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421-000-439

MM Rev.1   8/03

1

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

Summary of Contents for Mini Maglite SERIES

Page 1: ...ashlight 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 ...

Page 2: ...OT 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...

Page 3: ...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 ...

Page 4: ...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 Ass...

Page 5: ...rel 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 Lo...

Page 6: ...2 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 t...

Page 7: ...he 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 ...

Page 8: ... 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 1...

Page 9: ...t 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...

Page 10: ...g flashlights include Nos 2 687 693 2 074 795 and 1 808 998 2003 MAG INSTRUMENT INC 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 ...

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