STEP 1 - Maglite

Rechargeable Flashlight System™ (Ni-Cad)
repair
manual
Mag-Lite®
Rechargeable
Flashlight
RX1019/RX1016
RX2019
RX3019
RX4019
RX5019
RX6019
RX7019
Repairs must be performed by Mag Instrument
certified warranty service personnel
IMPORTANT NOTICE
This copyrighted Manual, bearing Copy Control #_______________, is the property of
Mag Instrument, Inc., and must be returned to Mag Instrument upon demand. It is for use only
by factory-certified technicians performing authorized warranty service on the Mag-Lite®
Rechargeable Flashlight and/or other Mag-Lite® Rechargeable Flashlight System™
components.
This Manual is a confidential document. It is not for sale and is not to be shown, lent or
otherwise disclosed to unauthorized personnel.
Copying of this document is not authorized. Copying would therefore constitute a violation of
the copyright laws. If additional copies are desired, they should be requested directly from
Mag Instrument, Inc.
421-000-438
MR Rev.1 8/03
1
MAINTENANCE AND REPAIR INSTRUCTIONS
Rechargeable Flashlight
Warnings: Any battery may leak harmful chemicals which may damage skin, clothing,
or the inside of the flashlight TO AVOID RISK OF INJURY, DO NOT LET ANY MATERIAL
LEAKED FROM A BATTERY COME IN CONTACT WITH EYES OR SKIN. Any battery may
rupture or explode if put in a fire or otherwise exposed to excessive heat. TO AVOID
RISK OF INJURY, DO NOT EXPOSE BATTERIES TO EXCESSIVE HEAT.
INSPECTION AND MAINTENANCE
Battery Pack - Remove the battery pack from the flashlight and visually inspect for
signs of gas or chemical leakage. Indications of leakage are discoloration of the plastic
sleeve or white fuzzy material near the top (positive side button) of each cell. Another
indication would be a bulging deformation of the bottom (negative flat end) of the cell
can. If any of these signs are observed the battery pack should be removed from
service to prevent chemical damage to the inside of the flashlight.
Electrical Contacts - The bare (bright) metal surfaces between the tail cap and barrel
must be clean as well as the spring contact surface of the tail cap.
O-ring Seals and Screw Threads - To keep seals from drying out and the threads
operating smoothly, apply several drops of clean petroleum oil or jelly.
2
MR Rev.1 8/03
Rechargeable Flashlight
421-000-438
RECHARGEABLE SWITCH REPLACEMENT
Rechargeable Flashlight
Tools Required:
1. Barrel Holder
2. Spanner Wrench
3. Multimeter
Testing Procedures
(Troubleshooting)
1. Bulb 2. Battery 3. Charge Module 4. Converter 5. Circuit Board
1. Bulb
a. Verify that you have a good LAMP and
BATTERY PACK
Probe placement
• Place red probe on one lamp pin
• Place black probe on the other lamp pin (it makes no
difference which probe goes to what pin)
• If the lamp is good you will get a (000) reading
• A (1.) is a bad lamp
2. Battery
a. Warranty – 12
months from the
four number
DATE CODE on
the battery pack
(0324). First two numbers (03) indicate
year Second two numbers (24) indicate
week of year.
b. Battery Damage. Look for:
1). Signs of gas or chemical leakage.
2). Discoloration.
3). Fuzzy material near positive button.
4). Bulging or deformation.
5). Charge for 15 minutes prior to test.
6). Test.
421-000-438
Battery Test
Meter Settings
Dial set at V-20 Volts
Probes: Black in
“COM” port
Red in “VΩmA” port.
Rechargeable Flashlight
MR Rev.1 8/03
3
c. Lead Placement
d. Battery
Red probe on positive button.
Black lead on flat negative end.
WARNING: do not touch bare leads
during test. Very Hot.
Less than 6.00
volts but higher
than 4.8 volts
indicates battery
should be
charged longer
prior to test. Less
than 4.8 volts
indicates bad
battery.
SCHEMATIC - FLASHLIGHT
PARTS LIST FOR RECHARGEABLE MAGLITE
ITEM NO.
