MAG Mini Maglite SERIES User manual

Brand: MAG

Model: Mini Maglite SERIES

Type: User manual

MAG Mini Maglite SERIES: The versatile flashlight for everyday use and emergencies. Its compact size and durable construction make it ideal for everyday carry, while its bright beam and long battery life make it a reliable companion in emergencies. The MAG Mini Maglite SERIES is water-resistant and features a textured reflector for a smooth, even beam. It also has a tailcap switch for easy one-handed operation. With its long history of reliability, the MAG Mini Maglite SERIES is the perfect flashlight for anyone looking for a dependable light source.

421-000-439

MM Rev.1 8/03

FLASHLIGHTS

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

Mini Maglite® Flashlight and/or other Mini Maglite® 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.

Mini Maglite

AA/AAA

Flashlights

repair

manual

Repairs must be performed by Mag Instrument

certified warranty service personnel

AA/AAA Flashlight

MM Rev.1 8/03 421-000-439

TROUBLESHOOTING

for Mini Maglite

AA/AAA 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. Also check the

contact inside the barrel to make sure it is clean & free of

obstruction (see photo).

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

)

) setting

LAMP TEST - STEP 2

PROBE PLACEMENT

• Place Red probe on one lamp pin

• Place Black probe on the other lamp pin (it

make no difference which probe goes to

what pin)

• If the lamp is good you will get a 000 or

higher reading

AA/AAA Flashlight

MM Rev.1 8/03

421-000-439

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

AA/AAA Flashlight

MM Rev.1 8/03 421-000-439

AA/AAA SWITCH REPLACEMENT

Tools required to replace switches in

Solitaire

, AAA/AA Mini Maglite

flashlights

Each tool has a long and short pin end.

The long pins remove the switch. The

short pins are to install the switch (23).

SCHEMATIC - FLASHLIGHT

Parts List for Standard Black Mini Maglite

AAA Flashlight

ITEM NO QTY. PART NUMBER DESCRIPTION

1 1 N/A Head Sub-Assembly

2 1 216-000-020 Face cap, Black

3 1 108-000-068 'O' Ring, Face cap

4 1 108-000-063 Clear Lens

5 1 108-000-064 Reflector

6 1 108-000-065 'O' Ring, Head

7 1 216-000-008 Head, Black

8 1 LM2A001 Bulb

9 1 108-000-261 Barrel & Switch Sub-Assembly

10 1 N/A Insulator, Upper

11 1 108-000-066 'O' Ring, Barrel

12 1 216-000-032 Barrel, Black

13 1 N/A Contact/Lamp, Side

14 1 N/A Contact/Lamp, Center

15 1 N/A Insulator, Lower

16 1 108-000-197 Tail cap Sub-Assembly

17 1 108-000-069 Spring, Tail cap

18 1 108-000-618 Ground Contact

19 1 108-000-204 Lip Seal

20 1 220-000-156 Tail cap, Black

21 1 109-000-468 Long/Short pin tool AAA

22 1 108-000-071 Switch Assembly AAA

Items 10, 13, 14 and 15 are included in item 22

AA/AAA Flashlight

MM Rev.1 8/03

421-000-439

Parts List for Standard Black Mini Maglite

AA Flashlight

ITEM NO QTY. PART NUMBER DESCRIPTION

1 1 N/A Head Sub-Assembly

2 1 203-000-004 Face cap, Black

3 1 108-000-045 'O' Ring, Face cap

4 1 108-000-046 Clear Lens

5 1 108-000-038 Reflector

6 1 108-000-041 'O' Ring, Head

7 1 203-000-273 Head, Black

8 1 LM2A001 Bulb

9 1 108-000-252 Barrel & Switch Sub-Assembly

10 1 N/A Insulator, Upper

11 1 108-000-042 'O' Ring, Barrel

12 1 203-000-254 Barrel, Black

13 1 N/A Contact/Lamp, Side

14 1 N/A Contact/Lamp, Center

15 1 N/A Insulator, Lower

16 1 108-000-215 Tail cap Sub-Assembly

17 1 108-000-044 Spring, Tail cap

18 1 108-000-062 Bulb Protector

19 1 108-000-205 Lip Seal

20 1 203-000-172 Tail cap, Black

108-000-211 Switch Assembly

21 1 109-000-469 Long/Short Pin Bench Tool

STEP 2

Unscrew (counterclockwise) and remove the

entire HEAD ASSEMBLY (1)

STEP 1

Unscrew (counterclockwise) and remove the

entire TAIL CAP ASSEMBLY (16) and the

BATTERIES.

