421-000-391 ML Rev.1 8/03
1
FLASHLIGHTS
Mag-Lite®
C & D Cell
Flashlights
repair
manual
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® Flashlight and/or other Mag-Lite® Flashlight 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.
Repairs must be performed by Mag Instrument
certified warranty service personnel
C & D Flashlight
ML Rev.1 8/03 421-000-391
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TROUBLESHOOTING
for Mag-Lite® C&D Cell Flashlights
Troubleshooting a non working flashlight must be done prior to
commencing any repair operations
1. FLASHLIGHT FAILURE: Check the lamp and the batteries with the meter.. If the
lamp has burned out, be sure to replace it with the correct size genuine Mag
replacement lamp. Each battery should test at least 1.4 volts (see testing
procedures on the following pages.
2. FLASHLIGHT DOES NOT TURN ON OR STAY ON: Check the tail cap. The shiny
metal surfaces on the Tail cap and barrel should be clean and free of any
obstructions (see cleaning instructions on the following pages)
3. If all the above steps have been followed and the flashlight still does not perform
properly, replace the switch as shown in the repair manual.
LAMP TEST - STEP 1
Meter settings
• Black probe in COM port
• Red probe in VΩmA port
• Set dial at o))) setting
LAMP TEST - STEP 2
PR based lamps - Probe Placement
• Place Red probe on the positive tip of the lamp.
• Place Black probe anyplace on the metal base
• If the lamp is good you will get a 000 or higher
reading
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421-000-391
LAMP TEST - STEP 3
Bad Lamp - If the lamp is bad the meter
setting will not change and will stay at 1.
BATTERY TEST - STEP 1
• Black Probe in COM port
• Red Probe in VΩmA port
• Dial set at 2
BATTERY TEST - STEP 2
PROBE PLACEMENT
• The Red Probe goes on the positive
battery button
• The Black Probe goes on the flat
negative end
BATTERY TEST - STEP 3
METER READING
• Meter should read 1.40 or higher for a
good battery
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BARREL - STEP 1
Using the emery paper, wipe the shiny
surfaces as shown until they are clean.
CLEANING METAL SURFACE
BARREL - STEP 2
Place the sheet of emery paper on a flat
surface.
BARREL - STEP 3
• Place the tail cap end (shiny surface) flat
on the emery paper
• Using a figure eight pattern, wipe the
barrel across the paper
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421-000-391
SWITCH REPLACEMENT
FOR REVISED (New Style) C & D CELL (WITH A ‘D’ OR ‘C IN
FRONT OF THE SERIAL NUMBER)
BATTERY LEAKAGE
Mag Instrument’s flashlight warranty does not cover battery leakage unless the batteries
involved are Rayovac, Eveready or Duracell.
If the batteries are one of the three, the WSC may exchange the flashlight for a new
replacement. If the WSC is unable to determine which type of battery is in the flashlight then
they may assume it is one of the above batteries and make the exchange.
If a flashlight has evidence of a battery leak but the batteries have been removed and not
accompanying the flashlight the warranty is void.
All battery leaks caused by any other battery are not covered by Mags warranty and the
customer may exchange their flashlight for a new one at the exchange fee per the WSC price
schedule or, the WSC may advise the customer to contact the particular battery manufacturer
for further instructions.