QTY
PART NUMBER
1
1
205-000-001
2
1
405-000-051
3
1
108-000-060
4
1
108-000-020
5
105-000-002
6
1
108-000-104
7
1
108-000-557
8
1
405-000-049
9
1
205-000-014
10
1
405-000-016
11
2
LR00001
12
1
108-000-106
13
1
108-000-025
14
1
205-000-007
15
1
105-000-008
16
1
205-000-047
17
1
108-000-032
18
1
108-000-601
19
1
108-000-207
20
1
201-000-191
21
22
1
108-000-439
23
1
24
1
105-000-010
4
MR Rev.1 8/03
DESCRIPTION
FACE CAP
LENS SEAL
LENS (SODALIME)
LENS ASSEMBLY
FACE-REFLECTOR ASSEMBLY
REFLECTOR-HOUSING ASSEMBLY
SWITCH SEAL (old) or 108-000-643 (revised)
NYLON WASHER
SWITCH HOUSING CASING
O-RING, SWITCH HOUSING
HALOGEN LAMP
SWITCH ASSEMBLY
O-RING, HEAD
HEAD
CHARGER MODULE
BARREL
MAIN SPRING
BULB PROTECTOR
O-RING, TAIL CAP
TAIL CAP
TAIL CAP ASSEMBLY
6 VOLT NI-CAD BATTERY PACK
INSULATOR SLEEVE, DIODE
DIODE
Rechargeable Flashlight
421-000-438
U.S.A., STANDARD COMMERCIAL
FLASHLIGHT SPECIFICATION
FLASHLIGHT
OVERALL LENGTH:
BARREL DIAMETER:
HEAD DIAMETER:
WEIGHT WITHOUT BATTERY:
WEIGHT WITH BATTERY:
* BEAM CANDLEPOWER @ 10 feet / 3.0 meters
* BATTERY LIFE CONTINUOUS ON TIME:
LAMP LIFE:
BATTERY VOLTAGE OUTPUT:
EXTERIOR BODY COMPONENTS:
EXTERIOR BODY FINISH:
LENS:
BATTERY:
6 volt 2.2 amp hr. to 2.5 amp hr.
REFLECTOR:
SWITCH:
12-19/32 in.
319.79 mm
1-9/16 in.
39.67 mm
2-5/16 in.
58.72 mm
18.0 oz.
510.29 gm
32.0 oz.
907.18 gm
40,000 Peak Beam Candlepower
2 hours from full charge
50-65 hours continuous
6 volts
Machined high strength aluminum alloy
Anodized commercial type III hard, inside and outside
Ground and tempered glass
Five (5) 1/2 D size NI-CAD (Nickel-Cadmium) pack
Highly polished metal
Recessed push button, sealed, self cleaning, On-Off
and momentary on
LAMP:
6 volt 1.4 amp 8.4 watts
High pressure Halogen, G-4 Bi-pin base
SPARE LAMP:
Spare lamp located in tail cap
O-RING SEALED:
Sealed throughout for improved water resistance
FOCUS:
Adjustable beam, spot to flood (1/4) head turn
SERIAL NUMBERED:
Stamped on barrel
CHARGE CONTACTS:
360 degree contacts. Flashlight charges in any position
* Candlepower and battery on time may vary between lamps and battery packs.
Note: The battery discharge rate when not in use is approximately 1% per day.
CHARGER
• Accepts 12-14 volts maximum DC input (Not for use with 24 volt circuits)
• Battery charge time to full charge 14-16 hours
• Charge rate: 220 mA constant current
• Reverse voltage protected output (battery in backwards)
• Red LED charge indicator
• Mounts in any position
• Two (2) detachable mounting brackets (i.e. for mounting in two locations)
CONVERTOR U.S.A.
• INPUT: 117 volts AC, 60 Hz
• OUTPUT: 14 volts DC, .22 Amps
CONVERTOR EUROPEAN (Not for all countries)
• INPUT: 230 volts AC, 50 Hz
• OUTPUT: 14 volts DC, .22 Amps.
Note: All information contained in this specification is for reference purposes only. Mag Instrument, Inc. reserves
the right to change any information without notice.
421-000-438
Rechargeable Flashlight
MR Rev.1 8/03
5
STEP 1
STEP 2
Remove TAIL CAP ASSEMBLY(21)
(counterclockwise) and BATTERY PACK (22).
