StreamLight Vulcan Operating Instructions

							Operating
Instructions
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OPERATING INSTRUCTIONS FOR STREAMLIGHT VULCAN®
SAFETY
A.Before using your Vulcan and charger read all instructions in this manual and
all cautionary markings on the unit.
B. 
WARNING:Never leave your Vulcan with its lamp face against any surface,
including skin, while in operation. The resultant heat build-up can cause a
fire or burns.
C. 
IMPORTANT:Careful observation of the LEDs serves as an important warning
of possible charge circuit malfunction, which may cause battery overcharg-
ing, the green LED should turn on steadily and the red LED should turn off
completely within twelve (12) hours of charging time. If the red LED stays on
past this time remove the light from service and return it immediately to the
Streamlight factory at 30 Eagleville Road, Eagleville, PA 19403 for free
evaluation and repair. In extremely rare circumstances an overcharged bat-
tery may release a flammable hydrogen gas mixture. In the unlikely event
that this mixture should ignite, bodily harm could result.
D.The Vulcan should not be switched on and off during charging unless only the
green LED is lighted. Recycle the battery responsibly when no longer service-
able. DO NOT INCINERATE THE BATTERY, EVEN IF IT IS SEVERELY DAM-
AGED OR COMPLETELY WORN OUT. The battery could explode in a fire.
Handle the battery carefully and never allow it to short circuit. A shorted bat-
tery can easily start a fire. 
E. The Vulcan is approved for use in hazardous locations. You are responsible
for the proper application of this product in a properly defined location. 
DO NOT charge in potentially hazardous areas. 
OPERATION
The Vulcan is available in two (2) basic models: the single filament and the dual
filament safety back-up model. Both come with convenient recharging racks,
either AC/DC or vehicle mount that store light conveniently and do not require
Vulcan disassembly for charging. The battery is rated at a nominal 4.5 ampere-
hours and is capable of being recharged up to 500 times.
To release the light from the rack push the black bar down, slide the light for-
ward and lift up. The on/off switch is underneath the handle. Turn it in either
direction for on or in the dual filament model, rotation of the switch to the right 
						

							selects one filament, to the left, the other. Slide the switch lock, located on the
front of the handle, down to prevent accidental activation. The strap attachment
clips on the handle. Store down in a retracted position when not in use. O
Rings in the facecap ensure that Vulcan is waterproof to 100 feet. To maintain
waterproofness, lubricate both O Rings with silicone grease and keep 
facecap tight.
CHARGING AND CHARGE RACKS
Charge your Vulcan overnight before its first use. Charging will occur only when
the lamp is off. The battery should be charged as soon as possible after use to
ensure maximum service life. The batteries should never be exercised in an
attempt to erase memory, which never occurs with lead-acid batteries. a pair
of charging indicators are on the charging rack. The red LED means that the
light is charging. The green LED means it is fully charged and ready for use. It is
important to understand that a battery can take only minutes to a maximum of
twelve (12) hours to fully charge, depending on the batterys residual charge
and other factors. When fully charged the red LED should turn off completely
and the green LED should turn on steadily.
The charge rack is designed to hold the Vulcan in virtually any position. Three
(3) self-tapping #8 x 1 1/2 screws are included to mount the charger; use
1/8 holes. Two types of racks are available. The AC/DC charge rack can
use three (3) interchangeable power cords: P/N: 22051 12V DC cord with
cigarette lighter plug (DC1); P/N 22311 120V AC cord and P/N 21725
230V AC cord. The vehicle mounted direct wire rack has a tinned and striped
cord and is meant for permanent installation in a vehicle.
VEHICLE INSTALLATION
WARNING: A shorted auto battery can easily start a fire. Use the proper insulat-
ed connectors and be sure that your installation is fused with a 2 amp slow
blow fuse. If you are not comfortable with this type of work have the Vulcan
charger installed by a skilled professional. Never attempt to directly wire this
rack to a 110 volt AC power source. It is intended for 12-15 volts.
If the vehicle is used daily connect the charge rack directly to the battery or an
unswitched terminal on the vehicle fuse block. Route the wires from the mounted
charger base to the 12 volt power source. The positive lead has a colored
trace and should be connected to the side of a fuseholder which is dead when
the fuse is removed. The untraced lead is negative and may be connected to
any convenient chassis ground.
