FUEL LEVEL SENSOR FAIL
Gillette
Fuel Level Sender Circuit Fault
Controller displays FUEL LEVEL SENSOR FAIL or FUEL SENDER ERROR; fuel gauge reads empty or full regardless of actual level.
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Safety Warning
This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.
If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.
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Possible Causes
Failed fuel level sender in tank, Open or shorted sender wiring, Poor ground at tank
How to Fix / Troubleshooting
Safety first: Turn OFF the generator, disconnect battery negative, and avoid sparks near the fuel tank.
Steps:
- Access sender: On the Gillette base tank, remove the access cover to reach the fuel level sender mounted on top of the tank.
- Check wiring and ground: Ensure the sender ground strap is secure to the tank and that signal wires are intact and firmly connected.
- Test sender: Move the float arm manually (if accessible) and measure resistance between sender terminals. Compare to spec; no change or infinite resistance indicates failure.
- Replace sender: Remove the sender mounting screws, lift out the unit carefully, and install a new sender with a fresh gasket. Reconnect wiring and test.
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Repair Difficulty
Medium
3/5
Required Part
Fuel Level Sender
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