Vulcan Service Manual (43pgs)
Contents
1. 5 ON amp N3MOd 50009 N31803d jOSNVHO LON TIIM 3ALHO3M S310 IV43N395 SSA JHL S SJANAM3IIVE JHL 530 ON SOW 1d uy vid 82d HOLIMS 42 ON 9 d 24009 SALON TVSH3N39 Ld SHI SI LINDYID HOLIMS 5300 SSA SSA SHA 39V 1d3M NOILN1OS HOIY JHL NO NOILAIOS V OL 139 JINNA SMOMNV JHL MOTIOS ON MO SJA V HLM 5 016300 M3MSNY jetielsSOas ONILQOOHSS INOX LHON NO Nant LON TIIM W3180dd GENERAL NOTES Troubleshooting Note A troubleshooting diagram is provided page 3 to help enable a repair technician to isolate and repair electrical problems which can arise The diagram describes a condition and suggests the underlying cause Repair procedures are provided in the chapters indicated in the solution blocks The troubleshooting procedure does not attempt to isolate individual components Instead it suggests replacement of modules or assemblies such as the printed circuit board the battery etc Occasionally problems may arise which are not included in the troubleshooting procedure In these cases a thorough physical inspection may reveal a broken wire cracked or damaged printed circuit board PCB or some other mechani2. and note the run time Also observe the lamp intensity 1 Run time is the time from when the Vulcan is turned on to the point where it becomes no longer usable 2 Nominal run times and charge times are listed below Lamp Option Time Charge Time AC Charge Time DC 6 75 hrs 12 0 hrs 6 watt spot 3 75 hrs 12 0 hrs 8 watt spot 2 75 hrs 12 0 hrs 10 hrs 2G 3 Normal intensity and short run time may indicate sulfation 4 Low intensity and normal run time may indicate shorted cells 5 Batteries which exhibit signs of sulfation or shorted cells must be replaced sealed lead acid battery in this product is recyclable At the end of its useful 6 9 life under various state laws it be illegal to dispose of this battery in the municipal solid waste stream Check with your local solid waste officials for Pb details in your area for recycling options or proper disposal D If the Vulcan has normal intensity and normal run time the battery is good Removing and Replacing the Vulcan Battery See pictures on Page 11 A Remove the facecap as described in Section B Place the Vulcan on a table or bench with the open end facing upwards and with the handle away from you C Carefully lift the reflector lens assembly from the body and unscrew it from the lamp socket D Unscrew the Phillips head screws on each side of the battery clamp and remove the battery clamp E Carefully disconne
3. and the Vulcan still does not light If the Vulcan has a toggle switch replace the board If the Vulcan has the older style C shaped contact check the switch contact on the printed circuit board See page 19 25 Testing the Toggle Switch Note There are procedures included for testing the toggle switch However the toggle switch is not serviceable and if it fails any test it must be replaced A The toggle switch contact points on the PCB are aligned vertically for the single filament Vulcan and horizontally on the dual filament Vulcan see pictures below B Place a multimeter into the Continuity Check position C For the single filament Vulcan place one meter lead on each toggle switch contact of the PCB With the toggle switch up there should be no continuity When the toggle switch is down the meter should indicate continuity D For the dual filament Vulcan put the toggle switch in the center position off E Place one meter lead on the center switch contact and the other lead on the right switch contact There should be no continuity Put the toggle switch to the left The meter should indicate continuity Put the toggle switch to the right There should be no continuity F Place one meter lead on the center switch contact and the other lead on the left switch contact There should be no continuity Put the toggle switch to the left There should be no continuity Put the toggle switch to the right The meter s
4. black from the negative battery terminal and remove the positive lead red from the positive battery terminal Place the known good Vulcan into the charge rack to be tested Insure the charge rack is connected to a known good power source 1 If the green LED is lighted and the red LED is off follow the test procedures below a Set the multimeter to the DC volts position b Place the positive meter lead on the red battery lead c Place the negative meter lead on the black battery lead d The meter should read between 7 1 and 7 4 volts 1 The green LED should be on 2 The red LED should be off e Keep the multimeter connected to the battery leads 1 Place a 15 10 watt resistor across the battery leads 2 The multimeter should read between 6 65 and 6 95 volts 3 The green LED should be off 4 The red LED should be on 5 If the PC board performs as outlined in the steps above it is functional Reassemble the Vulcan as shown in Section 6 If the PC board did not perform satisfactorily it should be replaced 2 If the red LED is lighted both LED s are lighted or neither LED is lighted the circuit board should be replaced 27 Replacing the Charge Rack PCB A Unscrew the Phillips head screw located above the single base plate mounting post Mounting Screw B Carefully lift the PCB assembly straight up and out of the charger housing C Obtain the proper replacement assem
