FLASHLIGHTS
®
repair
manual
Mini Maglite
AA/AAA
Flashlights
Repairs must be performed by Mag Instrument
certified warranty service personnel
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.
421-000-439
MM Rev.1 8/03
1
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 2
LAMP TEST - STEP 1
Meter settings
• Black probe in COM port
• Red probe in VΩmA port
• Set dial at o))) setting
2
MM Rev.1 8/03
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
421-000-439
BATTERY TEST - STEP 1
LAMP TEST - STEP 3
Bad Lamp - If the lamp is bad the meter
setting will not change and will stay at 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
421-000-439
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
3
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
Items 10, 13, 14 and 15 are included in item 22
Parts List for Standard Black Mini Maglite® AAA Flashlight
ITEM NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
4
MM Rev.1 8/03
QTY.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
PART NUMBER
N/A
216-000-020
108-000-068
108-000-063
108-000-064
108-000-065
216-000-008
LM2A001
108-000-261
N/A
108-000-066
216-000-032
N/A
N/A
N/A
108-000-197
108-000-069
108-000-618
108-000-204
220-000-156
109-000-468
108-000-071
DESCRIPTION
Head Sub-Assembly
Face cap, Black
'O' Ring, Face cap
Clear Lens
Reflector
'O' Ring, Head
Head, Black
Bulb
Barrel & Switch Sub-Assembly
Insulator, Upper
'O' Ring, Barrel
Barrel, Black
Contact/Lamp, Side
Contact/Lamp, Center
Insulator, Lower
Tail cap Sub-Assembly
Spring, Tail cap
Ground Contact
Lip Seal
Tail cap, Black
Long/Short pin tool AAA
Switch Assembly AAA
AA /AAA Flashlight
421-000-439
Parts List for Standard Black Mini Maglite® AA Flashlight
ITEM NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
QTY.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
21
1
PART NUMBER
N/A
203-000-004
108-000-045
108-000-046
108-000-038
108-000-041
203-000-273
LM2A001
108-000-252
N/A
108-000-042
203-000-254
N/A
N/A
N/A
108-000-215
108-000-044
108-000-062
108-000-205
203-000-172
108-000-211
109-000-469
DESCRIPTION
Head Sub-Assembly
Face cap, Black
'O' Ring, Face cap
Clear Lens
Reflector
'O' Ring, Head
Head, Black
Bulb
Barrel & Switch Sub-Assembly
Insulator, Upper
'O' Ring, Barrel
Barrel, Black
Contact/Lamp, Side
Contact/Lamp, Center
Insulator, Lower
Tail cap Sub-Assembly
Spring, Tail cap
Bulb Protector
Lip Seal
Tail cap, Black
Switch Assembly
Long/Short Pin Bench Tool
STEP 1
STEP 2
Unscrew (counterclockwise) and remove the
entire TAIL CAP ASSEMBLY (16) and the
BATTERIES.
Unscrew (counterclockwise) and remove the
entire HEAD ASSEMBLY (1)
421-000-439
AA /AAA Flashlight
MM Rev.1 8/03
5
STEP 3
STEP 4
Remove the LAMP (8) by pulling it straight
out of the receptacles. A spare LAMP (8) is
located in the TAIL CAP (20).
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).
STEP 5
STEP 6
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).
You can now remove the UPPER
INSULATOR (11) from the BARREL (12).
6
MM Rev.1 8/03
AA /AAA Flashlight
421-000-439
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.
Replacement SWITCHES will come
assembled.
To separate the SWITCH ASSEMBLY prior
to installation, place the SWITCH
ASSEMBLY on the LONG PIN TOOL (21).
Push down on the lower half of the SWITCH
ASSEMBLY (15), this will cause the UPPER
INSULATOR (11) to pop up.
421-000-439
AA /AAA Flashlight
MM Rev.1 8/03
7
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).
*Note: make sure the SIDE CONTACT (14) and
CENTER CONTACT (13) are in the switch.
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).
STEP 10
STEP 11
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.
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).
8
AA /AAA Flashlight
MM Rev.1 8/03
421-000-439
ALL VISIBLE SEALS (6, 10 & 19) SHOULD HAVE A LIGHT
COAT OF OIL ON THEM. IF NOT, LIGHTLY COAT WITH
SUPER LUBE GREASE.
STEP 12
STEP 13
Replace the HEAD ASSEMBLY (1)
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).
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.
421-000-439
AA /AAA Flashlight
MM Rev.1 8/03
9
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: warranty@magmail.com
Sales & Parts:
Tel: (800) 289-6241 • (909) 947-1006
E-mail: salesdesk@magmail.com
©2003 MAG INSTRUMENT, INC.
Manufactured in U.S.A.
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 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.
421-000-439
MM Rev.1 8/03