AA/AAA Flashlight

MM Rev.1 8/03 421-000-439

STEP 3

Remove the LAMP (8) by pulling it straight

out of the receptacles. A spare LAMP (8) is

located in the TAIL CAP (20).

STEP 5

Place the TOOL (23) and the BARREL (12) in

the tool base and push down on the

BARREL (12). The UPPER INSULATOR (11)

will move upward and separate from the

LOWER INSULATOR (15).

STEP 6

You can now remove the UPPER

INSULATOR (11) from the BARREL (12).

STEP 4

Insert the end of the SWITCH REPAIR TOOL

(23) with the longest pin protrusion into the

bottom of the BARREL (12). Rotate the tool

until the two pins enter the two holes in the

bottom of the LOWER INSULATOR (15).

(Note: The SWITCH ASSEMBLY (22) may

tend to rotate, if so place your finger on it

prior to rotating the tool).

AA/AAA Flashlight

MM Rev.1 8/03

421-000-439

Replacement SWITCHES will come

assembled.

STEP 7

Slowly lift the BARREL (12) off of the TOOL

(23), the LOWER INSULATOR (15) should be

on the TOOL (23). If not, tap the BARREL

(12) lightly and the LOWER INSULATOR (15)

should fall out.

Push down on the lower half of the SWITCH

ASSEMBLY (15), this will cause the UPPER

INSULATOR (11) to pop up.

To separate the SWITCH ASSEMBLY prior

to installation, place the SWITCH

ASSEMBLY on the LONG PIN TOOL (21).

AA/AAA Flashlight

MM Rev.1 8/03 421-000-439

STEP 8

REPLACING SWITCH

Place the LOWER INSULATOR (15) on the

SHORT PIN TOOL (21) making sure the pins

of the TOOL (21) are in the holes of the

LOWER INSULATOR (15).

STEP 10

While firmly holding the TOOL (23) and

BARREL (12), line up the pins of the UPPER

INSULATOR (11) with the holes of the

LOWER INSULATOR (15). Push the UPPER

INSULATOR (11) down into the LOWER

INSULATOR (15) until it presses into place.

STEP 11

Reinstall the LAMP (8) in the receptacles of

the UPPER INSULATOR (11). Adjust the

LAMP (8) so it is as vertical and straight as

possible. Using a clean soft cloth, gently

wipe the moisture and oil from the glass on

the LAMP (8).

STEP 9

Insert the TOOL (23) with the LOWER

INSULATOR (15) into the bottom of the

BARREL (12). Push the TOOL (23) into

the BARREL (12) until it stops at the top

of the BARREL (12).

*Note: make sure the SIDE CONTACT (14) and

CENTER CONTACT (13) are in the switch.

AA/AAA Flashlight

MM Rev.1 8/03

421-000-439

STEP 12

Replace the HEAD ASSEMBLY (1)

STEP 13

Before installing the BATTERIES, check for

leakage or corrosion. Reinstall or replace the

BATTERIES, (two ‘AA/AAA’ series alkaline

only) install with the positive (+) end toward

the lamp. Reinstall TAIL CAP (20). *Note:

always make sure the TAIL CAP (20) is tight

for good positive electrical contact.

NOTICE: Replace o-ring style TAIL CAP (20)

with new LIP SEAL (21) and TAIL CAP (22).

ALL VISIBLE SEALS (6, 10 & 19) SHOULD HAVE A LIGHT

COAT OF OIL ON THEM. IF NOT, LIGHTLY COAT WITH

SUPER LUBE GREASE.

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.

MM Rev.1 8/03421-000-439

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.

The Mini Maglite® 2-cell AA and AAA flashlights are covered by one or more pending patent applications and U.S. Patent, Nos. 4,577,263; 4,656,565; 4,658,336; 4,819,141; 4,851,974;

4,899,265; 4,942,505; 5,003,440; 5,113,326; 5,143,441; 5,207,502; 5,226,722; 5,293,307; 5,349,506; 5,722,765; 6,135,611; 6,170,960; 6,361,183 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]

MAG INSTRUMENT, INC.

Manufactured in U.S.A.