Mercedes Mullins
Running two tanks of diesel fuel systems can be achieved through various methods, each with its own advantages and considerations. One approach is to install a Blazer or suburban tank in the rear and turn it around so the fill is on the left side, using a transfer pump and momentary switch to connect them. Another method involves joining the supply lines from both tanks with a Y connector and connecting the vent lines between the two tanks, allowing for equilibrium and maintaining the same fuel level in both tanks. Some people also add a manual dual-port valve to switch between the two tanks. The procedure for filling dual tanks and the order in which the tanks should be filled is also discussed, with some users mentioning that they only fill the rear tank or follow the instructions in their vehicle's manual.
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What You'll Learn
Filling up two tanks
Some vehicles with dual fuel tank options specify a particular filling order. For instance, the 2022 GMC 3500 cab & chassis manual recommends refuelling the primary front tank first and then adding fuel to the auxiliary rear tank. However, the manual's definition of the primary tank seems counterintuitive, as it lists the rear tank as having a larger capacity (40 gallons) than the front tank (23.5 gallons). This discrepancy raises the question of whether it truly matters which tank is filled first.
In general, it appears that ensuring both tanks are filled equally is crucial. If only one tank is filled, the fuel will not equalize between the two tanks. This imbalance can lead to running out of fuel in one tank, even with the other still containing fuel.
To address this issue, some people opt for installing a manual dual-port valve to switch between the two tanks. This setup allows for control over which tank is being used, ensuring that both are depleted evenly. Additionally, a dual circuit ball valve can be used to switch both the supply and return simultaneously.
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Using a transfer pump
Transfer pumps are a popular method for running two diesel fuel tanks. They are used to move fuel from the rear tank to the front tank as the front tank's level drops. This can be done manually or automatically.
One way to set up a transfer pump system is to use a momentary switch to control the transfer of fuel. This involves installing a transfer pump and a switch that allows you to manually transfer fuel from the auxiliary tank to the main tank as needed. This method gives you control over the fuel transfer and can be a simple and inexpensive setup. However, it requires you to monitor the fuel levels and turn on the transfer pump at the right time.
Another way to set up a transfer pump system is to use an electric transfer pump that automatically moves fuel from the auxiliary tank to the main tank. This type of system typically has a sensor in the main tank that detects when the fuel level drops and activates the transfer pump to refill it from the auxiliary tank. This method ensures that the main tank always has enough fuel, but it may require more complex wiring and components.
It is important to note that transfer pumps can fail, so regular maintenance and monitoring are necessary. Additionally, when using a transfer pump, it is important to ensure that the fuel levels in both tanks are equal when refuelling to maintain equilibrium. This can be achieved by filling up both tanks simultaneously or by installing a tube between the two tanks at the lowest level to allow fuel to equalize.
Transfer pumps can be an effective way to manage dual diesel fuel tanks, but it is important to consider the potential challenges and maintenance requirements to ensure a smooth and safe operation.
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Joining supply lines
Joining the supply lines is a crucial step in setting up a dual diesel tank system. This process allows the two tanks to work in harmony, maintaining equilibrium in fuel levels. Here's a detailed guide on how to achieve this:
Y-Connector Setup:
The most common method for joining supply lines is by utilising a Y-connector. This involves connecting the supply lines from both tanks to the Y-connector, creating a unified fuel supply line. The Y-connector provides a simple and effective way to combine the output from the two tanks.
Vent Line Connection:
In addition to the supply lines, it's important to connect the vent lines between the two tanks. This ensures that air can move freely within the system, allowing for smooth fuel flow and maintaining the equilibrium of fuel levels in both tanks.
Return Line Configuration:
Similar to the supply lines, the return lines from each tank should also be joined using a Y-connector. This setup ensures that any excess or returning fuel is directed back into the system, preventing leaks or pressure buildup.
Maintaining Equal Fuel Levels:
To ensure that both tanks maintain equal fuel levels, consider installing a tube between the tanks at their lowest level. This equalizing line ensures that the fuel level remains consistent across both tanks. However, it's important to be cautious when traversing rough terrain, as the tube can become a potential snag point.
