Sylvie Willis
There are various methods for plumbing semi-truck fuel tanks. One common method is to use a transfer pump and momentary switch to connect the two tanks separately. Another method is to plumb the tanks together as one, using a Y connector to join the supply lines and a one-way check valve to control the flow of fuel. Some people also choose to install auxiliary fuel tanks, which can be plumbed into the main fuel tank or the vent line. When installing an auxiliary fuel tank, it is important to consider the location of the tank and the type of valve used to control the fuel flow.
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What You'll Learn
Using a Y-connector to join supply and return lines
If you have dual fuel tanks, you may be considering plumbing them together as one. This can be done by joining the supply lines from both tanks with a Y-connector, as well as the return lines. The vent lines can also be connected between the two tanks. This design allows for equilibrium between both tanks, maintaining an equal fuel level on both sides.
However, it is important to note that connecting two tanks in this way requires drilling holes in both tanks, which can expose the fuel line to damage and potentially cause fuel loss. Additionally, the use of a Y-connector may affect the fuel gauge, as it will only show the level of the tank with the fuel gauge. This means that the dash gauge will indicate the same fuel level for both tanks combined, rather than individual levels.
To address the issue of fuel gauge inaccuracy, an electronic switch or a second fuel gauge can be installed. This allows for the transfer of fuel between the tanks and provides an accurate reading of the fuel level in each tank.
When using a Y-connector to join the supply and return lines, it is also crucial to consider the potential for fuel line damage and air leaks. Quick-connect fittings can introduce air into the system, affecting performance. Regular maintenance and inspections can help mitigate these issues and ensure the proper functioning of the fuel system.
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Installing an auxiliary tank
Before installing an auxiliary diesel fuel tank, ensure you have a spacious working area to avoid accidents and injuries. Clear the truck bed of any items, like a bed mat, and consider lifting the truck to gain better access to the undercarriage. Having an extra set of hands will be useful for lifting the tank into the truck bed and preventing damage to the truck's finish.
Next, place the auxiliary tank in the installation location, ensuring it is away from the sides, front, and back of the bed to prevent the tank from rubbing against the truck bed. Mark the holes where you will install the tank, using mounting tabs as a guide, and brightly coloured markers to avoid drilling mistakes. Once marked, remove the tank and use a centre punch to create a pilot hole with a small drill bit. Then, drill the final hole with a bit that matches your bolts. Before drilling, check the undercarriage to avoid drilling into the existing fuel tank or other important components.
Now, determine the routing of the fuel supply line from the auxiliary tank to the factory tank. You can connect the auxiliary tank directly to the filler hose of the main tank, or use a transfer pump to maintain equal fuel levels in both tanks. If you choose to connect the tanks directly, you may need to install an electronic switch to control fuel flow and prevent issues with the truck computer.
Finally, install the fuel supply line, ensuring it is secure and does not rub against any components. If you are using an electronic switch, install it according to the manufacturer's instructions, and ensure it is properly connected to the fuel supply line. Test your setup to ensure there are no leaks and that the fuel is flowing correctly between the tanks.
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Using a transfer pump
There are a few different ways to set up a transfer pump. One common method is to use a dip tube from the top of the tank down to within 1/2 inch of the bottom. This tube is then connected to a fuel pump, such as a Holley 110 GPH fuel pump, using fuel hose. A fitting is brazed into the stock filler neck, about a foot from the fill cap, to accommodate the fuel hose. A switch is installed in the cab to control the fuel pump, which transfers fuel from the auxiliary tank to the main tank.
Another option is to use a transfer pump controlled by an upfitter switch. This setup typically includes a valve on the suction side of the fuel pump to switch between tanks. It is important to note that if the fuel return goes back to the tank, this could present a problem.
Some people also choose to install a filter in the fuel line near the pump to ensure that clean fuel is being transferred. Additionally, a fuel gauge for the auxiliary tank can be added to the cab, allowing the driver to monitor fuel levels in both tanks.
It is important to be aware of potential leaks when using a transfer pump. To address this, some people choose to install a return line to direct any overfill back into the auxiliary tank. This helps to prevent overfilling and potential spills.
Overall, using a transfer pump provides a convenient way to transfer fuel between tanks in a semi-truck fuel tank system, but it is important to carefully consider the specific setup and potential challenges.
