StreamLight FIRE VULCAN, Service Manual

Page 1: ...NG REPLACING THE SWITCH PCB ASSEMBLY 12 SECTION V TESTING REPAIRING THE CHARGER SYSTEM 22 SECTION VI THE BODY 29 VULCAN REPLACEMENT PARTS AND DIAGRAM 30 VULCAN SWITCH PCB SCHEMATIC 31 VULCAN CHARGE RACK PCB SCHEMATIC 32 FIRE VULCAN TROUBLESHOOTING DIAGRAM 34 FIRE VULCAN GENERAL NOTES 35 TESTING REPLACING THE SWITCH PCB ASSEMBLY 36 FIRE VULCAN REPLACEMENT PARTS AND DIAGRAM 42 FIRE VULCAN SWITCH SCH...

Page 2: ...lay 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 assistance contact STREAMLIGHT INC Repair Department 30 Eagleville Road Eagleville Pa 19403 Phone 610 631 0600 Phone 800 523 7488...

Page 3: ...ighted With a good Vulcan in the suspect Charge Rack and power applied either the Red or the Green LED should be lighted if not the problem is most likely with the Charge Rack When a suspect Vulcan is discharged for several minutes and placed in a known good Charge Rack if the Red LED does not light the problem is most likely with the Vulcan Detailed testing instructions can be found in Section V ...

Page 4: ...ory 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 ...

Page 5: ... Grasp the outside of the facecap and turn it counterclockwise until it comes free from the Vulcan body 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 ...

Page 6: ... the bulb 1 Test the bulb Dual Filament Common Lead 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 ...

Page 7: ...sue and alcohol Any oil left on the bulb will permanently smoke the inside 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 whe...

Page 8: ...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 the voltage is at least 20 Volts greater than the voltage ...

Page 9: ...cribed in Step C above I 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 Charge the Vulcan in a known good charge rack for 12 hours or until th...

Page 10: ...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 disconnect 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 dis...

Page 11: ...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 11 ...

Page 12: ...ultimeter 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 I Place the negative black meter lead onto the positive red charge contact Place the positive red meter lead onto the positive red b...

Page 13: ...tch 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 Plac...

Page 14: ...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 ...

Page 15: ...cing 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 ass...

Page 16: ... 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 t...

Page 17: ...itive 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...

Page 18: ...ote Original Vulcans used hex contact screws See page 32 These screws are not interchangeable Tri Wing screws CANNOT be used on the older Vulcans Tri Wing 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...

Page 19: ...gers 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 H...

Page 20: ...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 cont...

Page 21: ...attery 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 Ph...

Page 22: ...be tested by simply measuring its output voltage B Make sure that the wall charger is plugged into a functioning AC outlet C Place a multimeter in the DC volts position 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 p...

Page 23: ...garette 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 Charg...

Page 24: ...Charge Pins Positive Negative 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 plat...

Page 25: ...eter 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 negative black lead is connected to the charge rack PC...

Page 26: ...y position c Place one meter lead on the positive power input lead red stripe d Place the other meter lead onto the solder pad where the positive power lead is connected to the Printed Circuit Board e The meter should indicate continuity f Follow the same procedure using the negative lead and the other solder pad g If the meter does not indicate continuity and no obvious repairable problems are ev...

Page 27: ...ultimeter 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 ohm 10 watt resistor across the battery leads 2 The multimeter should read bet...

Page 28: ...lign the charge pins and LED s with their respective openings 2 Seat the PC Board in the charger housing Rib must be inside charge rack 3 Secure the PC Board with the Phillips screw 4 Hold the charger rack housing with the charger latch pointing downward 5 Make sure that the charger latch is properly seated 6 Place the power input connector in the opening in the charger rack a The keyed slot shoul...

Page 29: ...pplicable 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 plug protective cap if it is missing Valve Plug Check for Cracks Important Note When mounting or repairing the charge rack and...

Page 30: ...0114 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 SHOWN 14 1 45232 STRAP ASSY...

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Page 32: ...Obsolete Style With Paddle Switch 32 ...

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Page 34: ... 34 Note Review the charger note at bottom of Vulcan troubleshooting diagram on page 3 of this manual See General Notes p 35 for information regarding the tail lights on the Fire Vulcan ...

Page 35: ...st 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 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 i...

Page 36: ...ity 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 lead The meter should read between 5 and 7 Volts Continuity through a diode junction I Place the negative black meter lead onto the positive red charge contact Place the positive red meter lead onto the pos...

Page 37: ...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 F Place one meter lead on the center switch contact and the other lead on the left switch contact There should be no contin...

Page 38: ...d Battery Clamp Negative Battery Lead 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 Tri Wing Screw 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 ...

Page 39: ...D 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 ...

Page 40: ... 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...

Page 41: ...ng away from you and the positive red charge lead goes to the contact screw on the right 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 batt...

Page 42: ... 47 FIRE VULCAN REPLACEMENT PARTS 42 ...

Page 43: ...Jumper A Jumper B 43 ...