1. Industry Background
Excavators, loaders, and mining vehicles often operate under continuous vibration, dust, and long working hours. Fuel level affects not only operating range and dispatching but also refueling downtime, safety stock, and site management.
Construction-machinery fuel tanks vary in shape and depth. Equipment manufacturers and service providers therefore need a level-sensing element with customizable length, a simple structure, and flexible output options for connection to the original gauge or a control system.
The GLTV3 uses a magnetic float and reed-switch structure to convert level changes into resistance, voltage, or current signals. It is suitable for measuring diesel, lubricating oil, hydraulic oil, and similar media in equipment fuel tanks.
2. Industry Pain Points
Pain Point 1: Machinery vibration can cause complex sensor structures to fail
Construction machinery is exposed to sustained shock and vibration. Level solutions with complex structures and many connections may loosen, drift, or require frequent maintenance.
Pain Point 2: Different tank heights cannot be covered by one standard length
Tank depth and flange position vary between equipment platforms. A fixed-length sensor may leave measurement blind zones or interfere with tank structures.
Pain Point 3: Original gauges and controllers use different interfaces
Vehicles may use resistance gauges, 0–5 V, 4–20 mA, or other control interfaces. A single output type limits retrofit and OEM integration.
Pain Point 4: Manual fuel estimation disrupts replenishment planning
Relying on the operator's observation or experience can lead to refueling too early or too late, or even equipment shutdown caused by a low fuel level.
3. Recommended Product
The GLTV3 float moves up and down with the liquid surface. A magnet inside the float actuates the reed elements in the tube to produce an output corresponding to the liquid level. Its straightforward structure and clear maintenance path make it suitable for construction machinery, vehicles, marine equipment, and generator fuel tanks.
- Customizable 100–1500 mm range: The probe length can be configured according to tank depth, solving the dimensional differences between multiple equipment platforms.
- Reed switch and magnetic float structure: Reduces complex moving parts and submerged electronic modules, supporting long-term level detection on high-vibration equipment.
- Multiple output options: Supports 4–20 mA, 0–5 V, 0–190 Ω, and 240–33 Ω for compatibility with original gauges or PLCs.
- Selectable step accuracy: Available in 10 mm, and 21 mm specifications to balance accuracy, cost, and tank requirements.
- OEM installation adaptability: Flange, probe length, and alarm points can be configured for the project, reducing retrofit difficulty.
Key Selection Information
| Item | Configuration / Description |
|---|---|
| Measurement range | 100–1500 mm (OEM) |
| Outputs | 4–20 mA / 0–5 V / 0–190 Ω / 240–33 Ω |
| Step accuracy | 10 mm / 21 mm |
| Power supply | 10–36 VDC / 24 V |
| Typical media | Diesel, lubricating oil, hydraulic oil |
4. Customer Application Case
4.1 Project Background
A construction-machinery service provider wanted to upgrade fleet fuel tanks from manual estimation to gauge indication and low-level reminders. The equipment fleet included different models and tank depths, while some machines needed compatibility with original resistance gauges and others used newly installed controllers. The following is an anonymized typical project scenario.
4.2 Solution
Installation location: On the top flange of the fuel tank, with the probe entering vertically and the float free to travel through its full range without interference.
Product selection: GLTV3; the probe length is customized according to the measured depth of each tank, and the output is selected according to the original gauge or controller.
Monitoring objective: Provide continuous fuel-level indication and enable a replenishment reminder within a defined low-level range.
System integration: Resistance output connects to the original vehicle fuel gauge; 4–20 mA or 0–5 V connects to the controller, allowing the equipment-management terminal to create a refueling list.
4.3 Application Results and Acceptance Value
- 100–1500 mm customization One product series covers tanks of different depths and supports standardized spare parts across the fleet.
- Four output options Supports conventional gauges and digital controllers while reducing the need for additional signal conversion.
- Three step-accuracy options The appropriate specification can be selected according to tank capacity and management requirements.
- Visible online status Converts experience-based estimation into a readable level signal for replenishment planning and low-level reminders.
| Acceptance Dimension | Before Application | After Application |
|---|---|---|
| Measurement method | Experience-based or dispersed readings | A standardized measurement process matched to the product positioning |
| Data acquisition | Dependent on temporary operations | Repeatable results obtained at defined points or through defined procedures |
| Maintenance management | Action taken after a problem occurs | Inspection, recording, and abnormal-response actions included in routine management |
5. Solution Summary
The GLTV3 is suitable for construction-machinery fuel-tank projects that emphasize structural reliability, length customization, and interface compatibility. Before implementation, verify the effective tank depth, flange mounting pattern, medium, output matching, and float clearance, and establish the relationship between liquid level and remaining fuel through on-vehicle calibration.
Technical basis: GAMICOS GLTV3 official solution page—range, outputs, step accuracy, power supply, operating principle, and typical media.
