099.7834407.1723663659545 at mail.yahoo.com>
> Content-Type: text/plain; charset=UTF-8
> 
> My guage never worked since I bought our boat in 2017. Although I planned to someday figure it out, I (like Greg) have tracked my engine hours (Perkins M30)? to decide when to refuel.? My records indicate a very steady and reliabke consumption of about 0.4 gallons average per hour running.?
> Dave Hupe?
> 1994 C320 #32
> 
> Yahoo Mail: Search, Organize, Conquer
> 
>  On Wed, Aug 14, 2024 at 2:34 PM, Greg Flanagan via C320-list<c320-list at lists.catalina320.com> wrote:   Please keep apprised of what you learn. My fuel gauge (always a bit iffy) has recently locked on 1/4 full when I know the tank is full. I always fill on the basis of consumption ~ 1.75 litres/hr (.5 gals/hr) but it was nice that the fuel gauge was approximately close.
> 
> Thanks,
> 
> Greg
> Hoop Dancer #1076
> Sidney, BC
> 
>> On Aug 14, 2024, at 11:07?AM, mmellon via C320-list <c320-list at lists.catalina320.com> wrote:
>> 
>> ?Hi all. My cockpit fuel gauge spontaneously started reading full (actually above full, completely to the extreme right full scale) when i know the tank is not actually full.Removing the pink lead from the gauge results in a zero reading (needle at extreme left. I haven't gotten any further with testing at this point but will. The resistance measured from the disconnected pink lead to ground is 23 ohms, corresponding approximately to a full tank I think.I am suspicious that the float in the tank is either mechanically stuck in full tank position or is defective.1996 Hull number 324. 19-20 gal tank.Does anyone have comment on this? How difficult is it to replace the entire sender unit, leak-free?? If i just remove the sender from the tank, is the gasket reusable? If not, are replacement gaskets available? Is the entire replacement sender from catalina direct compatible?Thanks in advance.MikeSent from my Galaxy:Mike Mellon
> 
> 
> 
> End of C320-list Digest, Vol 4708, Issue 1
> ******************************************