After a complete discharge, charging a single Vulcan will consume six (6)
ampere-hours (Ah) from a vehicle battery in the first 12 hours and one Ah each
24 hours thereafter. If the vehicle stands unused and the Vulcan is wired directly
to the vehicle battery it will eventually drain the battery.
If the vehicle is not used daily wire the Vulcan to the switched side of the igni-
tion. The drawback to this is that while the vehicle battery does not get drained
during periods of inactivity, the Vulcan might never receive a full charge. If the
above is not practical, equip the vehicle with a supplemental trickle charger
which is connected to AC power when the vehicle is standing. The advantages
to this setup are that your vehicle battery will always be topped up, other
power accessories can be added to the electrical system and you may obtain
longer vehicle battery life.
LAMP REPLACEMENT
CAUTION: The inner bulb operates at a high temperature and is pressurized.
Allow to cool and wear safety glasses before handling. Two types of bulbs are
used in the Vulcan par 36 lamp assembly: a halogen bi-pin and a xenon dual
filament. The wattage and voltage is embossed on the single filament bi-pin
bulb. The standard dual filament is a 6 watt bulb with a blue base. Check to
see if you are installing the desired replacement.
1. Remove lens ring and lamp assembly from the lantern. Do not pull 
on the wires.
2. Remove white threaded lamp socket at the back of the assembly and 
pull the old bulb straight out from the socket.
3. Replace with new bulb by aligning its bi-pins with holes in socket and 
seating firmly. Use a clean cloth or tissue when handling bulb.
4. Wipe any fingerprints off the new bulb and thread socket into reflector
assembly. Socket can be screwed in or out, as required, to provide 
optimal focus. Reinstall assembly.
BATTERY REPLACEMENT
Remove the threaded facecap and lens assembly. Remove the two (2) screws
that retain the battery clamp and the two (2) wires and spade lug terminals on
the top of the battery. Connect the red wire to the positive (+) tab of the battery
and the black wire to the negative (-) tab. Reversing these connections will dam-
age the Vulcan. Replace the battery clamp, lamp, and facecap. Keep the face-
cap tight for maximum waterproofness.  
						

							FMAPPROVEDNFPA
Replacement Parts 
Item Quantity Part No. Description
1 1 440002 Face Cap
2 1 440003 O-Ring, Face Cap
3 1 450070 Reflector/Lens Assembly
4 2 440023 Screw, Battery Clamp
5 1 440005 Clamp, Battery
6 1 440006 Pad, Battery Clamp
7 1 44007 Battery
8 2 440020 Screw, PCB
9 1 440008 PCB Assembly, standard
440027 PCB Assembly, Dual Filament
10 1 440004 O-Ring, Body
11 1 45901 Bulb, 8W Bi-Pin
44912 Bulb, 6W Dual Filament
12 1 44009 Kit, Contact Screw
13 1 44012 Kit, Switch
1 44013 Kit, Switch (New Style)
14 1 45232 Strap Assembly, Shoulder
15 2 440018 Clip, Shoulder Strap
1 400262 D-Ring (New Style)
16 1 440019 Handle
1 440219 Handle (New Style)
17 1 440015 Plug, Valve
18 1 130018 Valve
19 1 440001 Body, Yellow
1 440001-1 Body, Orange
1 440001-6 Body, Green
20 1 440102 Cover, Charge Rack, Yellow
1 440102-1 Cover, Charge Rack, Orange
1 440102-6 Cover, Charge Rack, Green
21 1 450022 Spring, Latch Release
22 1 900047 Screw, 4 -- 24 x 1/2 Phillips
23 1 440115 PCB Standard
440114 PCB, Vehicle Mount
24 1 440106 Latch, Charger
25 1 440101 Housing, Charger, Yellow
1 440101-1 Housing, Charger, Orange
1 440101-6 Housing, Charger, Green
Not Shown 
1 22311 Cord, 120V AC Charge
1 21725 Cord, 230V AC Charge
1 22051 Cord, 12V DC Charge
1 440040 Body/Handle Assy, Yellow
1 440040-1 Body/Handle Assy, Orange
1 440040-6 Body/Handle Assy, Green 
						

							WARRANTY Streamlight Vulcan®
Streamlight makes no express warranties other than those expressly provided herein.  Streamlight does
not make, and hereby expressly disclaims, any implied warranties, including warranties of merchantabili-
ty or fitness for a particular purpose, except to the extent that implied warranties may not be disclaimed
under applicable law. To the extent any such implied warranties may not be disclaimed under applicable
law, the duration of such implied warranties shall be limited to the minimum period required by applica-
ble law. Streamlights responsibility under all warranties, both expressed and implied, shall be limited to
the repair, replacement or refund of the purchase price of any products covered by such warranty.