5. Over Tighten the Nut D Insert the battery into the body of the flashlight The battery terminals should be pointing upward and the positive battery contact should be adjacent to the charge contact mounting holes E Reconnect the battery leads and test the switch for function After confirming the switch functions properly remove the battery leads Reattach the charge leads to the charge contact screws and secure them in place 1 The negative black lead goes to the charge contact screw on the left side open side of body facing upward handle facing away from you and the positive red charge lead goes to the contact screw on the right 67 24 ef L4 Charge Contacts 2 Use a 5 16 wrench to tighten the lock nuts until they are snug against the body When the contact screws are snug turn the Tri Wing contact screw an additional 1 8th turn to insure a waterproof seal Note Do not over tighten the screws or the body may crack G Place the battery clamp on the battery but do not secure it in place 1 Route the positive battery and charge leads between the Vulcan body and the battery clamp on the right side of the Vulcan handle facing away from you 2 Route the negative charge lead only between the Vulcan body and the battery clamp on the left side of the Vulcan handle facing away from you H Secure the battery clamp into place with the two Phillips mounting screws Reassembl
6. Remove the facecap from the Vulcan as described in Section B Place the Vulcan on a table or bench with the open end facing upwards and with the handle away from you C Unscrew and remove the reflector assembly from the lamp holder and place the assembly aside D Disconnect the negative black battery lead See pictures on Page 11 E Place a multimeter into the Continuity Check position F Place one meter lead onto the negative charge contact and the other meter lead onto the negative black battery lead The meter should indicate continuity G Place a multimeter into the Diode Check Position H Place the positive red meter lead onto the positive red charge contact Place the negative black meter lead onto the positive red battery terminal The meter should read between 5 and 7 Volts Continuity through a diode junction Place the negative black meter lead onto the positive red charge contact Place the positive red meter lead onto the positive red battery terminal The meter should read Over Range Open circuit across reversed diode junction J Set a multimeter to the ohms position K Place one meter lead onto the positive charge contact and the other meter lead onto the negative charge contact The meter should read between 1 76 and 2 64 K ohms L If the switch PCB fails any of the above tests it must be replaced M If the switch PCB passes these tests the lamp is good the battery is good
7. V 4 SECTION I REMOVING REPLACING THE FACECAP The facecap of the Vulcan is designed to prevent water from entering and damaging the flashlight A proper seal is achieved through the use of two internally mounted O rings is very important that the facecap be properly reinstalled after it has been removed Removal A Support the body of the Vulcan The body should be placed in a bench mounted vise if one is available with the facecap pointing upwards Note Be sure to protect the body from damage B Grasp the outside of the facecap and turn it counterclockwise until it comes free from the Vulcan bogy Note A strap wrench minimum diameter 5 1 2 inches will greatly facilitate removal of the facecap Replacement A Support the body of the Vulcan as in step one above B Thread the facecap onto the body and tighten the facecap to the point that you cannot move the lens reflector within the facecap C Turn the facecap an additional 1 8th turn to insure its water resistance D Inspect the area between the facecap and the lens to be sure that no portion of the O ring is showing If the O ring is showing remove the facecap and reinstall it as in steps 1 2 and 3 above O ring must not be showing SECTION Il TESTING REPLACING THE LAMP A Remove the facecap from the Vulcan as described in Section B Carefully lift the lamp reflector assembly away from the Vulcan body C There are two different styles of bulb
8. 99 GREEN R3 a 568 Mes 2N3986 xm NU ERR PART OF EM 1N4148 E 2N3984 LANTERN 470 s NN Cu S 1N4148 P INPUT T em ACID CRE Ba 810 868 R5 Z CRS 278 x RED n8 243904 02 250 AW C 158 SI CR10 R9 a 7 VAN 118 TN4148 510 MW 398 2 4 7K ce 4 7 lt gt CRB m bo Y 1N4148 E MW 1 0 2H z UULCAN CHARGE BOARD SCHEMATIC 6 MARCH 00 FIRE VULCAN TROUBLESHOOTING PROCEDURE PROBLEM ANSWER QUESTIONS WITH A YES OR NO FOLLOW THE ARROWS UNTIL YOU GET TO A SOLUTION ON THE RIGHT NO LIGHT a WILL NOT ump NYES b om SOS ES TURN ON 60007 0000 FUNCTION P 6 P 41 NO NO NO LIGHT IS THE YES WILL NOT gt pied CHARGE P 9 YES YES Note Review the charger note at bottom of Vulcan troubleshooting diagram on PROBLEM page 3 of this manual See General Notes p 35 for information regarding the tail lights on the Fire Vulcan 7 7 w o 2 REPLACE 8 fe SWITCH PCB 2 4 N 25 5 j 5 gt H PCB 2340 gt gt SOLUTION FIRE VULCAN GENERAL NOTES Troubleshooting Note Troubleshooting the Fire Vulcan system involves essentially the same process as troubleshooting the standard Vulcan system Most repair issues except the battery lamp and charger will require the replacement of the entire switch pcb and LED tail light bo
