Mag-lite C CELL Istruzioni operative

421-000-391 ML Rev.1 8/03

FLASHLIGHTS

Mag-Lite®

C & D Cell

Flashlights

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® Flashlight and/or other Mag-Lite® 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.

Repairs must be performed by Mag Instrument

certified warranty service personnel

C & D Flashlight

ML Rev.1 8/03 421-000-391

TROUBLESHOOTING

for Mag-Lite®C&D 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 (see cleaning instructions on the following pages)

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 o))) setting

LAMP TEST - STEP 2

PR based lamps - Probe Placement

•Place Red probe on the positive tip of the lamp.

•Place Black probe anyplace on the metal base

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

reading

C & D Flashlight ML Rev.1 8/03

421-000-391

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

C & D Flashlight

ML Rev.1 8/03 421-000-391

BARREL - STEP 1

Using the emery paper, wipe the shiny

surfaces as shown until they are clean.

CLEANING METAL SURFACE

BARREL - STEP 2

Place the sheet of emery paper on a flat

surface.

BARREL - STEP 3

•Place the tail cap end (shiny surface) flat

on the emery paper

•Using a figure eight pattern, wipe the

barrel across the paper

C & D Flashlight ML Rev.1 8/03

421-000-391

SWITCH REPLACEMENT

FOR REVISED (New Style) C & D CELL (WITH A ‘D’OR ‘C IN

FRONT OF THE SERIAL NUMBER)

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.

Tools required to

replace new style

Mag-Lite®C & D

flashlights:

Hex wrench

C & D Flashlight

ML Rev.1 8/03 421-000-391

SCHEMATIC - FLASHLIGHT

PARTS LIST FOR BLACK ‘D’ AND BLACK ‘C’ MAG-LITE® FLASHLIGHTS (PREFIX 'D' or 'C' SERIAL NUMBER)

ITEM NO. QTY. PART NO. DESCRIPTION

11 HEAD SUB-ASSEMBLY, ‘D’or ‘C’

2 1 201-000-157 FACE CAP, Black

3 1 108-000-026 O RING, FACE CAP

4 1 108-000-031 CLEAR LENS

5 1 108-000-036 PARABOLIC REFLECTOR

6 1 108-000-025 O-RING, HEAD C & D

7 1 201-000-161 HEAD, ‘D’SIZE, Black

7 1 201-000-475 HEAD, ‘C’SIZE, Black

9 1 200-000-057 BULB RETAINER

10 1 LWSA201 LAMP, 2-CELL KRYPTON - ALKALINE

10 1 LWSA301 LAMP, 3-CELL KRYPTON - ALKALINE

10 1 LWSA401 LAMP, 4-CELL KRYPTON - ALKALINE

10 1 LWSA501 LAMP, 5-CELL KRYPTON - ALKALINE

10 1 LWSA601 LAMP, 6-CELL KRYPTON - ALKALINE

11 1 108-000-574 O-RING, ‘C’BARREL

11 1 108-000-206 O-RING, 'D' BARREL

12 1 108-000-034 SWITCH SEAL, ‘D’

12 1 108-000-575 SWITCH SEAL, ‘C’

13 1 201-000-178 BARREL 2D

13 1 201-000-179 BARREL 3D

13 1 201-000-180 BARREL 4D

13 1 201-000-181 BARREL 5D

13 1 201-000-182 BARREL 6D

13 1 201-000-476 BARREL 2C

13 1 201-000-477 BARREL 3C

13 1 201-000-478 BARREL 4C

13 1 201-000-479 BARREL 5C

13 1 201-000-480 BARREL 6C

14 1 400-000-067 SNAP RING, ‘D’

14 1 400-000-122 SNAP RING, ‘C’

15 1 108-000-208 SWITCH SUB-ASSEMBLY 'D' SIZE

15 1 108-000-498 SWITCH SUB-ASSEMBLY 'C' SIZE

17 1 108-000-032 SPRING, TAILCAP ‘D’SIZE

17 1 108-000-033 SPRING, TAILCAP ‘C’SIZE

18 1 108-000-037 BULB PROTECTOR, ‘C’& ‘D’

19 1 108-000-207 O-RING, TAILCAP ‘D’SIZE

19 1 108-000-030 O-RING, TAILCAP ‘C’SIZE

20 1 201-000-191 TAILCAP, ‘D’, Black

20 1 200-000-100 TAILCAP, ‘C’, Black

C & D Flashlight ML Rev.1 8/03

421-000-391

STEP 1

Unscrew & remove the entire TAIL CAP

ASSEMBLY (16) and remove the BATTERIES.

STEP 2

Unscrew and remove the the entire HEAD

ASSEMBLY(1).

STEP 4

Remove the SWITCH SEAL (12)

By grasping with the thumb and index

finger, buckle and pull to extract.

STEP 3

Remove the LAMP (10).

C & D Flashlight

ML Rev.1 8/03 421-000-391

STEP 5

Insert the HEX WRENCH (22) into the

SWITCH BUTTON (A) , through the SWITCH

(15) and into the SET SCREW (21).

STEP 6

Back out the SET SCREW (21) three turns to

release the SWITCH (15) from the pocket in

the BARREL (13).

STEP 8

REPLACING SWITCH.

CAUTION: DO NOT ATTEMPT TO REMOVE

THE RETAINING SNAP RING (14).

Insert the new SWITCH (15) into the tail cap

end of the BARREL (13).

STEP 7

The SWITCH BUTTON (A) must be in the

down (depressed) position (figure 1)

Remove the SWITCH ASSEMBLY (15) from

the tail cap end of the BARREL (13). *Note: a

wooden rod may be used to dislodge the

SWITCH (15) from the BARREL (13).

C & D Flashlight ML Rev.1 8/03

421-000-391

STEP 10

Using the HEX WRENCH (22) center the

SWITCH (15) and Tighten the SET SCREW

(21).

STEP 12

Replace the HEAD ASSEMBLY (1).

STEP 11

Replace the LAMP (10).

STEP 9

Push the SWITCH ASSEMBLY (15) into the

BARREL (13) until it stops at the SNAP RING

(14).

C & D Flashlight

ML Rev.1 8/03 421-000-391

STEP 13

Replace the BATTERIES and TAIL CAP

ASSEMBLY (16).

C&D SWITCH REPLACEMENT

OLD STYLE

Tools required to

replace old style

Mag-Lite®C&D

flashlights:

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