Streamlight shall, in no event, be liable for any other damages, including consequential or incidental
damages.  Some jurisdictions my not allow the waiver of or limitations on the scope or duration of
implied or expressed warranties or on the exclusion of consequential or incidental damages, in which
case the above waivers, limitations or exclusion may not apply to you.
Money Back Guarantee
Your Vulcan system is unconditionally guaranteed to perform to your satisfaction or your money will be
refunded. Return your Vulcan to the seller (shipping charges prepaid) within ten (10) days of purchase,
along with receipt or any proof of purchase for full refund.
Warranty Registration Card
Complete and return Warranty Registration Card within ten (10) days of purchase to register your warran-
ty. Retain your receipt or any proof of purchase. Failure to return the Warranty Card and receipt or proof
of purchase as required will invalidate the warranty and service coverages described herein.
One Year Warranty
Your Vulcan system, including battery, case, and chargers, but excluding lamp, is warranted for a period
of one (1) year from the date of purchase. Should your Vulcan fail to operate, return it (shipping charges
prepaid) to the factory or Authorized Service Center at the address listed with these instructions along
with receipt or any proof of purchase. Streamlight will repair or replace the defective parts without cost
and return the unit to you (shipping charges prepaid within the Continental USA), or at Streamlights
option, if permitted by law, Streamlight will refund your purchase price.
Switch Warranty
The switch of your Vulcan is guaranteed for life. In any country or jurisdiction where specific limitations
are placed on lifetime warranties Streamlight will honor a 10-year limited warranty. Should the switch fail
to operate, return the Vulcan (shipping charges prepaid) to the factory or Authorized Service Center at
the address listed with these instructions, along with your receipt or any proof of purchase. If you have
owned your Vulcan for more than one (1) year include $5.00 for handling. Streamlight will repair or
replace the switch without cost and return the unit to you (shipping charges prepaid within the
Continental USA).
Limitations on Warranty and Service Coverage
1. Warranty is invalid if, in Streamlights sole opinion, there has been tampering, alteration, abuse, mis-
use, or failure to follow proper care and maintenance procedures.
2. This warranty shall not extend to repairs by anyone other than Streamlight or other than service facili-
ties designated by Streamlight.
3. 
This warranty is limited to the original user-purchaser as such appears on the Warranty Registration Card.
Should your Streamlight fail to operate, contact the closest Authorized Service Center or the factory 
directly at (610) 631-0600 or (800) 523-7488.
Serial #________________________________  Date of Purchase ______________________
This warranty gives you specific legal rights and you may also have other rights.
©2001  11/01
MANUFACTURER Streamlight, Inc.30 Eagleville Road / Eagleville, PA USA 19403-3996(610) 631-0600 / (800) 523-7488 / Fax (610) 631-0712 / Fax (800) 220-7007 / www.streamlight.com
IMPORTANT– Be sure to use genuine Streamlightreplacement parts.
WARRANTY REGISTRATION:To register the warranty on your Streamlight, complete the card
enclosed and mail to Streamlight, Inc., within ten (10) days of purchase. When returning prod-
uct for warranty repairs, please provide receipt or other proof of purchase.
PRODUCT USE:The Streamlights are intended for use as high intensity, heavy duty, recharge-
able, portable light sources. Use of the Streamlights for any purpose other than light sources is
specifically discouraged by the manufacturer.
The rechargeable battery contained in this product is recyclable. At the end of its useful life, under
various country and state laws, it may be illegal to dispose of this battery in the municipal solid
waste stream. Check with your local solid waste officials for details in your area for recycling options
or proper disposal.
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