9. C volts position Donnector Pins D Hold the charge connector facing towards you with the black key at the top of the connector see illustration 1 Place the positive lead of the meter onto the left pin of the connector 2 Place the negative meter lead on the right pin E The meter should give a reading between 13 and 22 volts and there must be no indication of reversed polarity F If the voltage or polarity is wrong replace the charger G Do not attempt to repair the AC charger Testing the DC 1 Charge Cord Cigarette Lighter Plug A Connect the DC 1 charger plug to its power source power point cigarette lighter adapter etc B Place a multimeter into the DC Volts position 22 C Measure the voltage as in Step D on page 22 AC testing D The meter reading must reflect the vehicle s supply voltage and be between 11 and 15 Volts DC 1 If there is no reading the charge cord needs to be checked a e Place the multimeter into the continuity test position and place one meter lead onto the right charge connector pin with the connector facing you key on top Place the other meter lead onto the ground spring on the cigarette lighter plug The meter should indicate continuity Place one meter lead on the left charge connector pin connector facing you key on top Place the other meter lead onto the tip of the cigarette lighter plug f The meter should indicate continuity If i
10. OWN 14 1 45232 STRAP ASSY SHOULDER 22311 CORD 120V AC CHARGE 15 2 440018 CLIP SHOULDER STRAP 21725 CORD 230V AC CHARGE 400262 D RING NEW STYLE 22666 CORD 100V AC CHARGE OLD STYLE NOT SHOWN 22241 CORD 240V AC CHARGE 17 1 440015 PLUG VALVE 22051 CORD 12V DC CHARGE 18 1 130018 VALVE 440040 BODY HANDLE ASSY YELLOW 440040 6 BODY HANDLE ASSY GREEN SWITCH FOR QUAL FILAMENT SWITCHS SHOWN IN OFF POSITION VULCAN SWITCH BOARO SCHEMATIC TOGGLE SWITCH VERSION SWITCH FOR SINGLE FILAMENT THESE PARTS NOT INCLUDED FOR SINGLE FILAMENT CONFIGURATION 5 1N4002 CRI LAMP 2 CHARGE POUER INPUT BATTERY 2 a ZTX849 ZTX849 01 02 02 CHARGE POWE INPUT FUSE Obsolete Style With Paddle Switch SHOWN IN E PARTS NOT INCLUDED CR1 1N4002 LAMP 25 180 2 2K BATTE BOARD SCH VULCAN SWITCH R SINGLE FILAMENT CONFIGURATION d EMATIC REV D eS WW WW R18 R19 4 7K 4 7K 5 213906 2177 gp CRI REGULATOR 1N4002 Quin 5 5 T i 2 0 1N4002 REF a 33e 560 R6 mus wi CR11 AM CRE CR4 p 5
11. TABLE OF CONTENTS PREFACE TROUBLESHOOTING DIAGRAM GENERAL NOTES SECTION REMOVING REPLACING THE FACECAP SECTION TESTING REPLACING THE LAMP SECTION Ill TESTING THE VULCAN SECTION IV TESTING REPLACING THE SWITCH PCB ASSEMBLY SECTION V TESTING REPAIRING THE CHARGER SECTION VI THE BODY VULCAN REPLACEMENT PARTS AND DIAGRAM een VULCAN SWITCH PCB VULCAN CHARGE RACK PCB SCHEMATIC FIRE VULCAN TROUBLESHOOTING DIAGRAM FIRE VULGAN OENERAL NO RES TESTING REPLACING THE SWITCH PCB 55 FIRE VULCAN REPLACEMENT PARTS AND FIRE VULCAN SWITCH 5 VULCAN SERVICE MANUAL PREFACE The purpose of this manual is to provide the information needed to service the Streamlight Vulcan flashlight system This manual is dated see front cover Additions deletions and changes to this manual will display a later date A set of tools including a Phillips screwdriver a 3 Tri Wing driver a 5 16 wrench needlenose pliers a 15 ohm 10 Watt resistor and a multimeter are required to service the Vulcan Lamp may be changed without special tools For additional information and or a
12. and secure them in place 1 The negative black lead goes to the charge contact screw on the left side open side of body facing upward handle facing away from you and the positive red charge lead goes to the contact screw on the right 2 Use a 5 16 wrench to tighten the lock nuts until they are snug against the body When the contact screws are snug turn the Tri Wing contact screw additional 1 8th turn to insure a waterproof seal Note Do not over tighten the screws or the body may crack C Place the toggle switch PCB assembly with the toggle switch through the switch hole 1 The Toggle switch side of the assembly must face down See picture below Positive Battery and Charge Leads Negative Charge Lead 2 Route the battery leads and charge leads between the mounting posts and the walls of the body 3 Reconnect the battery leads and test the switch for function After confirming the switch functions properly remove the battery leads and proceed to Step D D Replace the battery clamp above the battery but do not secure it 1 Route the positive battery and charge leads between the Vulcan body and the battery clamp on the right side of the Vulcan handle facing away from you 2 Route the negative charge lead only between the Vulcan body and the battery clamp on the left side of the Vulcan handle facing away from you E Secure the battery clamp into place with the two Phillips mounting screws F Re
13. ard assembly Tail Light Lenses The tail light lenses on the rear of the body of the Fire Vulcan are sonically welded in place and are not field serviceable The integrity of the lenses must be maintained to assure the hermetic integrity and class rating of the flashlight If the lenses are damaged the entire flashlight should be returned to Streamlight for factory service UK 26664 Fire Lantern NG To redu ify WARNI ead Tail Light Lenses Tail Light Issues If the taillights operate improperly or fail to light the wiring connection between the tail light PC boards and the switch PC board should be inspected If the connections are intact and the tail light PC boards are in place there be a misplaced switch PC board jumper See the jumper position table on page 43 for the correct positioning of each jumper If the problem persists the entire switch PC board and tail light PC board will need to be replaced p 38 35 TESTING REPLACING THE SWITCH PCB ASSEMBLY Testing the Printed Circuit Board Charge Circuit A B Place the positive red meter lead onto the Place the negative black meter lead onto the Remove the facecap from the Vulcan as described in Section page 5 Place the Vulcan on a solid work surface with the open end facing upwards and with the handle away from you Unscrew and remove the reflector assembly from the lamp holder Place the assembly aside Disconnect the
