Katerina Swanson
Wiring dual fuel tanks can be a complex process, and it's important to understand the different methods and components involved. Whether you're dealing with a boat, truck, or another vehicle, there are various factors to consider, such as the type of switch, sending units, fuel pump configuration, and plumbing design. One common challenge is rewiring dual fuel tanks to a single gauge, which requires careful consideration of the wiring diagram and an understanding of how to separate the circuits for accurate readings. In this discussion, we will explore the intricacies of wiring dual fuel tanks, addressing common issues, best practices, and potential solutions to ensure a functional and safe fuel system.
| Characteristics | Values |
|---|---|
| Wiring dual fuel tanks | Requires a switch to select the tank the gauge is monitoring |
| Needs to keep +12 volts separated from signal and ground | |
| Requires a dual circuit ball valve to switch supply and return at the same time | |
| Needs a single pole dual throw switch | |
| Requires a dual port valve to switch between the two tanks |
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What You'll Learn
Wiring dual fuel tanks to one gauge
Wiring dual fuel tanks to a single gauge can be achieved in several ways, depending on the vehicle's setup and your preferences. Here are some methods and considerations:
Using a Switch
One common method is to use a switch to select which tank the gauge monitors. This can be a manual or electric switch. The switch is connected to the positive leads on both sending units, allowing you to read the fuel level in each tank individually. This method helps prevent confusion and ensures you are aware of the fuel level in the tank you are currently using.
Wiring Considerations
When wiring dual fuel tanks to a single gauge, it is important to ensure that the sending units are grounded properly, or they may not work. Additionally, wiring diagrams can provide valuable information on how to connect the tanks, gauge, and switch. Factory wiring diagrams can give you an idea of the original wiring setup, while diagrams specific to dual fuel tank setups can guide you in rewiring your system.
Fuel Pump and Selector Valves
The fuel pump setup is an important consideration. If your fuel pump pulls from both tanks simultaneously, you may need to install a selector valve to choose which tank is being monitored. Some vehicles come equipped with electric tank selector valves, while others may require manual operation. Selector valves can help ensure that fuel levels are accurately reflected on the gauge.
Fuel Sender Units
It is important to test and ensure that the fuel sender units are functioning correctly. Faulty sender units may cause inaccurate readings on the gauge. Additionally, the sender units should be grounded for proper functioning.
Tank Capacity and Volume Considerations
If the dual tanks have different volumes, a simple divider network may not work for accurately reflecting fuel levels. In such cases, a ratio divider network or other methods may be required to account for the different tank sizes and provide accurate fuel level readings.
By considering these factors and choosing the appropriate setup for your vehicle, you can successfully wire dual fuel tanks to a single gauge, ensuring accurate fuel level readings and a seamless driving experience.
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Using a single pole double throw switch
A single pole double throw switch is a switch with one source of power coming in and it leaves to two different locations, on, off, on. It is used to switch between two tanks with separate fuel lines. The wiring for this setup involves connecting the wire from the power source to the middle terminal, with wires from each pump connected to the outer terminals.
The dash-mounted switch has five wires: four go through the firewall, and one is a 12v power feed that leads over to the fuse box. The four wires that go through the firewall include the left tank sender, right tank sender, and fuel gauge. The fuel gauge wire goes through the firewall, into the engine wiring loom, and then back through the firewall to the gauge. The left and right sending unit wires attach to the throws of the switch.
In a dual fuel tank system, such as in a Ford Motor Home, the two separate fuel lines meet at a 12v solenoid-operated fuel valve with two inlets and one outlet. The fuel line continues from the valve to the fuel pump. The double pole double throw electric toggle switch is mounted on the dashboard. Depending on the position of the switch, it energizes the solenoid valve and allows fuel to flow to the engine from either tank one or tank two.
A 6-port fuel selector valve is required when there are also fuel return lines going to each tank. This allows for both the supply and return lines to be switched to the correct tank.
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Troubleshooting dual fuel tank wiring
Understanding the System
Before troubleshooting, it's important to understand the components of the dual fuel tank system. This includes the sending units, gauges, switches, and wiring. Sending units are responsible for measuring the fuel level in each tank and sending this information to the gauges. Gauges display the fuel level, while switches allow you to select between tanks.
Common Issues and Solutions:
Issue 1: Gauges Not Working
If both your gauges stop working simultaneously, it's unlikely that both sending units have malfunctioned. Check the wiring diagram for your specific setup and verify the connections. Ensure the senders are grounded, as a lack of grounding can cause issues. Additionally, test the sending units to ensure they are functioning correctly.
Issue 2: Inaccurate Fuel Level Readings
If your gauges consistently show full or empty readings regardless of the actual fuel level, there may be an issue with the sending units or wiring. Check the resistance of the sending units; they should read about 30 ohms when empty and near zero ohms when full. If the resistance is incorrect, the sending unit may need replacement. Also, ensure the sender wires are correctly connected to the tanks.
Issue 3: Difficulty Switching Tanks
If you experience issues switching between tanks, there may be a problem with the diverter valve or sending units. Test the electrical diverter by having someone operate the switch while you listen for the sending units to activate. If this doesn't work, check for clogs in the sending units, especially if one tank is not drawing fuel as expected.
