Katerina Swanson
Dual fuel tanks are a fuel system that allows a vehicle to have two fuel tanks, which can be switched between while driving. This setup is common in trucks and other large vehicles, such as Ford F-150 models from the 1980s and 1990s, and military vehicles like the M1028 and M1031. The tanks can be plumbed together with a Y connector for a single fuel supply, or they can be manually switched between with a valve. The gauge will indicate the level of the tank currently in use, but this may not be accurate if the gauge or wiring is faulty.
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What You'll Learn
Dual fuel tanks can be switched between manually
One way to set up dual fuel tanks is to keep them separate and use a transfer pump and momentary switch. This allows for control over which tank is being used and when. Another way is to simply plumb the two tanks together for one larger fuel supply. This can be done by joining the supply lines from both tanks with a Y connector, as well as the return lines, and connecting the vent lines between the two tanks. This allows for equilibrium between the two tanks so that the fuel level on both sides stays the same.
It is possible to switch between dual tanks while driving. However, it is best not to wait until one tank runs dry, as there is a chance that the fuel from the next tank will not make it to the fuel bowl/filter in time before the engine dies. It is recommended to switch when one tank is below a quarter full. Additionally, it is important to note that when refuelling, fuel must be added to both tanks to maintain equilibrium. If only one tank is filled, the tanks will not equalize and fuel will not flow back down into the other tank.
Some vehicles with dual fuel tanks have a switch to control which tank is being used. This switch may be located in a compartment behind the driver's seat, in the splash well, or on the transom in the rear. The control pad can tell how much fuel is in each tank, allowing the driver to set it to run on the tank with the most fuel.
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A Y connector can join supply lines from both tanks
A Y-connector can be used to join the supply lines from both tanks, as well as the return lines, while the vent lines can be connected between the two tanks. This plumbing design would allow both tanks to maintain equilibrium, keeping the fuel level on both sides the same. The fuel gauge would still indicate the same fuel level in the OEM tank, but it would be indicating a higher fuel capacity. For example, a user installing an auxiliary fuel tank on their M1028 vehicle mentioned that the Y-connector setup would allow their fuel gauge to indicate a level of 40 gallons instead of 20.
This setup can be beneficial in maintaining equal fuel levels in both tanks, but it may come with certain challenges. For instance, filling up both tanks can be inconvenient, as it requires filling up on one side and then turning the vehicle around to fill up the other side. Additionally, when using a Y-connector to join the supply lines, it is important to ensure that the tanks are at the same level to ensure the proper functioning of the system.
Another user mentions that road tractors (semis) have employed a similar approach by drawing fuel from a single side and utilising an equalizing line at the bottom of the tanks to maintain equal fuel levels. This method can also be applied to dual fuel tank setups to achieve equilibrium.
By utilising a Y-connector to join the supply lines, return lines, and vent lines between the two tanks, a balanced fuel level can be achieved. This setup can be advantageous in ensuring a consistent fuel level across both tanks, providing a higher overall fuel capacity while still relying on the existing fuel gauge. However, it is important to carefully consider the tank positioning and fill up procedure to ensure a smooth implementation.
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A dual port valve can be added to switch between tanks
A dual port valve can be added to switch between the two tanks in a dual fuel tank system. This is a manual process and can be achieved with a 3-port or 6-port valve. The 3-port valve has two inlets and one outlet, while the 6-port valve will also switch the return lines. The valve can be mounted under the cab, with the lever coming through a rubber grommet in the cab floor, allowing for easy access. This setup also allows for passive anti-theft, as the valve has an off position.
The plumbing design of a dual fuel tank system can be configured in different ways. One way is to join the supply lines from both tanks with a Y-connector, as well as the return and vent lines. This creates equilibrium between the two tanks, keeping the fuel level the same on both sides. Another method is to use a transfer pump and a momentary switch to connect the tanks.