14. attach the battery leads 1 Attach the positive red lead to the positive battery terminal Note Use needlenose pliers if necessary 2 Attach the negative black lead to the negative battery terminal G Place the lamp into the lamp socket Note Detailed instructions are in Section 11 H Put the switch boot over the toggle switch and using a 5 8 wrench carefully tighten it until it is snug Reassemble the Vulcan as described in Section Toggle Switch without Boot Toggle Switch with Boot Before Tightening 16 Testing the Paddle Switch Contacts Note Replacement parts for the Paddle Switch versions are no longer available If adjusting the switch contacts does not fix the problem the entire Body PCB assembly must be replaced A Reconnect the negative black battery lead B Remove the two mounting screws which hold the switch PCB assembly in place Remove mounting screws Insulating Washer Under Screw Head Note There is a washer on the mounting screw located below the positive leads This screw and insulating washer combination is critical and must be retained for reassembly C Carefully lift the switch PCB from the mounting posts and tilt it towards you D At the front of the switch PCB is a U shaped contact Press the raised left end of the contact against the pad of the PCB The lamp should light Raised ends of the contact E Repeat the process using the raised right end o
15. bly 1 2 D Reassemble the charge rack 1 Seat the PC Board in the charger housing Secure the PC Board with the Phillips screw Make sure that the charger latch is properly seated Place the power input connector in the opening in the charger rack Align the bottom cover and snap it into place Standard PCB P N 440115 Vehicle Mount PCB P N 440114 Standard Rack Carefully align the charge pins and LED s with their respective openings Hold the charger rack housing with the charger latch pointing charge rack Rib must be inside downward a The keyed slot should point toward the charger base b The strain relief rib must be inside the charge rack opening Direct Wire Rack 28 SECTION VI THE BODY It is important to inspect the Vulcan body for any cracks Be sure to thoroughly check around the charge contacts Cracked bodies must be replaced to maintain the Vulcan s hermetic integrity and safety ratings Streamlight strongly recommends that any cracked Vulcan bodies be returned to the factory for proper replacement Streamlight will vacuum test for proper hermetic integrity and compliance with applicable safety rating requirements Note Paddle style switch versions are no longer available Note There is a pressure vent located between the charge contacts of the Vulcan The very small opening of this vent must be kept free of debris dirt and residue Replace the valve pl
16. cal damage which results in an apparent electrical problem If the problem remains elusive the Vulcan and all of its available components including the charge rack and plug in wall transformer should be returned to Streamlight for factory service Charge Contacts The charge contacts located on the Vulcan and the charge rack must be kept clean If the charge rack contacts become dirty they can become stuck in the down position and fail to make proper contact resulting in the Vulcan not receiving a proper charge If the contacts become dirty they can be cleaned with a mild non corrosive cleaner WD 40 In extreme cases fouling can be removed by using a pencil eraser Be careful not to remove the protective plated surface of the charge contacts lt Charge Contacts lt The Red and Green Charge Indicators The Vulcan charge rack is equipped with two LED s which light to indicate the mode that the charging circuit is in The red LED indicates that the battery is being charged The green LED indicates that the charging cycle is complete and the battery is at maximum capacity The LED s can warn of malfunctions within the charging circuitry The red oM HE LED should turn off completely twelve 12 ins or less after the charge SIREAMLGHT cycle is initiated and the green LED should turn If the red LED remains for more than 12 hours the charging circuit dt be tested and repaired or replaced as necessary see section
17. ct the battery leads Use needle nose pliers if necessary Move the battery leads aside F Move the charge leads aside enough to allow the battery to pass Do not disconnect the charge leads G Carefully pull the battery from the Vulcan body Note Always handle the battery with care and do not allow it to become short circuited A short circuited battery can deliver hundreds of amperes of current which can start a fire H Install the new battery in the Vulcan 1 Place the battery terminal side up into the Vulcan body Position the battery with the negative black terminal closest to the Printed Circuit Board and the positive red terminal closest to the charge contacts 2 Attach the battery leads to the battery terminals observing proper polarity 10 Negative Terminal Positive Terminal Battery Clamp Positive Charge and Battery Leads 3 Replace the battery clamp routing the positive red charge and battery leads between the body and the clamp 4 Secure the clamp to the body with the Phillips head screws 5 Replace the reflector lens assembly and reassemble the Vulcan as described in Section I zia SECTION IV TESTING REPLACING THE SWITCH PCB ASSEMBLY Note There are currently several different switch versions The instructions for checking the PCB are the same for all versions The different switches are addressed individually in this chapter Testing the Printed Circuit Board Charge Circuit A
