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HyCO 2DT MANUAL

How-To build a simple device to install on turbo-charged diesel engines that saves you money! Tested by major diesel engine manufacturers on their own dyno's and operated by truck drivers all over North America
George Wiseman

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. . . . Automatic function is one of the assets of the HyCO 2DT.) but the fuel could be so dirty it would barely pour and the HyCO 2DT wouldn't care a bit. . .Table of Contents How the HyCO 2DT works . P12 Warranties and liabilities. because they needed a design of heater that would burn any fuel. . Note: Diesel fuel must be vapor and mixed with oxygen before it can burn. . . . . When the turbo pressures are low or nil. . . It takes time for the liquid fuel sprayed into a combustion chamber (from an ordinary injector) to turn to vapor and then to mix with oxygen and burn. . . . because the HyCO vapors are way too lean to Other options and considerations Air pump. The "ball" technique operates with relatively low pressures and has no fuel orifice to plug up.P9 Air tank. . . The turbocharger homogenizes the air and vapor fuel. . . . most of the mist actually turns into vapor. Note: When diesel turns to vapor it requires a large amount of heat. . . . P10 Fuel Pump on drain. . . . Note: This ball technique was originally developed for use in military heaters. . . . P2 Routing fuel hoses. . Fuel must be vapor before it can burn and so this is one way they did it. . P8 Routing vent hoses. . . The turbo charger further mixes the mist with air. .com 1 . . the HyCO 2DT doesn't put any vapor into the engine. There is no chance that the HyCO 2DT vapors will burn before the injector sprays. . . Please read carefully. . P8 Hooking up the buzzer. It takes that heat from the air around it. . This is called "lag time". . . . propane. And because more of the heat energy of the fuel was converted to mechanical energy. dirt. . . . . . The air then becomes denser. you will note a net mileage gain as well! The working principle of the HyCO 2DT is to apply a film of fuel over the ball and allow the compressed air on the inside of the ball to spray through the film. . These droplets are produced without the high pressures and complications of injectors. . The rest of the fuel simply drains back to the fuel tank. the engine governor will automatically reduce the fuel flow to the regular injectors! Most truckers note that they can "keep their foot in it" longer because the HyCO 2DT effect makes faster combustion so the exhaust temperatures are lower. You do have to feed it clean pressurized gas (air. Usually this "gains a gear" on the hills. . . thereby having a net cooling effect. . . . . . The mist created by the ball is so fine that it will not wet a mirror held in it. P12 HyCO 2DT / www.P6 Mounting Vent container. . . P11 Cautions. . P8 How the HyCO 2DT Works The HyCO 2DT is a container that installs in the fuel return line of a diesel engine. so the inherent droplet size is usually ten times smaller than a normal nozzle spray. . . . so there is no idle adjustment needed to the ordinary fuel pump or injectors. your turbos kick in and the HyCO 2DT gives you an additional boost. over spraying the liquid out of a fuel injector nozzle is that the ball bypasses the laminar stage. regardless of viscosity. . . . . P8 Deceleration shutoff. The very fine mist is directed to the intake side of the turbocharger. converting a portion of the film to micron sized droplets.P3 Installing Vapor tube assembly. . . . . .P2 Mounting HyCO 2DT container. . If the RPM was to try to rise too far. Another advantage of the "ball" technique. . . . . . etc. etc. P11 Dual Turbo Chargers. And when you use power. . . . . So the HyCO 2DT assists the turbocharger and the inter-cooler with this side effect. .eagle-research. . P7 Venting fuel tank/s. water. .