Remove the FACE CAP ASSEMBLY (5)
(counterclockwise).
STEP 3
STEP 4
Remove the REFLECTOR (6) from the FACE
CAP (1). The REFLECTOR (6) unscrews
(counterclockwise) . To replace it push hard
on the REFLECTOR (6) to get it past the
threads.*Note: Removal of reflector should
not be necessary unless the LENS (3) or
REFLECTOR (6) is damaged.
Remove the SWITCH SEAL (7) by grasping
the seal with your thumb and index finger,
buckle and pull to extract.
6
MR Rev.1 8/03
Rechargeable Flashlight
421-000-438
STEP 5
STEP 6
Remove the LAMP (11) by pulling straight
up until the pins are clear of the receptacle.
*Note: It is easier to change the LAMP (11) if
you push the HEAD (14) down over the
SWITCH HOUSING (9).
Lift up the plunger of the barrel holder and
insert the flashlight, BARREL (16), first into
the front of the barrel tool holder, lining the
switch hole up with the plunger.
CAUTION: This bulb is pressurized and CAN SHATTER OR EXPLODE,
causing PERSONAL INJURY. Wear protective eyeglasses and clothing
when handling; never exceed rated voltage (6.0 VDC); never scratch
bulb’s glass envelope; never splash bulb with liquids. Bulb BURNS
VERY HOT and CAN CAUSE BURN INJURY OR HEAT OR FIRE DAMAGE.
Remove battery pack and let bulb cool before handling; avoid operating
near materials that are flammable or prone to heat or drying damage.
Dispose of lamp with care.
STEP 7
STEP 8
Push the plunger into the barrel switch hole.
Unscrew BARREL (16) counterclockwise.
421-000-438
Rechargeable Flashlight
MR Rev.1 8/03
7
STEP 9
STEP 10
Insert the SPANNER WRENCH into the back
of the BARREL HOLDER TOOL and match
the pins of the holder with the holes in the
CHARGER MODULE (15).
Unscrew (counterclockwise) the CHARGER
MODULE (15) 2-3 turns.
STEP 11
Lift up the plunger and remove the HEAD
(14), SWITCH HOUSING (9), and CHARGER
MODULE (15) from the TOOL HOLDER.
8
MR Rev.1 8/03
STEP 12
Unscrew and remove the CHARGER
MODULE (15) from the SWITCH HOUSING (9)
Rechargeable Flashlight
421-000-438
CHARGER MODULE TEST
A. METER SETTINGS
Dial should be at 2k Ω ohms.
1. The black probe in the“COM” Port
2. The red probe in the “V_mA” port.
3. The meter should be reading “1.”
B. LEAD PLACEMENT
1. The black lead is on the spring.
2. The red lead is on the outer
charging ring.
A. CHARGE MODULE METER SETTINGS
Meter reading is .005 – .764 mA. A bad
module will register .000 or 1 mA.
PROBLEM
421-000-438
Occasionally the CHARGER MODULE
(15) will stay in the BARREL (16) when it
is unscrewed. If this happens do the
following:
Rechargeable Flashlight
MR Rev.1 8/03
9
PROBLEM (cont.)
Separate the silver ring and black insulator
from the MODULE (15) by inserting your
finger nail or a knife blade between the ring
and the second insulator. The ring is held in
place by the spring loaded diode shown
next to the top thumb.
After you have removed the silver ring and
insulator ring you will see the flat surface
where the rings had been.
Try to unscrew the MODULE (15) without
damaging the flat surface or the threads. Use
a pair of pliers and a rubber band, grip the
flat surface as gently as possible and
unscrew the MODULE (15)
(counterclockwise).
The diode shown in the picture is attached to a
spring and insulated by a plastic sleeve. In this
picture the sleeve is not shown and is still in
the diode hole of the MODULE (15).
Occasionally the diode might fall out when you
are unscrewing the MODULE (15), note how it
goes back into the hole and MAKE SURE THE
PLASTIC SLEEVE IS IN PLACE. A severe SHORT
will occur if the sleeve is missing.
10
MR Rev.1 8/03
Rechargeable Flashlight
421-000-438
When replacing the ring onto the MODULE
(15) place the ring over the diode pin, push
down and snap the ring in place.