18. e the Vulcan as described in Section sad REPLACEMENT PARTS 4000 BATTERY _ LB 1 450116 BOOT SWICH 5 5 5 Ge GE ZIMMER SUM E nl L 10 _ 2 440009 LOCK NUT CHARGE CREW CHARG L 12 2 440017 O RING CI 3 31 119147 Ar 3wTeH BOARD BATTERY VOLTAGE 6 4 VOLTS FLASH REP RATE 2 1 PPS FLASH DUTY CYCLE 42 ON LEO CURRENT lt STEADY gt 76 LEO CURRENT lt FLASH 133 M Jumper A STEADY FLASH MODE JUMPER CONFIGURATIONS 4 Jumper B STEADY LEDs 8 FLASHING LAMP PULL UP ON JUMPERS TO REMOVE 43
19. e voltage is at least 20 Volts greater than the voltage noted in Step D proceed to the Quick Battery Test 2 If the voltage is less than 20 Volts greater than the voltage noted in Step D proceed to Testing the Printed Circuit Board located in Section IV Quick Battery Test A Charge the Vulcan in a known good charge rack for 12 hours or until the Green LED lights Remove the Vulcan from the charge rack Place a multimeter into the DC Volts position Place the red meter lead onto the positive red battery terminal and the black meter lead onto the negative black battery terminal The voltage should measure above 6 5 Volts If the voltage is less than 6 5 Volts the battery will need to be replaced If the voltage is 6 5 Volts or greater place the battery under load by running the Vulcan with a six watt bulb for 10 minutes Leave the Vulcan on during the following test Re test the battery as described in Step C above The voltage should measure between 6 0 Volts and 6 4 Volts 1 If the voltage is less than 6 0 Volts the battery will need to be replaced 2 If the voltage is 6 0 Volts or greater the battery is probably usable If the customer s complaint is short run time proceed to the run time test below Run Time Test A B Charge the Vulcan in a known good charge rack for 12 hours or until the Green LED lights Remove the Vulcan from the charge rack C Turn the Vulcan on
20. enter position off Place one meter lead on the center switch contact and the other lead on the right switch contact There should be no continuity Push the toggle switch to the left The meter should indicate continuity Push the toggle switch all the way to the right There should be no continuity Place one meter lead on the center switch contact and the other lead on the left switch contact There should be no continuity Push the toggle switch to the right The meter should indicate continuity Push the toggle switch all the way to the left There should be no continuity Center Switch Contact Toggle Switch Contacts zu s Toggle Switch PCB Removal Note As you remove the toggle switch PCB note the routing of battery and charge leads A Unscrew the two Phillips mounting screws which secure the battery clamp and remove the battery clamp Negative Battery Lead Positive Battery Lead Battery Clamp Screws Charge Contacts and Lock Nuts B Remove the negative black lead from the battery and remove the positive red lead from the battery C Remove the battery from the flashlight body D Remove the leads from the charge contacts 1 Fire Vulcans utilize a special contact screw and require a 3 Tri Wing driver P N 440051 to hold the charge contact screw for disassembly Tri Wing Screw 2 Use a 5 16 wrench to loosen the lock nuts e E Unscrew the Phillips mounting screws tha
21. f the contact The lamp should light F If the lamp does not light the switch PCB must be replaced G If the lamp does light the U shaped contact on the PCB may need to be adjusted H Remove the switch PCB from the Vulcan and follow the procedures on page 18 17 Paddle Switch PCB Removal Note As you remove the switch PCB note the routing of battery and charge leads A Unscrew the two Phillips mounting screws which secure the battery clamp and remove the battery clamp B Remove the negative black lead from the battery and remove the positive red lead from the battery C Remove the leads from the charger contacts 1 Use a 5 16 wrench to loosen the lock nuts 2 Newer Vulcans utilize a special contact screw and require a 3 Tri Wing driver P N 440051 to hold the charger contact screw for disassembly Note Original Vulcans used hex contact screws See page 32 These screws are Tri Wing not interchangeable Tri Wing screws CANNOT be used on the older Vulcans Screw D Lift and remove the switch PCB assembly and associated leads from the Vulcan body E Check the Phillips screw which secures the switch actuator Tighten if necessary Insure screw is tight Adjusting the Contacts A Remove the switch PCB from the Vulcan as described above B Place the short end of a 1 16 Allen wrench under the raised portion of the U shaped contact See pictures on page 19 C Hold the end of the contact a
