Topic: FireCharger installation instructions my version

I recently finished installing a Firecharger AFFF system into the 200sx. The instructions were kind of lacking in some details which I thought needed to be spelled out better. I ended up backtracking and redoing a few things once I figured out how its all supposed to work. So I re-wrote the instructions. This is for your benefit if you are installing a Firecharger AFFF system into your car.

1.    Unpack everything and lay it out in a clean space and compare the parts received to the drawing shown in the middle of this book so you understand what pieces go where in the system.
2.    Check that the safety collar is installed on the handle end of the pull cable (#16) correctly and insert the Safety Handle Clip (#17) into the collar and the handle to prevent movement. If the collar is not installed, remove the nut and washer and slip the collar onto the handle, then insert the safety clip.
3.    Using a vice to hold the 2 port cylinder head (#18) and screw in the 2 - AN Adapters (#19).
4.    Screw the hose assembly (#27), the cylinder head O-ring (#26), and a burst disk (#25) into the 2 port cylinder head (#18). The burst disk should be installed so you can see the red mark when installing. Tighten to compress the O-ring.
5.    Take the CO2 bracket cover (#1) off of the Cylinder bracket (#13).  Temporarily tape the actuator arm down so that it does not accidently move during installation of the cylinder and discharge the CO2 cartridge (#6).
6.    Screw the CO2 cartridge into the actuator (#6).
7.    Fill up the cylinder with some water and screw the 2 port cylinder head (#18) and hose assembly into the cylinder and tighten so it does not leak. No water should be leaking from the cylinder.
8.    Temporarily mount the hold down brackets (#28) to the cylinder.
9.    The cylinder may be mounted vertically with the 2 port head on top, or horizontally with the actuator on top.  Choose a location that is close enough to the driver and the engine to allow for routing of the hard lines and nozzles. The cylinder mounting location should also allow for the Cylinder to be removed for re-charging when needed. It must also be within the length of the pull cable.

NOTE*** Mounting the cylinder vertically allows for more of the fluid to be discharged, but complicates installation of the cylinder when it is filled, as the CO2 cartridge must be installed to prevent leakage from the actuator. With the CO2 cartridge installed it is possible to accidentally discharge the water/AFFF when removing or installing the filled cylinder.

10.    Once a location has been chosen, mark the bracket locations, remove the cylinder, removed the brackets from the cylinder and mount the brackets to the car. The brackets should be mounted no closer than 6” apart using a minimum of 5/16” Grade 5 bolts, washers and nuts (Nylocks are recommended).  Then install the cylinder to the mounted brackets.
11.    The driver’s nozzle or nozzles should be mounted low to mid height in the car and pointed at the drivers torso and legs. Do not point the nozzle so the spray pattern sprays at the drivers face.  The engine nozzle or nozzles should be mounted high in the engine bay and pointed to cover as much of the engine area as possible. If two nozzles are used, install one on each side of the engine.
12.    The discharge lines can be hand formed, and should have smooth radiused bends.  Use the included Adel cushion clamps to secure the metal line to the car body along the length of the line. The mounting clamps should also be mounted in such a way as to prevent the rotation of the line in the clamps.
13.    Slide on the threaded collars (#21) at each end of the tubing, then slide on the AN tube sleeves (#20) in the proper direction. Using a flaring tool, flare the ends of the tubing to mate with the AN adapter (#19) and the nozzle (#24)
14.    Install the nozzle (#24) onto the tubing and tighten the AN Nut (#20) and then install the tubing onto cylinder head AN adapter (#19). Secure the tubing with the Adel clamps.
15.    Determine a location for the pull handle that is within reach of a belted in driver and also route the cable smoothly to the cylinder actuator bracket (#13). Fabricate a handle bracket with a 3/8” hole and install the cable into that bracket and tighten the washer and nut to hold it in place.
16.    Pull the safety pin out from the pull handle and remove the pull wire from the cable.
17.    Route the pull cable to the cylinder actuator bracket (#13) with the pull cable end (#15) and nuts (#14) to determine the needed length of the pull cable housing. Cut the cable to the desired length +1” with a pair of wire cutters.
18.    Reinstall the pull wire and handle and insert the safety Clip (#17).
19.    Cut the pull wire 1” past the actuator lever end (small hole in the end of the actuator lever).
20.    Bend the end of the pull wire up 90 degrees so that the bent wire passes through the hole of the actuator lever.
21.    Remove the pull cable (#6) from the cylinder bracket (#13), undo the tubing connections and remove the cylinder from the car.
22.    Remove the 2 port cylinder head (#18) from the cylinder and empty out the water.
23.    Remove the CO2 cartridge from the Actuator (#6).
24.    Temporarily re-install the cylinder into the brackets in the car and test the pull cable action with the pull wire in the actuator. The pull wire only needs to move about ¼” to puncture the CO2 cartridge and release the pressurized CO2, but the pull wire should pull the actuator smoothly outward.
25.    Remove the cylinder from the car and Install the Co2 cartridge into the actuator and tighten.  Tape down the actuator arm.
26.    Fill the cylinder completely full with water. Insert the 2 port cylinder head and hose into the cylinder. Some water will overflow out of the cylinder. Remove the 2 port cylinder head and hose assembly.
27.    Pour 12 ounces of water from cylinder into a measuring cup. Discard that water.
28.    Wearing safety glasses pour the AFFF into the water filled cylinder and install and tighten the 2 port cylinder head.

NOTE*** The cylinder is now filled and ready to discharge. so be careful with the next couple steps.

29.    Install the cylinder into the mounting brackets and tighten the brackets. Re-connect the tubing.
30.    Install the pull cable into the cylinder bracket.
31.    Un-tape the actuator arm and carefully route the pull wire up through the actuator arm hole. Then bend the end of the pull wire down to create a Z end to the wire through the actuator arm hole.
32.    Install the CO2 bracket cover (#1) onto the cylinder bracket (#13).
33.    Apply the “E” stickers to the car doors. The system is ready use when the safety clip is removed

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