Then all one morning getting your parts and are at about 2 in the afternoon before being ready to start installing. automatically starting the HyCO 2DT misting action. The homogenized air/fuel vapors simply assist combustion once it is initiated by the injector. I've always found that when you depend on moving parts. Make sure it is 2 www. Step three. If any HyCO 2DT is required to be mounted so that the diesel fuel cannot flow freely back to the fuel tank. It requires no maintenance and is entirely automatic in its operation. liquid. By "gas" I mean a state of matter. they will eventually fail.. with the better results being on the heavier loads. The benefits of a homogenized air/fuel mixture are. "gas". I would always choose to install a large drain line because. figure out where everything is going to be. go get all your hoses and fittings. a slight reduction in the lag time. As of today on large trucks our results have been a net fuel mileage gain of between 7 and 14 percent. Once you're experienced.burn (not enough fuel). All internal parts to a HyCO 2DT are set. we find the turbo pressure to be adequate and convenient. You have a choice of upgrading the drain line to at least a #10 (I prefer #12) or installing an electric fuel pump to assist the HyCO drain. (the fuel just drains through it) so it is automatically not working at idle. The HyCO 2DT kit uses SAE fittings. It will take you one to four hours to install. as in solid. there are no adjustments to make. But for simplicity. we've achieved over 40% fuel economy gain when the turbo is activated.eagle-research. SAE fittings are usually brass and can be picked up in a hardware store. Remember that JIC and SAE fittings are different. Mounting HyCO 2DT Container You will have to build your own mounting bracket. all the liquid fuel must drain away. making the HyCO 2DT more efficient. then You have two choices (1) put in a separate (new) fuel return line or (2) the HyCO 2DT must be equipped with a float switch that powers an electric pump to make sure the HyCO 2DT container doesn't fill up with diesel. I like to keep it that way. Given a choice. in this case the compressed gas is air. At this time we haven't designed a universal mounting system. Step one. made for high pressure hydraulic applications. So I design the HyCO 2DT to operate under 30 psi.com / HyCO 2DT . you likely spent a couple of hours looking over this instruction manual. It is not easy to cause diesel fuel to evaporate. a HyCO 2DT doesn't work if there is no air pressure applied. slightly increased power. the truck's drain line is too small to make an adequate drain for gravity feed. The ordinary HyCO 2DT installation depends on gravity to drain its container. If you are doing this for the first time. Be sure to get DOT approved fuel hose that will fit your fittings. JIC fittings are usually steel. We have found in some cases. any pressure greater than 30 psi does increase efficiency but in a greatly reduced amount. The HyCO 2DT is built heavy duty and will easily outlast the engine it is attached to. The HyCO 2DT doesn't really start to do anything until the turbo air pressure is above 5 psi. depending on how good you are. The HyCO 2DT is designed to have zero fluid level. We have HyCO 2DT's installed on test vehicles since November/91 and they are doing well. the turbo pressures rise. The draining action is assisted by the slight pressure created by the ball. The HyCO 2DT does require a source of compressed gas. because the turbo pressures are higher. reduced pollution and dramatically reduced fuel consumption. These figures are based on my actual experience. as an inventor. As the engine begins to work. a full installation will take you less than three hours. so only a very small amount of fuel turns to vapor and gets homogenized with the air. It is best to use all of one or the other. In normal operation. Normally we use turbo pressure for the source of compressed gas. It is also possible to use many other sources of compressed gas. start mounting your HyCO 2DT. propane for example. Step two. because there is no turbo pressure. Make up the parts you need to fabricate on the spot. Such as the Cat's #4 line. The HyCO 2DT is designed to operate with no moving parts. Then measure the hose lengths and determine if you need any more fittings. Then the response from the HyCO 2DT is rather linear till about 30 psi. In small vehicles. It produces its fine mist with a patented procedure using liquid fluid films and exact application of moving gaseous fluids. smoother combustion. depending on load. I've see it done in two. decreased exhaust temperatures.