22. gainst the PCB D Slowly rock the Allen wrench until the contact bends slightly upward above the wrench E Repeat the procedure for the other end of the contact 18 F Inspect the ends of the contact to insure that they are not touching the pads on the PCB The ends should be about 1 32 above the board Note There is a somewhat critical relationship between the ends of the contact the bends in the contact and the circuit board The switch actuator presses against the contact at the spot where you bend it upward The ends of the fingers are pressed down against the PCB If the ends of the fingers are too high or the contact bend is too low the lamp will not turn on If the ends are set too low they may fatigue over time and not turn off If you are unable to obtain proper operation by adjusting the contacts you will need to replace the entire Vulcan Body Switch assembly Insert short end of 1 16 Allen wrench under contact here Hold the end of the contact down while bending it Allen wrench Hold the end of the contact down while bending it Ends of the contact should be about 1 32 above the PCB 448 Paddle Switch PCB Installation Single Filament Assembly P N 440008 Dual Filament Assembly P N 440027 B Reattach the leads to the charge contact screws and secure them in place 1 The negative black lead goes to the charge contact screw on the left side open side of body facing upward ha
23. hould indicate continuity Single Filament Toggle Switch Contacts Dual Filament Toggle Switch Contacts Dual Filament Center Switch Contact Toggle Switch PCB Removal Note The Vulcan body with the toggle switch is physically different from and not interchangeable with the Vulcan body using the paddle switch Note As you remove the toggle switch PCB note the routing of battery and charge leads A Unscrew the two Phillips mounting screws which secure the battery clamp and remove the battery clamp B Remove the negative black lead from the battery and remove the positive red lead from the battery C Remove the leads from the charger contacts 1 Use a 5 16 wrench to loosen the lock nuts 2 Newer Vulcans utilize a special contact screw and require a 3 Tri Wing driver P N 440051 to hold the charger contact screw for disassembly D Use a 5 8 wrench to loosen the toggle switch boot see picture below Tri Wing Screw E Once the toggle switch boot has been loosened it can be unscrewed and removed from the toggle switch The toggle switch can now be removed from the Vulcan Toggle Switch Boot Toggle Switch with Boot removed aas Toggle Switch PCB Installation A Obtain a replacement toggle switch PCB assembly Single Filament Assembly P N 440118 Dual Filament Assembly P N 440119 This nut must be bottomed on the threads Do not over tighten B Reattach the leads to the charge contact screws
24. ndle facing away from you and the positive red charge lead goes to the contact screw on the right 2 Use a 5 16 wrench to tighten the lock nuts until they are snug against the body When the contact screws are snug turn the Tri Wing contact screw additional 1 8th turn to insure a waterproof seal Note Do not over tighten the screws especially the older style hex screws or the body may crack C Place the switch PCB assembly onto the mounting posts in the Vulcan body Mounting Posts 1 The switch contact side of the assembly must face down See picture on page 21 for proper orienteering 2 Route the battery leads and charge leads between the mounting posts and the walls of the body 20 Positive Battery and Charge Leads Negative Charge Lead 3 Align the holes in the switch PCB with the mounting standoffs and secure the assembly with the Phillips screws Note Insure that there is an insulating washer under the head of the mounting screw located on the side with the positive leads 4 Reconnect the battery leads and test the switch for function After confirming the switch functions properly remove the battery leads and proceed to Step D If the switch does not function properly readjust the contacts as described on page 19 D Replace the battery clamp above the battery but do not secure it 1 Route the positive battery and charge leads between the Vulcan body and the battery clamp on the right
25. nside of the reflector c Screw the socket back into the reflector assembly d The socket can be adjusted in the spot reflector assembly 1 Turn the Vulcan on and shine it on a wall approximately 10 feet away 2 Adjust to the desired focus by screwing the socket inward towards the fully seated position or outwards until the point where the socket O ring starts to leave the surrounding screw shell of the reflector Note The focus should be attained somewhere between the two limits described try 1 4 turn out from the fully seated position D Place the reflector lens assembly back into the Vulcan body E Reassemble the Vulcan as shown in Section l ay ae SECTION Ill TESTING REPLACING THE BATTERY Test for Charge Power to the Battery A Remove the facecap from the Vulcan as described in Section B Place a multimeter into the DC Volts position C Place the red meter lead onto the positive red battery terminal and the black meter lead onto the negative black battery terminal Negative Terminal Positive Terminal D Note the voltage E Place the Vulcan into a known good charge rack and connect it to a power supply F Allow the Vulcan to charge for 5 minutes G Leave the Vulcan charging in the charge rack and re test the battery as described in Step C above H The voltage of the battery while charging in the charge rack should be at least 20 Volts above the voltage noted in Step D above 1 If th
