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

Eagle-Research
Energy Solutions

since 1984

Patent-free Technology Brown's Gas Fuel Savers Free Energy

www.eagle-research.com

5 things to know about this eBook 1. This eBook is best read using Adobe Acrobat Reader 2. This eBook is a direct electronic representation of the physical book, therefore, it is not optimized for viewing on a computer screen. Youll need to scroll up and down to read the columns. We kept it this way to allow reference, to exact locations in all versions, when answering questions or addressing corrections. 3. The eBook page numbers may not match the PDF le page numbers. In print books, there are commonly a number of pages, at the front and back, that are not numbered or use Roman numerals. PDF les typically start by numbering the front cover page 1. All our references to pages in this eBook will assume the print page numbering. 4. This eBook has full page links over most of its pages. Clicking on a page will connect you to the Eagle-Research website (usually the Resources Section). Scroll using the sidebar. 5. This eBook was State of Art when it was initially published. Today it is still excellent basic information. However, as always, our technologies improve, and information becomes obsolete, faster than we can print, publish and circulate updates. Our solution - Eagle-Research Online Resource sections that contain: Parts and services supplier information; application comments; options; updates; upgrades; support links; support documents; FAQ entries; wiki entries; blog entries; forum discussions; test results;, product installers; product manufacturers; post-publication technical corrections. Since 1984 Eagle-Research has been committed to gathering energy information from diverse sources, experimenting with it , merging possibilities into actuals and distributing solutions that empower the individual. The Eagle-Research Online Resources will help you start your project with the latest information ... then continue to upgrade your projects when new information becomes available.

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Eagle-Research
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Patent-free Technology Brown's Gas Fuel Savers Free Energy

www.eagle-research.com

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EAGLE-RESEARCH MISSION
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Table of Contents
How the HyCO 2DT works . . . .P2 Mounting HyCO 2DT container. . P2 Routing fuel hoses. . . . . . . . .P3 Installing Vapor tube assembly. . .P6 Mounting Vent container. . . . . P7 Venting fuel tank/s. . . . . . . . P8 Routing vent hoses. . . . . . . . P8 Hooking up the buzzer. . . . . . P8

How the HyCO 2DT Works

The HyCO 2DT is a container that installs in the fuel return line of a diesel engine. Automatic function is one of the assets of the HyCO 2DT. When the turbo pressures are low or nil, the HyCO 2DT doesn't put any vapor into the engine, so there is no idle adjustment needed to the ordinary fuel pump or injectors. And when you use power, your turbos kick in and the HyCO 2DT gives you an additional boost. If the RPM was to try to rise too far, 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. Usually this "gains a gear" on the hills. And because more of the heat energy of the fuel was converted to mechanical energy, 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, converting a portion of the film to micron sized droplets. These droplets are produced without the high pressures and complications of injectors. The "ball" technique operates with relatively low pressures and has no fuel orifice to plug up. You do have to feed it clean pressurized gas (air, propane, etc.) but the fuel could be so dirty it would barely pour and the HyCO 2DT wouldn't care a bit. Another advantage of the "ball" technique, over spraying the liquid

out of a fuel injector nozzle is that the ball bypasses the laminar stage, so the inherent droplet size is usually ten times smaller than a normal nozzle spray. Note: This ball technique was originally developed for use in military heaters, because they needed a design of heater that would burn any fuel, regardless of viscosity, dirt, water, etc. Fuel must be vapor before it can burn and so this is one way they did it. The mist created by the ball is so fine that it will not wet a mirror held in it. The rest of the fuel simply drains back to the fuel tank. The very fine mist is directed to the intake side of the turbocharger. The turbo charger further mixes the mist with air, most of the mist actually turns into vapor. The turbocharger homogenizes the air and vapor fuel. Note: When diesel turns to vapor it requires a large amount of heat. It takes that heat from the air around it, thereby having a net cooling effect. The air then becomes denser. So the HyCO 2DT assists the turbocharger and the inter-cooler with this side effect. Note: Diesel fuel must be vapor and mixed with oxygen before it can burn. 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. This is called "lag time". There is no chance that the HyCO 2DT vapors will burn before the injector sprays, because the HyCO vapors are way too lean to

