3. Remove the lamp from the flashlight as described in Testing/Replacing the Lamp
4. Test the switch.
a. Place a multimeter in the continuity position.
1. Place one meter lead on the negative battery lead.
2. Touch the other meter lead to either of the lamp leads.
3. The meter must indicate continuity with one of the lamp leads.
4. If continuity is established with one of the lamp leads put that lead aside.
5. If neither lamp lead indicates continuity the wiring will need to be checked
(see 6 below).
b. Place one meter lead on the positive battery lead.
1. Place the other meter lead on the lamp lead which was not connected to the negative
battery lead.
2. Cycle the switch at least 8 times (four on/off cycles).
3. If continuity is not indicated in all four “on” cycles the switch will need to be replaced.
5. Disassemble the SL-40.
a. Remove the shoulder strap D - Rings (if present) on the
carry
handle by opening them outwards from the handle.
b. Loosen and remove the adjustable wing nut assembly which
fastens the lamp housing to the flashlight body.
c. Use a Phillips screwdriver to remove the body screws
located
on the side and foot of the flashlight.
Note : Use caution when removing the screws as their
anchor nuts (located on the opposite side) will be
freed from their mountings and could be misplaced.
d. Carefully separate the two halves of the body.
e. Remove the rubber footpads at the bottom of the flashlight
and place them aside.
6. Inspect the wires to make sure that none of them are disconnected or broken and replace
them as necessary.
7. Use the switch boot tool (P/N 450074) to remove the switchboot and integrated lock ring.
8. Desolder the switch leads from the circuit board. (The replacement switch is P/N 400157)
9. Solder the leads of the replacement switch to the circuit board at the solder pads
marked “sw” (either lead to either pad).
10. Place the new switch into the opening in the handle.
11. Use the switch boot tool to secure the switch boot and integrated lock ring in place.
12. Reassemble the SL-40.
a. Align the two halves of the flashlight body.
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1. Make sure the circuit board is inserted in the slots provided.
2. Join the two halves of the flashlight body together.
3. Check to make sure that there are no pinched wires.
b. Place the body screws in their mounting holes and secure them with their anchor nuts.
c. Replace the rubber footpads in their openings at the bottom of the flashlight.
d. Place the lamp housing mounting screw and wing nut into the mounting hole located on
the flashlight body forward of the carrying handle and secure the lamp housing in position.
e. Reattach the D-Rings (if desired) by aligning them with their mounting holes and
squeezing them into place with pliers.
f. Reinstall the battery and rear cover as described in the battery section.
Testing/Repairing the Circuit Board