Tools required to
replace new style
Mag-Lite®C & D
flashlights:
Hex wrench
C & D Flashlight
ML Rev.1 8/03 421-000-391
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SCHEMATIC - FLASHLIGHT
PARTS LIST FOR BLACK ‘D’ AND BLACK ‘C’ MAG-LITE® FLASHLIGHTS (PREFIX 'D' or 'C' SERIAL NUMBER)
ITEM NO. QTY. PART NO. DESCRIPTION
11 HEAD SUB-ASSEMBLY, ‘D’ or ‘C’
2 1 201-000-157 FACE CAP, Black
3 1 108-000-026 O RING, FACE CAP
4 1 108-000-031 CLEAR LENS
5 1 108-000-036 PARABOLIC REFLECTOR
6 1 108-000-025 O-RING, HEAD C & D
7 1 201-000-161 HEAD, ‘D’ SIZE, Black
7 1 201-000-475 HEAD, ‘C’ SIZE, Black
9 1 200-000-057 BULB RETAINER
10 1 LWSA201 LAMP, 2-CELL KRYPTON - ALKALINE
10 1 LWSA301 LAMP, 3-CELL KRYPTON - ALKALINE
10 1 LWSA401 LAMP, 4-CELL KRYPTON - ALKALINE
10 1 LWSA501 LAMP, 5-CELL KRYPTON - ALKALINE
10 1 LWSA601 LAMP, 6-CELL KRYPTON - ALKALINE
11 1 108-000-574 O-RING, ‘C’ BARREL
11 1 108-000-206 O-RING, 'D' BARREL
12 1 108-000-034 SWITCH SEAL, ‘D’
12 1 108-000-575 SWITCH SEAL, ‘C’
13 1 201-000-178 BARREL 2D
13 1 201-000-179 BARREL 3D
13 1 201-000-180 BARREL 4D
13 1 201-000-181 BARREL 5D
13 1 201-000-182 BARREL 6D
13 1 201-000-476 BARREL 2C
13 1 201-000-477 BARREL 3C
13 1 201-000-478 BARREL 4C
13 1 201-000-479 BARREL 5C
13 1 201-000-480 BARREL 6C
14 1 400-000-067 SNAP RING, ‘D’
14 1 400-000-122 SNAP RING, ‘C’
15 1 108-000-208 SWITCH SUB-ASSEMBLY 'D' SIZE
15 1 108-000-498 SWITCH SUB-ASSEMBLY 'C' SIZE
17 1 108-000-032 SPRING, TAILCAP ‘D’ SIZE
17 1 108-000-033 SPRING, TAILCAP ‘C’ SIZE
18 1 108-000-037 BULB PROTECTOR, ‘C’ & ‘D’
19 1 108-000-207 O-RING, TAILCAP ‘D’ SIZE
19 1 108-000-030 O-RING, TAILCAP ‘C’ SIZE
20 1 201-000-191 TAILCAP, ‘D’, Black
20 1 200-000-100 TAILCAP, ‘C’, Black
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STEP 1
Unscrew & remove the entire TAIL CAP
ASSEMBLY (16) and remove the BATTERIES.
STEP 2
Unscrew and remove the the entire HEAD
ASSEMBLY(1).
STEP 4
Remove the SWITCH SEAL (12)
By grasping with the thumb and index
finger, buckle and pull to extract.
STEP 3
Remove the LAMP (10).
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STEP 5
Insert the HEX WRENCH (22) into the
SWITCH BUTTON (A) , through the SWITCH
(15) and into the SET SCREW (21).
STEP 6
Back out the SET SCREW (21) three turns to
release the SWITCH (15) from the pocket in
the BARREL (13).
STEP 8
REPLACING SWITCH.
CAUTION: DO NOT ATTEMPT TO REMOVE
THE RETAINING SNAP RING (14).
Insert the new SWITCH (15) into the tail cap
end of the BARREL (13).
STEP 7
The SWITCH BUTTON (A) must be in the
down (depressed) position (figure 1)
Remove the SWITCH ASSEMBLY (15) from
the tail cap end of the BARREL (13). *Note: a
wooden rod may be used to dislodge the
SWITCH (15) from the BARREL (13).