Other options and considerations Air pump. . . . . . . . . . . . . P8 Deceleration shutoff. . . . . . . .P9 Air tank. . . . . . . . . . . . . P10 Fuel Pump on drain. . . . . . . P11 Dual Turbo Chargers. . . . . . . P11

Cautions; Please read carefully. . P12 Warranties and liabilities. . . . . P12

HyCO 2DT / www.eagle-research.com

burn (not enough fuel). It is not easy to cause diesel fuel to evaporate, so only a very small amount of fuel turns to vapor and gets homogenized with the air. The homogenized air/fuel vapors simply assist combustion once it is initiated by the injector. The benefits of a homogenized air/fuel mixture are; a slight reduction in the lag time, smoother combustion, slightly increased power, decreased exhaust temperatures, reduced pollution and dramatically reduced fuel consumption. The HyCO 2DT is built heavy duty and will easily outlast the engine it is attached to. It requires no maintenance and is entirely automatic in its operation. We have HyCO 2DT's installed on test vehicles since November/91 and they are doing well. As of today on large trucks our results have been a net fuel mileage gain of between 7 and 14 percent, depending on load, with the better results being on the heavier loads, because the turbo pressures are higher, making the HyCO 2DT more efficient. In small vehicles, we've achieved over 40% fuel economy gain when the turbo is activated. All internal parts to a HyCO 2DT are set, there are no adjustments to make. It produces its fine mist with a patented procedure using liquid fluid films and exact application of moving gaseous fluids. In normal operation, a HyCO 2DT doesn't work if there is no air pressure applied, (the fuel just drains through it) so it is

automatically not working at idle, because there is no turbo pressure. As the engine begins to work, the turbo pressures rise, automatically starting the HyCO 2DT misting action. The HyCO 2DT doesn't really start to do anything until the turbo air pressure is above 5 psi. Then the response from the HyCO 2DT is rather linear till about 30 psi, any pressure greater than 30 psi does increase efficiency but in a greatly reduced amount. So I design the HyCO 2DT to operate under 30 psi. The ordinary HyCO 2DT installation depends on gravity to drain its container. If any HyCO 2DT is required to be mounted so that the diesel fuel cannot flow freely back to the fuel tank, 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. The HyCO 2DT is designed to have zero fluid level, all the liquid fuel must drain away. The draining action is assisted by the slight pressure created by the ball.. We have found in some cases, the truck's drain line is too small to make an adequate drain for gravity feed. Such as the Cat's #4 line. 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. Given a choice, I would always choose to install a large drain line because, as an inventor, I've always found that when you depend on moving parts, they will eventually fail. The HyCO 2DT is designed to operate with no moving parts, I like to keep it that way. The HyCO 2DT does require a source of compressed gas. By "gas" I mean a state of matter, as in solid, liquid, "gas". Normally we use turbo

pressure for the source of compressed gas, in this case the compressed gas is air. It is also possible to use many other sources of compressed gas, propane for example. But for simplicity, we find the turbo pressure to be adequate and convenient. Step one, figure out where everything is going to be. Then measure the hose lengths and determine if you need any more fittings. Remember that JIC and SAE fittings are different. It is best to use all of one or the other. The HyCO 2DT kit uses SAE fittings. SAE fittings are usually brass and can be picked up in a hardware store. JIC fittings are usually steel, made for high pressure hydraulic applications. Step two, go get all your hoses and fittings. Be sure to get DOT approved fuel hose that will fit your fittings. Make up the parts you need to fabricate on the spot. Step three, start mounting your HyCO 2DT. If you are doing this for the first time, you likely spent a couple of hours looking over this instruction manual. Then all one morning getting your parts and are at about 2 in the afternoon before being ready to start installing. It will take you one to four hours to install, depending on how good you are. These figures are based on my actual experience. Once you're experienced, a full installation will take you less than three hours, I've see it done in two.

