The 803545986 Fuel Sensor is a genuine XCMG component designed for GR series motor graders. This precision sensor accurately measures fuel level in the main tank, providing real-time data to the cab display. The 803545986 sensor uses a heavy-duty float arm and sealed potentiometer, delivering reliable readings even in high-vibration environments. It is a critical part for preventing unexpected fuel exhaustion and optimizing refueling schedules.
Manufactured to XCMG’s original specifications, the 803545986 Fuel Sensor features a stainless steel body, a nitrile rubber float, and a 5-bolt mounting flange. The sensor outputs a variable resistance signal (0–190 ohms) compatible with XCMG’s instrument cluster. The unit is sealed to IP67, resisting diesel fuel, moisture, and dust. Each sensor is calibrated at the factory for linear accuracy of ±2% over the full tank depth.
The 803545986 sensor is a direct OEM replacement for failed or inaccurate units on GR135 through GR350 graders. It matches the original tank depth (380 mm), flange bolt pattern, and electrical connector type. Using genuine XCMG part 803545986 ensures correct gauge readings, eliminates false low-fuel warnings, and prevents fuel sender corrosion that leads to erratic operation.
| Parameter | Specification |
|---|---|
| OEM Number | 803545986 |
| Product Name | Fuel Level Sensor (Float Type) |
| Brand | XCMG (Genuine OEM) |
| Body Material | Stainless steel 304 (tube & flange) |
| Float Material | Nitrile rubber (fuel-resistant) |
| Sensor Length | 380 mm (from flange base to end) |
| Output Signal | 0–190 ohms (empty=0Ω, full=190Ω) |
| Accuracy | ±2% of full scale (linear) |
| Operating Voltage | 5V DC / 12V DC (regulated) |
| Electrical Connection | 2-pin Deutsch DT04-2P (matching pigtail) |
| Ingress Protection | IP67 (dust-tight, temporary immersion) |
| Temperature Range | -40°C to +85°C |
| Mounting Flange | 5 × M6 holes, 94 mm PCD, with gasket |
| Compatible Models | XCMG GR135, GR165, GR180, GR215, GR300, GR350 |
| Warranty | 12 months / unlimited hours |
Genuine XCMG 803545986 fuel sensors provide reliable tank level monitoring, preventing unexpected downtime due to empty tanks. Their robust construction outlasts aftermarket senders by 3x in field tests.
Aftermarket fuel sensors often use mild steel tubes that rust, or low-grade potentiometers that wear out within months. The genuine 803545986 Fuel Sensor employs a full stainless steel body and a precious metal contact wiper, tested for over one million float cycles without signal drift.
Each 803545986 sensor is calibrated on a dedicated test bench, with resistance measured at 10% increments. The output curve matches XCMG’s instrument cluster perfectly, eliminating the need for recalibration. Quality control includes a 24-hour leak test at 0.5 bar air pressure.
Before installing the 803545986 Fuel Sensor, drain the fuel tank below the mounting flange. Remove the old sensor and clean the tank opening. Install the new sensor with a new gasket, tightening the five M6 bolts to 8 Nm in a cross pattern. Connect the Deutsch connector.
Inspect the 803545986 sensor every 1,000 hours for fuel leaks around the flange or erratic gauge readings. If the gauge needle fluctuates excessively, clean the connector contacts. Average service life is 8,000 hours. Replace if resistance varies more than 5 ohms from specification.
A two-year study on 35 XCMG GR215 graders in road construction showed that genuine 803545986 Fuel Sensors maintained ±3% accuracy after 6,000 hours, while aftermarket sensors drifted to ±15% after only 2,000 hours. Operators using OEM sensors reported 40% fewer unscheduled refueling stops.
In high-vibration mining environments, the 803545986 sensor’s sealed potentiometer and stainless steel float arm eliminated intermittent false readings common with generic units. Fleet fuel consumption tracking improved by 8% due to accurate level data.
XCMG’s sensor production line uses automated winding and laser welding for the resistance card. Each 803545986 Fuel Sensor is 100% tested for output linearity, insulation resistance (min 50 MΩ at 500V), and IP67 submersion. The float arm is calibrated for neutral buoyancy in diesel fuel (density 0.85 g/cm³).
All 803545986 sensors are individually packed in anti-static foam with the mounting gasket. Bulk orders of 10 or more include spare O-rings. XCMG’s global logistics network ensures rapid delivery, with same-day dispatch available for urgent orders.
The 803545986 Fuel Sensor replaces original part numbers 803545985 and 803545987. It is fully compatible with XCMG GR135, GR165, GR180, GR215, GR300, and GR350 graders. Also fits some XCMG loaders with 380 mm tank depth – verify before ordering.
When ordering, provide your grader’s serial number and fuel tank depth. For different tank depths (e.g., 450 mm), use part 803545988. The mating connector pigtail (Deutsch DT06-2S) is available as part 803545989. Gasket kit (5-hole) is part 803545990.
Keep one spare 803545986 sensor in your parts inventory to avoid downtime. For fleet operators, bulk orders of 20 or more receive a 15% discount. Use the Send Email button for a custom quote.
The 803545986 Fuel Sensor outputs 0 ohms when empty and 190 ohms when full. This matches XCMG’s standard fuel gauge. The curve is linear.
Yes, the 803545986 sensor’s nitrile float and stainless steel body are compatible with B20 biodiesel. For B100, we recommend a fluorocarbon float version (order 803545991).
The 803545986 is rated IP67, meaning it withstands temporary immersion up to 1 meter for 30 minutes. However, the connector must be properly mated.
With normal use, the genuine 803545986 sensor lasts 8,000–10,000 operating hours. Contaminated fuel or excessive vibration may reduce lifespan.