Switching Between Tanks:
For added flexibility, you can incorporate a manual dual-port valve into your system. This valve allows you to switch between the two tanks as needed. Groco offers a FV-6-5038 bronze 6-port marine valve that can switch both the supply and return lines simultaneously. This valve can be conveniently mounted under the cab, providing easy access for switching.
By following these steps and paying close attention to the specific connections and configurations, you can successfully join the supply lines of your dual diesel tank system, ensuring a seamless and efficient fuel supply for your vehicle.
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Adding a second fuel gauge
Understanding Fuel Gauge Functionality
Before installing a second fuel gauge, it's important to understand how fuel gauges work. They are typically connected to a fuel sensor or sender unit, which is a variable resistor. The resistance value of the sensor changes as the fuel level in the tank changes, and this variation in resistance is what the fuel gauge interprets to display the corresponding fuel level.
Choosing the Right Gauge Type
You can choose between different types of fuel gauges, such as analog, digital, or graphical displays. Analog gauges often use a rheostat, which is a variable resistor, to measure the resistance and indicate the fuel level. Digital gauges, on the other hand, may have more advanced features and can provide a more precise reading.
Connecting the Second Fuel Gauge
When connecting the second fuel gauge, you have a few options:
- Using a Switch: You can install a switch that allows you to choose between the original and the second fuel gauge. However, this method can trigger the low fuel warning system on the original gauge, causing inaccurate readings on both gauges.
- Tapping into the Sensor: You can tap off the signal from the fuel sensor to connect to the second gauge. It's important to not disturb the resistor value of the sensor when doing so. One way to achieve this is by using a circuit with very high resistance, typically at least ten times that of the sensor. A JFET or CMOS op-amp can be used for this purpose.
- Op-amp as a Buffer: Another option is to use an op-amp as a unity-gain buffer. Connect the input of the op-amp to the junction of the sender and the first gauge, and the output to the second gauge. This setup ensures that the first gauge is unaffected, and the second gauge receives the same voltage and reading.
Additional Considerations
When working with fuel gauges and sensors, it's important to measure and understand the resistance values, open circuit voltage, and current behavior. You can use a potentiometer to determine the linearity of the system. Additionally, consider the type of fuel sender in your vehicle; some use a ground circuit return, while others may have different configurations.
In conclusion, adding a second fuel gauge to your diesel fuel system involves careful consideration of the electrical and resistance aspects of the fuel gauge setup. By following the steps outlined above and choosing the appropriate connection method, you can successfully install a second fuel gauge to monitor your fuel levels accurately.
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Installing a Blazer tank
When installing a Blazer tank, it is recommended to install it in the rear, turning it around so that the fill is on the left side. This setup allows for easier refuelling when compared to having one tank on each side. The fuel door and surrounding metal from the donor truck can be used to finish the outside.
For the plumbing, it is suggested to keep the tanks separate and use a transfer pump and momentary switch. Alternatively, the supply lines from both tanks can be joined with a Y-connector, as can the return lines, and the vent lines can be connected between the tanks. This setup allows for equilibrium, maintaining equal fuel levels in both tanks.
To switch between the two tanks, a manual dual-port valve can be added. Groco offers a FV-6-5038 bronze 6-port marine valve that can be mounted under the cab, with the lever accessible through a rubber grommet in the cab floor. This setup allows for easy switching between the tanks without having to get under the truck.
Additionally, an OEM tank switch can be added to the dash gauge, allowing for easy monitoring of the fuel levels in both tanks. This setup provides a functional and efficient dual-tank system, offering increased fuel capacity and flexibility for refuelling.
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Frequently asked questions
It is recommended to fill up the primary tank first and then the auxiliary tank. However, some people choose to only fill up one tank, which can be either the front or rear tank.
You can join the supply lines from both tanks with a Y connector and do the same for the return lines. The vent lines can be connected between the two tanks. This plumbing design will allow the fuel level to stay the same in both tanks.
A dual fuel tank system can provide a larger fuel capacity, allowing vehicles to travel further distances without refuelling. It also offers redundancy in the event of a fuel pump or injection issue with one of the tanks.