Mounting HyCO 2DT Container

You will have to build your own mounting bracket. At this time we haven't designed a universal mounting system. Make sure it is

www.eagle-research.com / HyCO 2DT

reason, the HyCO 2DT will not drain to the fuel tank by gravity. Usually there would be enough fuel return flow to simply split the fuel return and feed it into both containers. Both containers need to be drained separately to the fuel tank/s

HyCO 2DT retains fuel, the rising fuel level will interfere with the "misting" action and eventually will overflow the container, causing liquid fuel to drain over into the engine. Note: Fuel condensation in the inter cooler has been expressed as a concern. 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, so if you are concerned with this, 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); if in fact the mist did condense, then it would be purged to the HyCO 2DT drain. Note: Using propane or natural gas (methane) mixed with diesel enhances combustion. So using these gases to pressurize the ball will have double effect. But take care, vapor fuel is "more volatile", your current fuel mixture starts to explode when just over 5% of it finds the proper combination. 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. Then it is simply a wide spot in the fuel return line. Most truckers choose to exercise this option, for safeties sake. I seriously recommend it. I've never seen it needed but it's there. Note: Some gaskets and hoses in some Diesel air intake systems are not totally fuel compatible, This leads to gasket or hose failure as the gasket or hose absorbs the fuel mist over a period of time. Simply replace these gaskets and hoses with fuel compatible versions.

That wraps it up for now. These are very basic instructions and I apologize for that. I invite feedback from your tests and comments of any kind on the product or this presentation. It is my intention to write a very comprehensive Manual for the HyCO 2DT and feedback is extremely helpful. We have (Feb./93) run testing on one of the best dynamometers in America, using a Kenworth truck and a CAT engine model 3406 B. The tests confirmed everything the on-road truckers had been telling us. The tests were so good that the companies we are dealing with couldn't believe it and are setting up SAE testing to confirm. We have also tested the HyCO 2DT on a Perkins turbo-charged Diesel in Mexico City. This Perkins engine was hooked up to a Perkins Dynamometer at the Perkins engine manufacturing facility. 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, but they had to acknowledge the results.

Cautions; Please Read Carefully

Do not attempt to install a HyCO 2DT system without a complete understanding of the instructions in this booklet. Do not attempt to deviate from the instructions in this manual. I have often shaken my head when I've heard of an incorrect installation of the HyCO 2DT and the result. Many mechanics feel they can "do it better" and I'm sure some can; BUT I've spent decades learning about this specific system, if you feel you've got a better way, for your own good, 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, perhaps I can save you a lot of time, money and grief. Do not take a HyCO 2DT apart to see it's internal workings. As simple as it may seem, there are a lot of internal adjustments and techniques that are pre-adjusted and are not explained in this booklet. If a vacuum is allowed to form in the HyCO container, it will limit the draining action and cause the container to retain fuel. If the

Warranties and Liabilities

The installation of the HyCO 2DT system does not void any engine warranties. If anything goes wrong with your engine that would have "normally" have gone wrong, your warranty still covers it. I have personally phoned the engine manufacturers to confirm this. No warranty will cover damage caused by use or miss-use of the HyCO 2DT, so make sure you install it right!

12

www.eagle-research.com / HyCO 2DT

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, exactly between min/max lines. Tests performed in Boise, Idaho at Western States Cat. Tests Sponsored by Entech Corporation of Meridian, Idaho. Results qualify as independent confirmation HyCO 2DT performance.

V e h C p o w e r

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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.

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Caterpillar Performance Analysis Report

02-23-1993 13:57:45

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Control test shows normal fuel volume for new injectors.

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Caterpillar Performance Analysis Report 02-23-1993 18:25:44

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This test with the HyCO 2DT installed shows the engine's fuel volume to be lower than the manufactures expect for power. The actual fuel curve is BELOW the min/max lines.

