Vulcan-Hart Core One Service Manual Download Page 1 | Manualshive

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Vulcan Core One

SERVICE MANUAL

Watch the video version to this manual:

https://confluence.ekupd.com/support/burner-head-exchange-maintanance-manual-75925450.html

Rev. 09/2020

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Summary of Contents for Core One

Page 1: ...Vulcan Core One SERVICE MANUAL Watch the video version to this manual https confluence ekupd com support burner head exchange maintanance manual 75925450 html Rev 09 2020 ...

Page 2: ...s 6 3 3 Disconnect Internal Electric Connectors 7 3 4 Remove Burner Head 8 3 5 Exchange Nozzle 9 3 6 Assemble Burner Head 10 3 7 Reattach Burner Head 10 3 8 Connect Internal Electric Connectors 10 3 9 Attach Fuel Lines 10 3 10 Side Panel on 11 3 11 Disassemble Fuel Filter 12 3 12 Exchange Filter 13 3 13 Close Vulcan and Reconnect 14 4 Notes 15 ...

Page 3: ...nuts bolts that are to be mounted with a specific tight ening torque The torque values are shown at the symbol and are binding Further documentation to be used The use of additional service literature may be re quired Use the following documents during operation and maintenance of the Vulcan Installation Instructions Operating Instructions Spare Parts List Workshop Manual by Valeo Safety informati...

Page 4: ...luminum DN 3687 2 M10 Single Hollow Screw A2K DN 1914 4 M10 Sealing Washer Aluminum DN 3463 4 M6 Washer A2K DN 66 4 M6 Hex Lock Nut Brass DN 3689 1 Fuel Filter Insert DN 3778 1 High Pressure Atomizer Nozzle DN 3776 1 Vulcan Service Handbook Tools required for the task 10mm wrench or socket 13mm wrench or socket 16mm wrench 17mm wrench 19mm open end wrench Flex ratchet handle with 16mm socket Torqu...

Page 5: ...ON Prior to disassembling components the heater must be disconnected from the vehicle elec trical system ATTENTION Sealing elements between disassembled components must be principally discarded and re placed This does not apply to the temperature sensor gasket ring as it is permanently attached Screws with coated threads must be discarded and replaced It is permitted to remove components from the ...

Page 6: ...panels of Vulcan enclosure 1 Service Feet 2 Side Panel 3 Flat Washer DN 66 4 M6 Hex Lock Nut DN 3689 Open the front and back door Open the side panel 2 Fig 1 by unscrewing all four nuts 4 Fig 1 NOTE The nuts are lock nuts and should only be used once Please dispose them ...

Page 7: ...N 1914 2 M10 Aluminum Seal Washer DN 3463 3 Fuel line 4 Fuel inlet Untighten the bolt on the return side first Put the bolt 1 Fig 2 and the sealing ring 2 Fig 2 in the trash Same goes for the supply side 4 Fig 2 ATTENTION Diesel fuel is leaking Make sure any fuel leaking is immediately contained and professional ly disposed ...

Page 8: ... 3 3 Disconnect Internal Electric Connectors Fig 3 Connectors on burner head 1 Temperature Sensor 2 Service Connector 3 Main Connector Disconnect all internal electric connectors Third from the top is just a cap It does not need to come off ...

Page 9: ...ve Burner Head Fig 4 Burner head disassembled from heater body 1 Burner Head 2 Nuts Two nuts 2 Fig 4 need to be unscrewed in order to remove the burner head 1 Fig 4 Please place the burner head on an even and clean surface to continue working on it ...

Page 10: ...tion electrodes 4 Fig 5 The slotted screwdriver may help Remove any diesel and dirt remnants from the disc 3 Fig 5 with a clean dry rag Lift the disk and put it aside so you can access the sensor tube 2 Fig 5 Remove the sensor tube Unscrew the top nozzle 5 Fig 5 with the 16mm socket and put it in the trash ATTENTION Do not bend the electrodes The distance is fixed and mandatory for operation ...

Page 11: ...he unit Plug in the ignition electrodes 4 Fig 5 Be careful not to bend the electrodes ATTENTION Careful with the sensor Contamination can lead to malfunction NOTE Do not touch the new nozzle s orifice Small particles could cause congestion 3 7 Reattach Burner Head See figure 4 Tighten the two nuts 2 Fig 4 with 8 0 5 Nm 3 8 Connect Internal Electric Connectors See figure 3 There is only one way the...

Page 12: ...ck if sealant ring 1 Fig 10 is in place Use new safety nuts DN 3689 and washers DN 66 included in maintenance kit Tighten all four nuts 4 Fig 10 with 7 1 Nm Fig 10 Reattachment of side panel 1 Sealant Ring 2 Side Panel 3 Flat Washer DN 66 4 M6 Hex Lock Nut DN 3689 ...

Page 13: ...semble fuel filter 1 Top Bolt 2 Sealing Washer 3 Filter Head 4 Filter Body Untighten the top bolt 1 Fig 11 on the filter s head 3 Fig 11 Hold the filter bottom 4 Fig 11 while unscrewing the top bolt ATTENTION The filter still contains diesel fuel Dispose of remaining fuel correctly ...

Page 14: ...Pull out the old filter 5 Fig 12 and replace with new one DN 3778 included in the maintenance kit ATTENTION Fuel filter must be filled with diesel Otherwise fuel lines and filter must be vented before starting the heater Assemble the filter body inside the Vulcan Use new aluminum sealing washer DN 3687 included in maintenance kit Tighten the top bolt 1 Fig 12 with 11 1 Nm Throw away old sealing ri...

Page 15: ...e Vulcan doors 1 Service Feet Unscrew the four feed on the bottom and place them back inside the box 1 Fig 13 Close both doors Mount the Vulcan back to its original location and reconnect the wires as well as the coolant lines Maintenance is done NOTE There are notes on the last page ...

Page 16: ...Vulcan Core One 4 Notes 15 4 Notes ...

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