26. positive and negative battery leads Place a multimeter into the Continuity Check position Place one meter lead onto the negative charge contact and the other meter lead onto the negative black battery lead The meter should indicate continuity Place a multimeter into the Diode Check Position positive red charge contact Place the negative black meter lead onto the positive red battery lead The meter should read between 5 and 7 Volts Continuity through a diode junction positive red charge contact Place the positive red meter lead onto the positive red battery lead The meter should read Over Range Open circuit across reversed diode junction Charge Charge Contact Contact Set a multimeter to the ohms position Place one meter lead onto the positive charge contact and the other meter lead onto the negative charge contact The meter should read between 1 76 and 2 64 K ohms If the switch PCB fails any of the above tests it must be replaced proceed to p 38 36 Testing the Toggle Switch Note There are procedures included for testing the toggle switch However the toggle switch is not serviceable and if it fails any test it must be replaced A B C D E Disconnect the negative battery lead Note the location of the toggle switch contacts in the photo below Place a multimeter into the Continuity Check position Place the toggle switch in the c
27. s The single filament bulbs have two leads Dual filament bulbs have three leads Note The single and dual filament bulbs are not interchangeable Follow the instructions below to test or replace the bulb 1 Test the bulb Common Lead Dual Filament Single Filament a Unscrew the threaded bulb socket from the reflector b Pull the old bulb straight out from the socket c Use a multimeter in the continuity position 1 For single filament bi pin bulbs place a meter lead on each bulb lead a beep or continuity indicates a good bulb 2 For dual filament bulbs three pin first establish the common lead the common lead connects with the long filament support visible inside the bulb Place one meter lead on the common lead and then test each of the remaining leads a beep or continuity indicates a good bulb 2 Bulb replacement Note Single and Dual filament bulbs are not interchangeable A single filament bulb socket is connected to the circuit board by two wire leads A dual filament bulb socket is connected by three wire leads 1 Dual Filament Socket Single Filament Socket a Replace the bulb by aligning the pins with the holes in the socket and seat the bulb firmly Note Use care and make sure that the leads are properly aligned when inserting the dual filament bulb b Wipe off any fingerprints from the bulb with a tissue and alcohol Any oil left on the bulb will permanently smoke the i
28. side of the Vulcan handle facing away from you 2 Route the negative charge lead only between the Vulcan body and the battery clamp on the left side of the Vulcan handle facing away from you E Secure the battery clamp into place with the two Phillips mounting screws F Reattach the battery leads 1 Attach the positive red lead to the positive battery terminal Note Use needlenose pliers if necessary 2 Attach the negative black lead to the negative battery terminal G Place the lamp into the lamp socket Note Detailed instructions are in Section 11 H Reassemble the Vulcan as described in Section 21 SECTION V TESTING REPAIRING THE CHARGER SYSTEM The Vulcan currently has two charge racks available a direct wire with a permanently attached 12 V DC power cord and a standard rack with a socket that accepts a variety of charge cords for various DC and AC power sources Note All power sources must provide the charge rack with 12 15 V DC during charging AC Chargers will read between 13 and 22 Volts under no load conditions depending upon your transformer DC Vehicle System Charge cords will read between 11 and 15 Volts the normal voltage of the vehicle Testing the AC Wall Charger A The AC wall charger can be tested by simply measuring its output voltage B Make sure that the wall charger is plugged into a functioning AC outlet Charge Connector Test Key C Place a multimeter in the D
29. ssistance contact STREAMLIGHT INC Repair Department 30 Eagleville Road Eagleville Pa 19403 Phone 610 631 0600 Phone 800 523 7488 FAX 610 631 0712 7 00 a m 5 00 p m EST NOILN IOS 4 0402 39 81 uo A eq UBD suoronjasui Huss payiejaq ULNA UM 150 s au 3461 poob umouy ui peoejd pue 10 si joedsns e u yM 991 150 SI eui JOU Ji pejuBi pjnous y JO eui pue 1oedsns y ui ueojnA poof e pay ou eg pinous pue 1oedsns y ui OU eui 10 ueo nA 19edsns 591 eui djay 9eu pue uMOUM V 910 JOW Id3M 124005 ON Cod NOILONNS QMJOO 9 YSMOd MOSHO vd SLOVLNOO SJA GHL 5300 39WNVHO Sid dod MOVE 9 doVidsd vd 5310 Wu3N39 vlc gOd HOLIMS ONIMIM vd ON ON ON Sod NOWLONN dod Move SLOWINOD MOVM JOUWHO 3ONVHO 3ONVHO JHL lt NBHL OL M3MOd SSA JHL S30Q SJA
30. t does not check the fuse 1 Remove the fuse by removing the end of the cigarette lighter plug Push and twist the end cap 2 Test the continuity of the fuse 3 If required replace the fuse with a 20mm X 5 mm fuse 2 amp slow blow 2 amp fast blow or 5 amp fast blow g If there is no continuity complete circuit in Step 1c above or after replacing the fuse the DC 1 should be replaced 2 If the meter shows proper voltage proceed to Testing the Charge Rack below Testing the Charge Rack The 12V DC direct wire charge rack has a permanently wired cord to supply input power If possible the direct wire charge rack should be checked while it is connected to its power source a known good 12V DC source is also suitable Note Direct Wire Systems must be connected to the vehicle battery through either a switched or un switched connection Streamlight recommends that Direct Wire Systems not be connected to the accessory rail of a battery saver or supplemental charger Some such devices can destroy the Vulcan charge circuitry and will void the warranty 23 A Connect the charge rack to its power supply Direct wire rack connected to vehicle battery Standard rack connected to a known good power supply B Measure the charge rack output at the charge pins at the front of the charge rack 1 Place the positive meter lead on the charge pin located closest to the Red and Green LEDs 2 Place the negati