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Eagle-Research
Energy Solutions

since 1984

Patent-free Technology Brown's Gas Fuel Savers Free Energy

www.eagle-research.com

Dear Alternative and Sustainable Energy Enthusiast, Im a full time self-employed inventor. I research things that interest me, for use in my own life. The plans I sell are not just some armchair theorist brainstorming (though I usually start a project that way). I build the projects and make them work. They need to (and do) work because I use them myself. I develop them, redesign them, refine them and once Ive figured out how to DO IT in the most practical way I can... I DO NOT PATENT! I write a book; the books allow me to 1. Help (teach) a LOT of people AND 2. Bring in the money I need to pay bills and fund further research. 3. Make sure the technology is not lost if/when the Vested Interest finally shuts me down. Ive been a self-employed inventor since 1986 (started Eagle-Research in 1984). I (and thus Eagle-Research) am ENTIRELY SELF FUNDED, literally from satisfied customers. I do not accept Government grants or any money from anywhere that has any strings attached. Selling these books is how I fund research worth millions of dollars (and bypassVested Interest Suppression). Most of the money I make and years of my time go into to developing (and upgrading) innovations. Innovations that you can now know for the price of a book. This is why, when people copy and/or give away my books, they hurt 1. Me (copyright violation and loss of income), 2. YOU (you are denied technology upgrades on technology youve purchased), 3. All of society (everyone is denied practical innovation choices that could have been) On Scribd.com, otherwise well-meaning and enthusiastic people uploaded my books, which were downloaded (for free) over 10,000 times. That could have financed my Gravity Machine or an improved Free Energy Accumulator... To help enthusiastic people spread the word LEGALLY, weve started an affiliate program. As an affiliate, you will get PAID when you refer people to us and they buy any of our products. By now youve likely realized that most of this books pages are not included in this free preview. You can find a full authorized latest edition of all our books and kits in our eStore. http://www.eagle-research.com/store/ All products sold with 100% money back Satisfaction Guarantee. Use coupon code Scribd130313 to get a one time 20% discount on an order (good until 2016). You can also find a (purchase separately) online Resources that keeps this technology current as there are corrections, upgrades, options, proofs, FAQ, Blogs, Forums, links, similar research by others, etc. (plus a lot of free information) You can also subscribe to my eNews (see website sidebar) to stay informed on whats happening. I thank you for your interest and I look forward to helping you achieve what Ive already done.

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www.eagle-research.com

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WHO IS GEORGE WISEMAN

George Wiseman is the founder and president of Eagle-Research, a non-profit organization that develops and distributes energy-saving solutions. He is multi-talented and multi-degreed, but singular in his mission: to promote self-sufficiency at the individual level by discovering and sharing the best, all-around, practical solutions. George attributes his self-reliance, resourcefulness and commitment to our natural environment, to his rural roots. Dad didnt believe in having any equipment on the place (hobby farms in Montana, Oregon, Alaska and finally a ranch in British Columbia) that we couldnt fix ourselves. We had running water if we ran and got it. And electricity was something that came in batteries. His farmgrown, western cowboy philosophy combine well with his inventor persona to create a world-class visionary. He takes the hand-up rather than the hand-out approach to everything. Since 1984, George has been making his living as an inventor and author. His fuel-savers have gained him a worldwide following of satisfied consumers who eagerly pursue his work for new offerings. George continues to impress his customers, peers and competition with practical innovations that can be successfully home-built. His latest product, the ERxxxx WaterTorch, is making great waves in dozens of industries around the globe. As much as anything, its his commitment to patentfree technology development that has earned George Wiseman a champion reputation. Openly sharing research findings benefits everyone by constantly elevating the standards of viable energy solutions. Georges work has been featured on radio and in newspapers around North America and at many alternative energy gatherings including the International Tesla Society Symposiums and Exotic Research Conferences. He lives with his bride, Tenaj, and their brood of cats, in a lush valley of the Rocky Mountains. Individuals wishing to participate in the project may access the required reading list, that will be updated from time-to-time, on the Eagle-Research website: (www.eagle-research.com) Comments and/or contributions are invited from anyone who is committed to cultivating dream seeds. Nay-sayers are better not to waste their time. Negative input will be wholeheartedly disregarded.

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