The Hydrolyst™ Installation Procedure

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Vinegar Spray Bottle

• As a safety precaution every installer is required to carry a vinegar spray bottle. It neutralizes the electrolyte solution found in the The Hydrolyst™ cell if it were to be spilled on the ground or if it came into contact with skin.

Cell Pressure Relief Valve

• The pressure relief valve found in the rear of the The Hydrolyst™ to the far right comes from the factory with a plug that must be removed before you carry on with anything else. Probably the most important procedure next to sloping the Hydroxy gas delivery line.

Pressure Relief Plug

• A close-up of the parts of the pressure relief fitting and the part that need to be removed.

Tools Necessary for Preinstall, Installation and Service.

• Quick Cable 303115 (Model BVA-300) Hand Held Battery and Electrical System Tester

• DC Amp Meter Clamp Style • Inter-cooler Pressure Tester• Magnetic Torpedo Level• Hand Angle Grinder c/w Metal Cutting Disks• Centre Punch, Hose Cutter, Soldering Gun or Iron, Wire Cutters• Wire Strippers, Crimp Tools, Heat Gun• Cordless Drill c/w assortment of screw bits and attachments• General Hand Tools: Sockets; Wrenches; Screwdrivers• Torque Wrenches; Vice Grips; Crescent Wrench and Pliers, Knife• High Speed Steel Drill Bit Set c/w ⅛” – ½” bits• ¼” NPT Tap c/w 7/16” Drill Bit• ½”x5’ HDPE Extension Pipe, 50 ft. Extension Cord• 500 ml Water Bottle & 18 Litre Bucket, ½” HDPE Tube

Extension

Different Types of Alternators and Layout of

• This is an example of a 2005 Volvo D12 alternator with two I-Terminals.

Test Customers Batteries Before Install

• We will have to demonstrate to the customer that the batteries are bad, marginal or good before preceding with the install.

• On some configurations you may be able to just remove a common rail to isolate the batteries and get a proper battery test done. This is very important for the installer to know.

Battery Connections

• This is a little different looking battery connection, but still the same concept for testing. Disconnect negative side to isolate each battery and test with tester.

Pictures of Important Information

• Always take pictures of key sources of information on all Pre-inspections and Installations and send them in a folder clearly identified with name of customer and serial number and type of Engine to Enviresol .

Example with Dash Showing Mileage

• This option on most trucks can be used for other information such as average fuel consumption, engine etc.

Pictures for Backup

• Always take a picture to record the serial number and model of the Engine and the The Hydrolyst serial number. You don’t want to drive back in some cases hours. You can look at the picture and you are done.

Turbo Pictures if Possible

• Inspect the Turbo and take pictures. If the Turbo looks damaged inform the customer and take pictures. We don’t want to be blamed for a damaged Turbo when it was already damaged.

Installation Issues

• This is an example of a truck that we had no other than this location to install the The Hydrolyst™. This required the fabrication of custom brackets to approve the install on this vehicle. Approval from EnvireSol is required.

Mounting the Brackets

• Mounting the brackets should go smoothly if the Pre-install inspection was done thoroughly in the first place. Learning to recognize potential issues and dealing with them helps towards having a headache free Installation.

Example of an Install in Single Enclosure

• This is an example of putting the The Hydrolyst™ in a single enclosure. This requires the relocation of LED indicators and fabrication of a custom bracket in this case by the customer.

Relocation of Electrical Box

• In some cases the electrical box may need to be relocated customized brackets.

Custom Install with Relocated Box

• Sometimes you need to get creative to make an install. Just remember, as long as you can slope the Hydroxy line uphill from the The Hydrolyst™ to the Point of Entry without creating any moisture traps you can do the install.

Typical Point of Entry Connection to Intake

• This a typical connection to a Volvo intake. Notice the compressor tube take off to the right. Point of Entry must be after the compressor tube or closer to turbo to avoid losing hydroxy gas to the compressor.

Point of Entry on a Cab Over Garbage Truck

• This type of install to the Point of Entry drops straight down to the frame and slopes back to the The Hydrolyst™ .

Example of Freightliner Point of Entry

• This is a Mercedes engine in a Freightliner sowing the best location for the Point of Entry.

Using a Steel Rod to Support the Hydroxy Line

You can use a steel rod to run the length of the truck from The Hydrolyst™ to where the line goes up to the Point of Entry, to support the Hydroxy line all the way along. This way the Hydroxy line will never sag and create moisture pockets.

Isolation From Vital Truck Parts

• Throughout the manual we talk about making sure The Hydrolyst™ parts don’t touch sharp edges, heat sources etc, and make sure the truck’s parts are not damaged by the components that we have added.

Hydroxy Delivery Line Supported by Rod

• Here you see a Hydroxy delivery line supported by a ⅜” rod with hangers from the underside of the truck body. NOTE: a minimum of 3 screws per hanger are required to support these hanger brackets.

Typical Bunk Storage Compartment

• On the trucks that have sleeper compartments the storage area under the bed is ideal for installing the remote refill reservoir.

Reservoir in Sleeper Storage

• This is an example of the refill reservoir in the storage compartment of a Freightliner during a pre-install inspection.

Refill Reservoir in Storage Bunk

• This example shows a refill reservoir completely installed in an storage area under sleeper bed.

Tying Wires

• There should never be loose or hanging wires. They should always be tied up securely. All wires should be loomed up all the way to their destination point. Run along existing truck harnesses for safety.

Start-up Procedure take pictures

• Record Amp meter readings • Also Cell & Truck Hour Meters