31. t secure the LED tail light boards to the flashlight body LED tail light board screws F Use a 5 8 wrench to loosen the toggle switch boot see picture below Toggle Switch Boot G Once the toggle switch boot has been loosened it can be unscrewed and removed from the toggle switch The toggle switch PCB and LED tail light boards can now be removed from the Vulcan 39 Toggle Switch PCB Installation A Obtain a replacement LED toggle switch assembly p n 440127 Negative Charge ms Negative Battery EE Lead S LED Tail Light Boards A on 4 Positive Battery Lead mc a Positive Charge Lead B Place the entire assembly into the flashlight body 1 Guide each of the tail light LED s into the openings for the tail light lenses 2 Guide the toggle switch handle through the opening in the flashlight body and seat the PC board with the lamp leads charge leads and battery leads facing toward the mounting holes for the charge contacts 3 Align the mounting brackets of the LED tail light boards with the guides molded into the top opening of the flashlight body a Route the charge and battery leads over the LED tail light board leads b Fasten each LED tail light board mounting bracket to the body with a 1 Phillips screw and tighten 40 C Place the toggle switch boot nut over the switch handle and tighten the nut with a 5 8 wrench Note Do Not
32. ug protective cap if it is missing Check for Cracks Valve Plug Important Note When mounting or repairing the charge rack and the charge contact screws in the body Do Not Use anaerobic thread locking compounds Loctite etc A chemical reaction caused by the curing of these compounds destroys the molded plastic and will void the factory warranty 29 UEM 15 SWITCH MECHANICAL Vulcan Replacement Parts I l ITEM QTY P N DESCRIPTION ITEM QTY P N DESCRIPTION 1 1 440002 FACE CAP 19 1 440040 BODY HANDLE ASSY YELLOW 2 1 440033 O RING FACE CAP 1 440040 6 BODY HANDLE ASSY GREEN 3 1 440070 REFLECTOR LENS ASSY 20 1 440102 COVER CHARGE RACK YELL 4 2 440023 SCREW BATTERY CLAMP 440102 6 COVER CHARGE RACK GRN 5 1 440005 CLAMP BATTERY 21 1 450022 SPRING LATCH RELEASE 6 1 440006 PAD BATTERY CLAMP 22 1 900047 SCREW 4 24 X 1 2 PHILLIPS 7 1 44007 BATTERY 23 1 440115 PCB STANDARD 8 1 440116 BOOT SWITCH 440114 PCB VEHICLE MOUNT 1 440116 1 BOOT D F SWITCH GREY 24 1 440106 LATCH CHARGER 9 1 440008 PCB ASSY STD TOGGLE 25 1 440101 HOUSING CHARGER YELLOW 440027 PCB ASSY D F TOGGLE 440101 6 HOUSING CHARGER GREEN 10 1 440046 O RING BODY 11 1 44913 BULB 8W BI PIN 44912 BULB 6W DUAL FILAMENT 12 1 44009 KIT CONTACT SCREW 13 1 44012 KIT SWITCH MECH W LOCK 44013 KIT SWITCH SHOWN NOT SH
33. ve black lead is connected to the charge rack PC Board g If the meter does not indicate continuity and no obvious repairable problems are evident broken solder joints etc the PCB assembly will need to be replaced The power input cord is not available separately 25 Positive contact Negative contact PC Board Positive contact Power Input 2 Testing the Direct Wire power input leads Note Disconnect charge racks with permanently wired input power from the input source a b Disassemble the charge rack as directed on page 24 Testing the Internal Wiring Place a multimeter into the continuity position Place one meter lead on the positive power input lead red stripe Place the other meter lead onto the solder pad where the positive power lead is connected to the Printed Circuit Board The meter should indicate continuity Follow the same procedure using the negative lead and the other solder pad If the meter does not indicate continuity and no obvious repairable problems are evident broken solder joints etc the PCB assembly will need to be replaced The power input cord is not available separately 26 Testing For Proper Charge Rack Function A B C D Use a known good Vulcan to test the charge rack Remove the facecap from the Vulcan as described in Section I Unscrew and remove the lens reflector assembly from the lamp holder Remove the negative lead
34. ve meter lead onto the other charge pin Charge Pins 3 The meter should show the supply voltage 11 to 22 volts a If there is no voltage or reverse voltage check the wiring between the rack and the supply also check any in line fuse b If there is no reading the charge rack internal wiring needs to be checked See below for testing procedures Testing the Internal Wiring A Turn the charging rack over to expose its base plate B Place a small flat screwdriver blade between the external power connector or strain relief lug direct wire version and apply a small amount of pressure See picture on Page 25 24 C Compress the mounting posts and remove the base plate of the charging rack Mounting Posts Key Slot D The power input connector has a key slot that faces toward the base plate of the rack 1 Testing the standard power input connector See pictures on Page 26 a Place the charge rack with the charge contacts down and the power input connector to the right b Place a multimeter into the continuity mode c Place one meter lead into the right hand positive contact of the power input connector d Place the other meter lead onto the solder pad where the positive red lead is connected to the charge rack PC Board e The meter should indicate continuity f Follow the same procedure using the negative contact of the power input connector and the solder pad where the negati
Download Pdf Manuals
Related Search