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421-000-438

MR Rev.1 8/03

1

Rechargeable Flashlight System

™

(Ni-Cad)

RX1019/RX1016

RX2019

RX3019

RX4019

RX5019

RX6019

RX7019

Mag-Lite

®

Rechargeable
Flashlight

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®
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.

Repairs must be performed by Mag Instrument

certified warranty service personnel

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2
3
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Содержание RX3019

Страница 1: ...d 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 l...

Страница 2: ...tery 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 servi...

Страница 3: ...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 tes...

Страница 4: ... 3 1 108 000 060 LENS SODALIME 4 1 108 000 020 LENS ASSEMBLY 5 105 000 002 FACE REFLECTOR ASSEMBLY 6 1 108 000 104 REFLECTOR HOUSING ASSEMBLY 7 1 108 000 557 SWITCH SEAL old or 108 000 643 revised 8 1 405 000 049 NYLON WASHER 9 1 205 000 014 SWITCH HOUSING CASING 10 1 405 000 016 O RING SWITCH HOUSING 11 2 LR00001 HALOGEN LAMP 12 1 108 000 106 SWITCH ASSEMBLY 13 1 108 000 025 O RING HEAD 14 1 205 ...

Страница 5: ... 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 wh...

Страница 6: ...ounterclockwise STEP 4 Remove the SWITCH SEAL 7 by grasping the seal with your thumb and index finger buckle and pull to extract STEP 3 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 ...

Страница 7: ...ER 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...

Страница 8: ...rns STEP 12 Unscrew and remove the CHARGER MODULE 15 from the SWITCH HOUSING 9 STEP 11 Lift up the plunger and remove the HEAD 14 SWITCH HOUSING 9 and CHARGER MODULE 15 from the TOOL HOLDER STEP 9 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 ...

Страница 9: ...Occasionally the CHARGER MODULE 15 will stay in the BARREL 16 when it is unscrewed If this happens do the following A CHARGE MODULE METER SETTINGS Meter reading is 005 764 mA A bad module will register 000 or 1 mA 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 CHARGER MODULE TEST ...

Страница 10: ...e 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 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...

Страница 11: ...insulator ring 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 When replacing the ring onto the MODULE 15 place the ring over the diode pin push down and snap the ring in place STEP 13 Push the HEAD 14 down and over the O RING 10 and remove it from the SWITCH HOUSING 9 ...

Страница 12: ...he SWITCH HOUSING 9 STEP 15 REPLACE SWITCH Insert the SWITCH ASSEMBLY 12 into the rear of 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 STEP 14 Depress the switch button...

Страница 13: ...tered in the switch hole of the HOUSING 9 STEP 18 Slide the HEAD 14 over the SWITCH HOUSING 9 make sure it slides over the O RING 10 STEP 16 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 STEP 19 Screw the CHARGER MODULE 15 clockwise into the SWITCH HOUSING 9 finger tight ...

Страница 14: ...s in the holder fall into the holes in the CHARGER MODULE 9 Tighten the CHARGER MODULE 9 clockwise as tight as possible STEP 20 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 STEP 23 Insert the silver ringed portion of the BARREL 16 into the rear of the tool holder a...

Страница 15: ... barrel holder tool STEP 27 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 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 bul...

Страница 16: ... the LAMP 11 in the REFLECTOR 6 hole DO NOT TOUCH THE REFLECTORS SURFACE or TRY TO CLEAN IT WITH ANYTHING STEP 28 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 STEP 31 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 ...

Страница 17: ...R e c h a r g e a b l e F l a s h l i g h t MR Rev 1 8 03 17 421 000 438 STEP 32 Replace the FACE CAP ASSEMBLY 5 ...

Страница 18: ...R e c h a r g e a b l e F l a s h l i g h t MR Rev 1 8 03 421 000 438 18 CIRCUIT BOARD REPLACEMENT RECHARGEABLE SYSTEM ...

Страница 19: ...05 000 025 SPRING CLAMP 3 1 105 000 021 CIRCUIT BOARD ASSEMBLY 4 1 405 000 028 SCREW CIRCUIT BOARD 6X5 16 5 1 405 000 103 FIBER WASHER 6 4 405 000 047 SCREW BASE PLATE 6X3 4 7 1 405 000 096 BASE PLATE 8 1 108 000 440 CHARGER BRACKET 1 108 000 437 110 VOLT AC CONVERTER 1 108 000 438 12 VOLT DC CORD W CIG LIGHTER PLUG 1 405 000 089 12 VOLT DC STRAIGHT WIRE ...

Страница 20: ...al is at V 20 volts 2 Black probe is in the COM port 3 Red probe is in the VΩmA port CONVERTER METER READING 1 Between 13 00 22 00 volts CIRCUIT BOARD TEST METER SETTING 1 Set the dial at A 10A Amps 2 Black probe in COM port 3 Red probe in 10ADC port CONVERTER 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 i...

Страница 21: ... 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 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 Put the flashlight in the CHARGER 1 with the CHARGER 1 plugged in the LED will light if the BOARD is good ...

Страница 22: ...T 8 from the from the BASE PLATE 7 STEP 3 Unscrew the 4 MOUNTING SCREWS 6 counterclockwise from the BASE PLATE 7 STEP 1 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 STEP 4 Remove the BASE PLATE 7 from the CHARGER CRADLE 1 ...

Страница 23: ...EP 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 STEP 5 Remove the INSULATOR WASHER 5 that is around the CIRCUIT BOARD SCREW 4 head STEP 8 Lift the CIRCUIT BOARD ASSEMBLY 3 out of the CHARGER CRADLE 1 ...

Страница 24: ... 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 STEP 9 The SPRING CLIP 2 will probably pop out if not leave the SPRING...

Страница 25: ...RD 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 STEP 12 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 STEP 15 Push the CIRCUIT BOARD 3 down until it bottoms out and is seated in...

Страница 26: ... in the two pin holes in the CHARGER CRADLE 1 and are protruding above the surface STEP 16 Replace the center CIRCUIT BOARD SCREW 4 And the wiring harness Make sure the red LED is showing fully in the rear hole of the CHARGER CRADLE 1 STEP 17 Place the FIBERWASHER 5 Over the head of the CIRCUIT BOARD SCREW 4 ...

Страница 27: ... c h a r g e a b l e F l a s h l i g h t MR Rev 1 8 03 27 421 000 438 STEP 18 Replace the 4 BASE PLATE SCREWS 6 The full head of the center screw must be fully visible STEP 19 Replace the CHARGER BRACKET 8 ...

Страница 28: ... 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 CORPORATE OFFICE MAG INSTRUMENT INC 1635 S Sacramento Ave P O...

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