Before replacing the plastic insulator note
the lip on one side of the insulator ring.
STEP 13
The lip on the insulator ring goes against the
silver ring so that the flat side will be facing
out. It will snap into place.
421-000-438
Push the HEAD (14) down and over the
O-RING (10) and remove it from the SWITCH
HOUSING (9).
Rechargeable Flashlight
MR Rev.1 8/03
11
STEP 14
FIGURE 1
REPLACEMENT SWITCH
Depress the switch button on the SWITCH
(12) and at the same time push the SWITCH
ASSEMBLY (12) out the back of the SWITCH
HOUSING (9).
The Replacement SWITCH (12) should come
with the internal mechanism partially out of
the housing, the push button will be down
and held in place by the housing so that the
SWITCH (12) can easily fit into the SWITCH
HOUSING (9).
FIGURE 2
If the push button is up, use a ball point pen
or pencil and: Push the button down and at
the same time push the entire mechanism
out the back of the housing.
When you remove the pen the button
should be locked under the housing as
shown in figure 1.
12
MR Rev.1 8/03
STEP 15
REPLACE SWITCH
Insert the SWITCH ASSEMBLY (12) into
the rear of the SWITCH HOUSING (9).
Rechargeable Flashlight
421-000-438
STEP 16
STEP 17
Make sure the SWITCH (12) is seated evenly
in the SWITCH HOUSING (9). Do not press on
the black plastic portion of the SWITCH (12)
until you are certain it is seated properly.
Push hard on the black plastic portion of the
SWITCH (12) and it should click into place
with the push button centered in the switch
hole of the HOUSING (9).
STEP 18
STEP 19
Slide the HEAD (14) over the SWITCH
HOUSING (9), make sure it slides over the
O-RING (10).
Screw the CHARGER MODULE (15)
(clockwise) into the SWITCH HOUSING
(9), finger tight.
421-000-438
Rechargeable Flashlight
MR Rev.1 8/03
13
STEP 20
STEP 21
Pull the plunger on the tool holder up and
place the flashlight, CHARGER MODULE (9)
end first into the front of the tool holder.
Make sure the switch hole is lined up with
the plunger.
Push the flashlight into the tool holder until
the HEAD (14) stops at the holder. Push the
plunger down into the switch hole.
STEP 22
STEP 23
Insert the spanner wrench into the tool
holder and rotate until the pins in the holder
fall into the holes in the CHARGER MODULE
(9). Tighten the CHARGER MODULE (9)
(clockwise) as tight as possible.
Insert the silver ringed portion of the
BARREL (16) into the rear of the tool
holder and screw it into the CHARGER
MODULE ( 9) (clockwise), tighten by
hand as tight as possible.
14
MR Rev.1 8/03
Rechargeable Flashlight
421-000-438
STEP 25
STEP 24
Push the head down and replace the LAMP
(11) by lining up the pins of the LAMP (11)
with the two holes in the switch receptacle
and apply a straight downward pressure.
Remove the flashlight from the barrel
holder tool.
CAUTION: This bulb is pressurized and CAN SHATTER OR EXPLODE,
causing PERSONAL INJURY. Wear protective eyeglasses and clothing
when handling; never exceed rated voltage (6.0 VDC); never scratch
bulb’s glass envelope; never splash bulb with liquids. Bulb BURNS
VERY HOT and CAN CAUSE BURN INJURY OR HEAT OR FIRE DAMAGE.
Remove battery pack and let bulb cool before handling; avoid operating
near materials that are flammable or prone to heat or drying damage.
Dispose of lamp with care.
STEP 26
STEP 27
Replace the SWITCH SEAL (7) by bowing it
slightly with the thumb and index finger to
get it started into the hole in the BARREL
(16). Push all outside edges of the SEAL (7)
into the BARREL (16) hole.
Replace the BATTERY PACK (22) be sure
you insert the positive (button end) into
the light first. replace the TAIL CAP
ASSEMBLY (21), make sure you put
lubrication on all o-rings and threads.
421-000-438
Rechargeable Flashlight
MR Rev.1 8/03
15
STEP 28
STEP 29
BULB ALIGNMENT
Before replacing the FACE CAP ASSEMBLY
(5) check for proper bulb alignment.
