If I do end up with a diesel trawler, it will be my first diesel powered boat with more than one fuel tank (previous were sailboats), so my first experience running with various valves and etc.
Reading through this thread I was able to gain a better understanding of how the system(s) work. OP: Sorry you have a problem, but your thread has been enlightening so thank you.
I now have a question that might also be of interest to the OP.
So let's say that like the OP, you have a single engine, two (saddle) tanks, a crossover, and only ONE return line (to only one side's tank). Presuming one does not mind doing the labor, is there any good reason not to add a return (with appropriate valves) to the other tank? Or to put it another way, what is the advantage to the user of the OP's "return to one side only so must leave crossover valve open" installation? Obviously fewer valves and fuel lines for the builder to install, but for the operator? Was it done as a "keep it simple and let's not confuse people with choices" type thing?
In summary, I want to test out my thought which is that while a system with return valves to both tanks requires more thought and action while operating; it also gives one more ability to control for list (which can be exacerbated by a waterfall effect as the low side tank encourages more and more fuel to head over that way through the "must be open" crossover). OTOH, the "only one return and must keep crossover open" is the "you don't need to think about it" approach (AS LONG AS the boat does not start to create a cascade of listing).
Thanks for any replies and OP, I hope this is useful to you as well (why I did not start another thread at least as of yet).
Frosty