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Drilling holes in both tanks
Before drilling, it's essential to plan the location of the holes carefully. Identify the lowest possible point on each tank, as this will be the optimal position for drilling. Mark the spots clearly to ensure accurate drilling. This step is crucial to avoid drilling multiple holes and weakening the tank's structure.
Use the appropriate drill bits designed for metal drilling. Select a drill bit size that corresponds to the fittings you will use to connect the tanks. It is important to use a drill bit that is slightly smaller than the fittings to ensure a tight and secure connection. Secure the tanks firmly to prevent any unnecessary movement during the drilling process. This can be done by clamping the tanks to a sturdy workbench or using a vice to hold them in place.
Drill slowly and with caution to avoid any damage or deformation to the tanks. Apply firm and consistent pressure while drilling to create a clean hole. Use a lubricant or cutting fluid to reduce friction and heat buildup, which can affect the integrity of the hole. Once the holes are drilled, deburr the edges to smooth out any rough surfaces. This step is important to prevent damage to the fittings and ensure a proper seal.
After drilling, it's crucial to install the necessary fittings securely. This may involve using connectors, valves, and hoses to establish a safe and leak-proof connection between the two tanks. Ensure all connections are tight and secure to prevent fuel leaks. Test the system for any leaks by performing a pressure test or a visual inspection. Address any issues promptly to ensure the safety and proper functioning of the fuel system.
By carefully drilling holes and following the necessary precautions, you can effectively connect the two fuel tanks in your semi-truck, creating a seamless fuel supply system. Remember to refer to manufacturer guidelines and seek expert advice if you have any concerns during the process.
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Using a dual circuit ball valve
When plumbing a semi-truck fuel tank, one of the methods you can use is a dual circuit ball valve. This method allows you to connect two fuel tanks together, providing a single large fuel supply. Here is a step-by-step guide on how to plumb a semi-truck fuel tank using a dual circuit ball valve:
Firstly, decide on the location of the tanks. Consider the available space and accessibility for mounting the tanks. One option is to install a larger tank, such as a Blazer or suburban tank, at the rear of the truck, ensuring the fill is on the left side.
Next, you will need to connect the two tanks together. This can be achieved by using a Y connector to join the supply lines from both tanks, as well as the return lines. Additionally, connect the vent lines between the two tanks. This design will allow for equilibrium, ensuring the fuel level stays the same in both tanks.
When plumbing the tanks, consider the use of a one-way check valve to control the flow of fuel. This is especially important when plumbing front to rear, as going up a hill can cause fuel to transfer to the rear tank. By using a check valve, you can prevent overfilling the rear tank and maintain proper fuel distribution.
You may also consider a gravity feed system for a simpler setup. Connect the two tanks with a hose at the bottom for fuel flow and a hose at the top for air movement. This eliminates the need for a secondary or transfer pump.
Additionally, pay attention to the ball valve installation. A 1/4-turn ball valve on the outlet of the tank provides ease of isolation in case of any issues or removal requirements. This type of valve also serves as a passive anti-theft feature when in the off position.
Finally, consider the use of a transfer pump and momentary switch to connect the tanks. This setup allows you to use one tank as a refiller for the other, ensuring a smooth fuel transfer. Remember to switch between tanks with each fill-up to prevent any issues.
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Frequently asked questions
You can plumb two tanks together at the lowest point on the smaller tank to ensure that fuel flows into the larger tank and not the other way around. You can use a Y-connector to join the supply lines, return lines, and vent lines of both tanks.
Plumbing two semi-truck fuel tanks together creates a larger fuel supply and allows for equilibrium between the tanks, keeping the fuel level the same on both sides.
Plumbing two tanks together can expose the fuel line to damage, potentially emptying both tanks. Additionally, connecting the tanks at a higher point can cause issues with hills, leading to overfilling.
You can plumb an auxiliary tank into the main tank by installing a kit that connects to the truck's fuel tank filler neck. This typically involves using a switch to control the flow of fuel between the tanks.
One potential issue is that the truck's computer may be confused by the fuel level, thinking the fuel tank sender is bad or that the tank is empty. This can be addressed by installing an electronic switch.