Using a test REFLECTOR (6) place it into the
head as shown.
Hold the REFLECTOR (6) down with your
thumb as you hold the HEAD (14) with your
fingers as shown. This allows you to hold
the REFLECTOR (6) down and turn the HEAD
(14) for adjustment.
STEP 31
STEP 30
Using a pencil eraser and with the light OFF,
center the LAMP) (11) in the REFLECTOR (6)
hole. DO NOT TOUCH THE REFLECTORS
SURFACE or TRY TO CLEAN IT WITH
ANYTHING.
16
MR Rev.1 8/03
While still holding the REFLECTOR (6) in the
HEAD (14) turn on the light, put it in spot
mode and observe the spot pattern. If the
LAMP (11) is aligned properly you should see
a dark “V” shape on each side of the spot.
(This is with all LAMPS after January 2002).
Rechargeable Flashlight
421-000-438
STEP 32
Replace the FACE CAP ASSEMBLY (5).
421-000-438
Rechargeable Flashlight
MR Rev.1 8/03
17
RECHARGEABLE SYSTEM
CIRCUIT BOARD
REPLACEMENT
18
MR Rev.1 8/03
Rechargeable Flashlight
421-000-438
ITEM NO#
QTY
PART NUMBER
1
2
3
4
5
6
7
8
1
1
1
1
1
4
1
1
1
1
1
109-000-485
405-000-025
105-000-021
405-000-028
405-000-103
405-000-047
405-000-096
108-000-440
108-000-437
108-000-438
405-000-089
421-000-438
DESCRIPTION
CHARGER CRADLE ASSEMBLY
SPRING CLAMP
CIRCUIT BOARD ASSEMBLY
SCREW, CIRCUIT BOARD #6X5/16
FIBER WASHER
SCREW, BASE PLATE #6X3/4
BASE PLATE
CHARGER BRACKET
110 VOLT AC CONVERTER
12 VOLT DC CORD W/CIG. LIGHTER PLUG
12 VOLT DC STRAIGHT WIRE
Rechargeable Flashlight
MR Rev.1 8/03
19
CHARGER TESTS
Tests should be performed to determine the problem area prior to
replacing the circuit board.
CONVERTER TEST
CONVERTER
METER READING
1. Dial is at V-20 volts.
2. Black probe is in the “COM” port.
3. Red probe is in the “VΩmA” port.
LEAD REPLACEMENT
1. Place the leads, Red & Black into the pin
receptacles of the converter plug, (it does
not make a difference which lead goes into
which hole).
CIRCUIT BOARD TEST
CONVERTER
METER READING
1. Between 13.00 & 22.00 volts.
20
MR Rev.1 8/03
METER SETTING
1. Set the dial at “A- 10A” Amps.
2. Black probe in “COM” port.
3. Red probe in “10ADC” port.
Rechargeable Flashlight
421-000-438
CIRCUIT BOARD
CIRCUIT BOARD
LEAD REPLACEMENT
1. Red lead on the front pin or pin closest to
head portion of charger.
2. Black lead on the rear pin
METER READING
Should be between 0.20 and
0.24 Amps.
ADDITIONAL CHARGER TESTS
Short the pins out using one of the tester
probes, paper clip etc. If the CIRCUIT BOARD
(3) is good the LED will light.
421-000-438
Put the flashlight in the CHARGER (1)
with the CHARGER (1) plugged in, the
LED will light if the BOARD is good.
Rechargeable Flashlight
MR Rev.1 8/03
21
STEP 1
STEP 2
Remove CHARGER BRACKET (8) by pushing
in on the chrome button and at the same
time pulling up on the edges of the
CHARGER BRACKET (8).
Remove the CHARGER BRACKET (8) from
the from the BASE PLATE (7).
STEP 3
STEP 4
Unscrew the (4) MOUNTING SCREWS (6)
(counterclockwise) from the BASE PLATE (7).
Remove the BASE PLATE (7) from the
CHARGER CRADLE (1).
22
MR Rev.1 8/03
Rechargeable Flashlight
421-000-438
STEP 5
STEP 6
Remove the INSULATOR WASHER (5) that is
around the CIRCUIT BOARD SCREW (4) head.