Issue 4: Fuel Tank Leaks
Leaking fuel tanks can lead to operational issues and safety hazards. If you notice leaks, inspect the tanks for cracks or damage and replace them if necessary. Also, check for loose connections or faulty components, such as the fuel pump or carb filter, which could contribute to leaks.
Seek Professional Help
If you're uncomfortable working with electrical systems or are unable to identify the issue, it's best to consult a professional mechanic or electrician. They can provide expert guidance and ensure your dual fuel tank wiring is safe and functional.
Remember to exercise caution when working with fuel systems, and always refer to reliable sources or seek professional advice for complex or persistent issues.
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Dual fuel tank plumbing methods
When plumbing dual fuel tanks, there are several methods you can use to ensure the system functions correctly. Here are some of the most common approaches:
Y Connector Method:
This method involves using a Y connector to join the supply lines of both tanks, as well as the return and vent lines. This design allows for equilibrium between the tanks, ensuring the fuel level remains the same on both sides. The dash gauge will still indicate the same fuel level, but it will represent a larger total fuel capacity. This method is a straightforward way to ensure both tanks function as a single, larger fuel supply.
Separate Filler Method:
In this approach, each tank has its own separate filler. This provides control over which tank is filled and when. It simplifies the process by eliminating the need for a complex valve system. However, it requires finding accessible spots for the fillers, and it may result in more frequent refuelling trips.
Dual Circuit Ball Valve Method:
This method utilises a dual circuit ball valve to switch both the supply and return lines simultaneously. It is often recommended for installations with a rear-mounted tank. This approach helps prevent issues with cross-feeding on hills. It is a good solution for keeping the tanks separate while still allowing for easy switching between them.
Manual Dual Port Valve Method:
This method involves installing a manual dual port valve to switch between the two tanks. The valve is typically mounted under the cab or frame, with easy access to the lever. This setup provides control over switching between tanks while also offering passive anti-theft benefits due to the valve's off position.
Fuel Transfer Pump Method:
This approach uses a fuel transfer pump to transfer fuel from the auxiliary tank to the main tank when the main tank gets low. A "tee" is added to the fuel filler pipe, allowing both tanks to fill simultaneously. The fuel is then pumped into the main tank's vent line via another tee. This method ensures a constant fuel supply to the main tank and is a relatively simple and inexpensive solution.
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Electric vs manual fuel tank selector valves
When it comes to dual fuel tanks, there are two main types of fuel tank selector valves: electric and manual. Both types of valves allow you to switch between two separate fuel tanks, but they differ in terms of operation and installation.
Electric fuel tank selector valves, such as the Wells FSV2K and the Standard Motor Products FV5K, offer a convenient way to switch between fuel tanks electronically. These valves are typically equipped with electronic sensors and actuators that automate the selection process. They are often controlled by a dashboard-mounted switch, allowing for easy operation without having to leave the driver's seat. Electric valves are ideal for vehicles with advanced fuel systems and electronic displays, providing a seamless and efficient way to manage multiple fuel tanks.
On the other hand, manual fuel tank selector valves, like the Groco FV-6-5038 bronze 6-port marine valve, offer a more traditional and mechanical approach to switching fuel tanks. These valves are operated manually, often via a lever or knob located near the valve. Manual valves are typically simpler in design and do not require electrical connections or complex wiring. They are suitable for vehicles where a more hands-on approach to fuel management is preferred or when electrical systems are not feasible.
One advantage of electric fuel tank selector valves is their convenience and ease of use. With the push of a button or flip of a switch, you can instantly switch between fuel tanks without any physical effort. This feature is especially useful when driving, as it eliminates the need to stop the vehicle and manually adjust the valve. Electric valves can also provide real-time information about fuel levels in each tank, making fuel management more efficient.
Manual fuel tank selector valves offer benefits in terms of simplicity and reliability. They do not rely on electrical systems, reducing the potential for malfunctions due to electrical issues. Manual valves are often easier to install and maintain, as they do not require complex wiring or electronic components. Additionally, manual valves can provide a level of tactile feedback when switching tanks, giving the operator a more direct sense of control.
In terms of installation, electric fuel tank selector valves typically require more intricate wiring and integration with the vehicle's electrical system. They may need to be connected to the dashboard switch, fuel level sensors, and other electronic components. On the other hand, manual valves often involve more straightforward plumbing and mechanical connections, without the need for electrical wiring. However, both types of valves require careful installation to ensure proper functionality and safety.
In summary, the choice between electric and manual fuel tank selector valves depends on factors such as vehicle type, fuel system complexity, and personal preference. Electric valves offer convenience and seamless integration with modern vehicle systems, while manual valves provide a simpler, more traditional approach to fuel tank selection. Ultimately, both options serve the same purpose of allowing drivers to switch between dual fuel tanks efficiently and safely.
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Frequently asked questions
You will need to wire a switch so that you can select either fuel sender and the gauge will read that tank. You can find wiring diagrams for fuel-level circuits in the archives.
You can use a silvertip switch, or an electric switch. You will need a different switch if you want to flip one switch to switch tanks.
The sender should read about 30 ohms empty, and near zero ohms full. You will need to switch the sender wire between the tanks, and be sure the senders are grounded or they won't work.
Yes, 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 two tanks. This will allow equilibrium between both tanks so that the fuel level on both sides will stay the same.