causing liquid fuel to drain over into the engine. then it would be purged to the HyCO 2DT drain. Many mechanics feel they can "do it better" and I'm sure some can. your warranty still covers it. using a Kenworth truck and a CAT engine model 3406 B. Most truckers choose to exercise this option. our recommendation is to draw some pressurized air from the spot in the inter-cooler most likely to accumulate liquid (like the bottom of the inter-cooler). Note: It is possible to totally shut off the HyCO 2DT by inserting a valve in the air pressure hose and in the vapor hose. But take care. perhaps I can save you a lot of time. your current fuel mixture starts to explode when just over 5% of it finds the proper combination. if you feel you've got a better way.com / HyCO 2DT . As simple as it may seem. for your own good. Usually there would be enough fuel return flow to simply split the fuel return and feed it into both containers.reason. We have (Feb. for safeties sake. We have also tested the HyCO 2DT on a Perkins turbo-charged Diesel in Mexico City. the HyCO 2DT will not drain to the fuel tank by gravity. No warranty will cover damage caused by use or miss-use of the HyCO 2DT. I've never seen it needed but it's there. Cautions. That wraps it up for now. These are very basic instructions and I apologize for that. If anything goes wrong with your engine that would have "normally" have gone wrong. Both containers need to be drained separately to the fuel tank/s HyCO 2DT retains fuel./93) run testing on one of the best dynamometers in America. so make sure you install it right! 12 www. Do not attempt to deviate from the instructions in this manual. Do not take a HyCO 2DT apart to see it's internal workings. This leads to gasket or hose failure as the gasket or hose absorbs the fuel mist over a period of time. So using these gases to pressurize the ball will have double effect. I seriously recommend it. if in fact the mist did condense. Please Read Carefully Do not attempt to install a HyCO 2DT system without a complete understanding of the instructions in this booklet. We got 10% increase in economy (used less fuel) and 14% increase in power AT FULL FUEL RAIL! It was funny to see the engineers trying to figure out that one. it will limit the draining action and cause the container to retain fuel. vapor fuel is "more volatile". Note: Some gaskets and hoses in some Diesel air intake systems are not totally fuel compatible. The tests confirmed everything the on-road truckers had been telling us. This Perkins engine was hooked up to a Perkins Dynamometer at the Perkins engine manufacturing facility. If the Warranties and Liabilities The installation of the HyCO 2DT system does not void any engine warranties. money and grief. It is my intention to write a very comprehensive Manual for the HyCO 2DT and feedback is extremely helpful. If a vacuum is allowed to form in the HyCO container. there are a lot of internal adjustments and techniques that are pre-adjusted and are not explained in this booklet. Note: Fuel condensation in the inter cooler has been expressed as a concern. but they had to acknowledge the results. I have personally phoned the engine manufacturers to confirm this. I have often shaken my head when I've heard of an incorrect installation of the HyCO 2DT and the result. Simply replace these gaskets and hoses with fuel compatible versions. Then it is simply a wide spot in the fuel return line. so if you are concerned with this. Our testing has shown this to be of little concern as the mist is (or very near) a vapor state when it comes out of the turbo and will not condense for minutes or hours. However we cannot say that it will not happen. I invite feedback from your tests and comments of any kind on the product or this presentation.eagle-research. BUT I've spent decades learning about this specific system. clear it with me first! I don't feel that I "know it all" but I've learned a lot about this application and if I can help you prevent a mistake or point out some considerations that you might not have thought of. the rising fuel level will interfere with the "misting" action and eventually will overflow the container. Note: Using propane or natural gas (methane) mixed with diesel enhances combustion. The tests were so good that the companies we are dealing with couldn't believe it and are setting up SAE testing to confirm.

Idaho at Western States Cat. Tests Sponsored by Entech Corporation of Meridian. exactly between min/max lines.Caterpillar Performance Analysis Report Minimum 400 350 300 250 200 150 100 50 0 Corrected Maximum 02-23-1993 13:51:10 Control test shows normal power curve. V e h C p o w e r 300 250 200 150 100 50 0 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 Engine Speed 14 . Idaho. Tests performed in Boise. Results qualify as independent confirmation HyCO 2DT performance. V e h C p o w e r 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 Engine Speed Caterpillar performance Analysis Report 02-23-1993 18:19:10 Minimum 400 350 Corrected Maximum This test with the HyCO 2DT installed shows the engine's power to be increased to the maximum allowed by the engine manufacturer.

15 10 5 1000 1100 1300 1500 1600 1800 1900 2000 Engine Speed 15 .Caterpillar Performance Analysis Report 02-23-1993 13:57:45 Minimum 20 Measured Maximum Control test shows normal fuel volume for new injectors. The actual fuel curve is BELOW the min/max lines. F u e l V o l u m e 15 10 5 1000 1100 1300 1500 1600 1800 1900 2000 Engine Speed Caterpillar Performance Analysis Report 02-23-1993 18:25:44 Minimum 20 Measured Maximum F u e l V o l u m e This test with the HyCO 2DT installed shows the engine's fuel volume to be lower than the manufactures expect for power.

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