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OLD STYLE C&D FLASHLIGHT SCHEMATIC
PARTS LIST FOR BLACK ‘D’ (OLD STYLE, PRIOR TO 1992) AND BLACK ‘C’ MAG-LITE® FLASHLIGHTS
ITEM NO QTY. PART NO. DESCRIPTION
11 HEAD SUB-ASSEMBLY, ‘D’ or ‘C’
2 1 201-000-157 FACE CAP, Black
3 1 108-000-026 O RING, FACE CAP
4 1 108-000-031 CLEAR LENS
5 1 108-000-036 PARABOLIC REFLECTOR
6 1 108-000-025 O-RING, HEAD C & D
7 1 N/A HEAD, ‘D’ SIZE, Black
7 1 200-000-047 HEAD, ‘C’ SIZE, Black
8 1 108-000-028 O-RING, ‘C’ BARREL
10 1 200-000-057 BULB RETAINER
11 1 LWSA201 LAMP, 2-CELL KRYPTON - ALKALINE
11 1 LWSA301 LAMP, 3-CELL KRYPTON - ALKALINE
11 1 LWSA401 LAMP, 4-CELL KRYPTON - ALKALINE
11 1 LWSA501 LAMP, 5-CELL KRYPTON - ALKALINE
11 1 LWSA601 LAMP, 6-CELL KRYPTON - ALKALINE
12 1 400-000-049 RETAINING RING 'D'
12 1 201-000-127 RETAINING RING 'C'
13 1 108-000-022 SWITCH SUB-ASSEMBLY 'D' SIZE
13 1 108-000-023 SWITCH SUB-ASSEMBLY 'C' SIZE
14 1 108-000-027 O-RING, 'D' BARREL
16 1 N/A BARREL 2D
16 1 N/A BARREL 3D
16 1 N/A BARREL 4D
16 1 N/A BARREL 5D
16 1 N/A BARREL 6D
16 1 N/A BARREL 2C
16 1 N/A BARREL 3C
16 1 N/A BARREL 4C
16 1 N/A BARREL 5C
17 1 N/A BARREL 6C
18 1 108-000-032 SPRING, TAILCAP ‘D’ SIZE
18 1 108-000-033 SPRING, TAILCAP ‘C’ SIZE
19 1 108-000-037 BULB PROTECTOR, ‘C’ & ‘D’
20 1 108-000-029 O-RING, TAILCAP ‘D’ SIZE
20 1 108-000-030 O-RING, TAILCAP ‘C’ SIZE
21 1 200-000-038 TAILCAP, ‘D’, Black
21 1 200-000-100 TAILCAP, ‘C’, Black
C & D Flashlight
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Follow instructions for Steps 1-7 from new style instructions (pg. 3-4)
STEP 9
Match the pins on the Spanner Wrench (25)
with the holes in the retaining ring.
STEP 11
Depress the switch button.
STEP 10
Insert the Spanner (25) into the front of the
barrel (16).
(small end for C cells and large end for D cells)
STEP 8
Unscrew the retaining ring
(counterclockwise).
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STEP 13
REPLACE THE SWITCH
Make sure the switch button is depressed.
Insert the Switch Assembly (13) into the
front of the barrel (16).
STEP 15
Insert the proper hex wrench (23) or (24)
for “D” into the switch button (A),
through the switch and into the set
screw (22). Center the switch button and
tighten the set screw (22).
STEP 14
Line up the switch button on the Switch
Assembly (13) with the switch hole in the
barrel (16) and push the Switch Assembly
(13) in until it stops.
STEP 12
Pull the Switch Assembly (13) out the front
of the barrel (16).
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STEP 17
Replace the lamp (11).
STEP 18
Replace the head (7).
STEP 16
Replace the switch seal (15) by grasping with
the thumb and index finger, buckle and push
it into the hole. Make sure it is seated all the
way around the hole.
STEP 19
Replace the batteries and the tail cap
assembly (17).
ML Rev.1 8/03421-000-391
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® flashlight is covered by pending U.S. Patent Applications and one or more of U.S. Patent Nos. 4,286,311; 4,388,673; 5,260,858; 5,749,645; 6,196,698;
6,428,182; Des. 263,170 and by foreign patents.
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.
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