A dual fuel tank setup allows for the use of two separate fuel tanks, drawing fuel from only one tank at a time. This can be achieved with a dual tank switching valve, which has one valve located between the fuel pump and the fuel tank. This setup is suitable for gasoline or diesel fuels and works with 12-volt systems.
The GROCO FV-Series Six-Port Fuel Valve is an example of a valve that can be used in a dual fuel tank setup. It is made of bronze and is suitable for marine use. It is important to note that some dual tank switching valves are not suitable for marine use or for systems with fuel return lines.
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The fuel gauge may not accurately reflect the amount of fuel
Additionally, issues with the float or float arm in the fuel tank can lead to inaccurate fuel gauge readings. The float arm may become stuck at certain levels, causing the fuel gauge to fluctuate between empty and full. In some cases, the float or float arm can break, leading to consistently incorrect or fluctuating fuel level indications.
Corroded or loose wires connected to the sending unit can also contribute to inaccurate fuel gauge readings. Over time, especially in harsh weather conditions or due to exposure to salt, the wires can become damaged or disconnected, affecting the accuracy of the fuel level signal transmitted to the gauge.
In some instances, the issue may lie with the fuel gauge itself. A faulty or malfunctioning fuel gauge may not accurately reflect the fuel level, even when the sending unit and related components are functioning correctly. This can occur due to electrical problems or mechanical failures within the gauge itself.
Finally, a bad fuse in the vehicle's electrical system can also impact the accuracy of the fuel gauge. If the fuse is faulty, it can affect the fuel gauge's reading, as well as the functionality of other nearby instruments on the dashboard, such as the oil gauge.
To diagnose and rectify these issues, it is advisable to consult a qualified mechanic. They can perform tests, inspections, and repairs to identify and resolve the specific problem causing the fuel gauge to display inaccurate fuel levels.
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Dual fuel tanks can be gravity-fed
Gravity-fed dual fuel tanks are a viable option for fuel storage and supply. This system involves two tanks, often referred to as saddle tanks, which are typically mounted on either side of a vehicle, with one tank on each side. Each of these tanks can be gravity-fed, supplying fuel to the engine. This setup is particularly useful when space is limited, as the tanks can be installed in areas such as wheel wells.
The gravity-fed mechanism is a simple and efficient way to manage fuel. It involves a ball valve system that allows fuel to drain from one tank into another. In this configuration, the auxiliary tank, often smaller, feeds fuel into the main tank. This process is driven by gravity, with fuel flowing from the higher tank into the lower one. This transfer ensures a consistent fuel level across both tanks, maintaining equilibrium.
To further enhance the functionality of gravity-fed dual fuel tanks, a manual dual-port valve can be employed. This valve enables the switching between the two tanks, providing flexibility in fuel usage. Additionally, a marine valve can be utilised to manage both the supply and return lines, offering a comprehensive solution for fuel transfer.
The plumbing design of gravity-fed dual fuel tanks is a critical aspect. By utilising a Y connector, the supply lines from both tanks can be joined together, promoting fuel equilibrium. Similarly, the return lines and vent lines can also be connected between the tanks, ensuring a cohesive fuel system. This setup allows for a unified fuel level reading on the dash gauge, providing accurate fuel level indications for the combined fuel supply.
Gravity-fed dual fuel tank systems offer a straightforward and effective approach to fuel management. They are particularly advantageous in constrained spaces and can be customised with various valve and plumbing configurations to suit specific requirements. These systems are a testament to the ingenuity of automotive engineering, providing efficient fuel storage and supply solutions for a range of vehicles.
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Frequently asked questions
There are different ways to plumb dual fuel tanks. One way is to use a transfer pump and momentary switch to keep the tanks separate. Another way is to simply plumb the tanks together for one large fuel supply by joining the supply lines, return lines, and vent lines.
Dual fuel tanks allow for a larger fuel supply and can be switched between when one tank is running low.
The installation of dual fuel tanks involves the consideration of mounting location, valving, switching, and plumbing.