Unscrew the CIRCUIT BOARD SCREW (4)
(counter-clockwise).
STEP 7
To remove the CIRCUIT BOARD ASSEMBLY
(3), it may be necessary to apply gentle
pressure under the board with a screw
driver or allen wrench to avoid bending the
CIRCUIT BOARD PLATE (3).
421-000-438
STEP 8
Lift the CIRCUIT BOARD ASSEMBLY (3) out of
the CHARGER CRADLE (1).
Rechargeable Flashlight
MR Rev.1 8/03
23
STEP 9
The SPRING CLIP (2) will probably pop out, if
not, leave the SPRING CLIP (2) in the
CHARGER CRADLE (1).
REPLACING THE CIRCUIT
BOARD - STEP 10
Before installing the new CIRCUIT BOARD
(3), test it to make sure the board is good.
Plug the board into a power converter and
touch the two spring loaded pins on the
board together, the LED should light if the
board is good.
STEP 11
Hold the clamps of the CHARGER CRADLE
(1) together as shown in fig.1, this will
create an opening at the base of the cradle
as shown on fig.2. If the clamps at the base
are not open you will not be able to get the
SPRING CLIP (2) installed.
FIG. 1
FIG. 2
24
MR Rev.1 8/03
Rechargeable Flashlight
421-000-438
STEP 12
STEP 13
Insert one end of the CLIP (2) into one of the
openings, bow the CLIP (2) and insert the
other end of the CLIP (2) into the other
opening.
Push the CLIP (2) into the CHARGER
CRADLE (1) and hold it with your thumb.
STEP 14
While holding the CLIP (2) with your thumb
insert the CIRCUIT BOARD (3) into the
CHARGER CRADLE (3) make sure the two
spring loaded pins line up with the two
holes in the CHARGER CRADLE (1) and the
LED is lined up with the rear hole in the
CHARGER CRADLE (1).
421-000-438
STEP 15
Push the CIRCUIT BOARD (3) down until it
bottoms out and is seated into the CHARGER
HOLDER (1).
Rechargeable Flashlight
MR Rev.1 8/03
25
Make sure the red LED is showing fully in the
rear hole of the CHARGER CRADLE (1).
Make sure the two contact pins are in the
two pin holes in the CHARGER CRADLE (1)
and are protruding above the surface.
STEP 16
STEP 17
Replace the center CIRCUIT BOARD
SCREW (4) And the wiring harness.
Place the FIBERWASHER (5) Over the head of
the CIRCUIT BOARD SCREW (4).
26
MR Rev.1 8/03
Rechargeable Flashlight
421-000-438
STEP 18
STEP 19
Replace the 4 BASE PLATE SCREWS (6).
The full head of the center screw must be
fully visible.
Replace the CHARGER BRACKET (8).
421-000-438
Rechargeable Flashlight
MR Rev.1 8/03
27
CORPORATE OFFICE
MAG INSTRUMENT, INC.
1635 S. Sacramento Ave. • P.O. Box 50600
Ontario, California U.S.A. 91761-1083
www.maglite.com
Warranty: Tel: (800) 283-5562 or (909) 947-1006
Fax: (909) 947-5041 • E-mail: [email protected]
Sales & Parts:
Tel: (800) 289-6241 • (909) 947-1006
E-mail: [email protected]
©2003 MAG INSTRUMENT, INC.
Manufactured in U.S.A.
The distinctive shapes, styles and overall appearances of all Mag® flashlights, and the circumferential inscriptions extending around the heads of all Mag®
flashlights are trademarks of Mag Instrument, Inc. The circumferential inscription on the head of every flashlight signifies that it is an original Mag® flashlight and
part of the Mag® family of flashlights. U.S. Trademark Registrations for the shape, style and overall appearance trademarks of Mag® flashlights and for
circumferential inscription trademarks of Mag® flashlights include Nos. 2,687,693; 2,074,795 and 1,808,998. ©2003 MAG INSTRUMENT, INC.
The Mag-Lite® Rechargeable Flashlight System™ is covered by one or more pending patent applications and U.S. Patent Nos. 4,286,311; 4,388,673; 4,527,223; and
Des. 263,170; and by foreign patents.
421-000-438
MR Rev.1 8/03