Mag-lite SOLITAIRE Series Setup guide

FLASHLIGHTS
Switch Repair
Instructions for
SOLITAIRE®
FLASHLIGHTS
SCHEMATIC - FLASHLIGHT
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. 1,808,998;
2,074,795; 2,687,693; 2,745,460;
2,765,978 and 2,765,979.
The Solitaire® Single Cell AAA
flashlight is 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; 4,864,474; 4,899,265;
4,942,505; 5,003,440; 5,052,602;
5,113,326; 5,143,441; 5,207,363;
5,207,502; 5,293,307; 5,349,506;
6,135,611; 6,170,960; Des.
308,109. and by foreign patents.
CORPORATE OFFICE
MAG INSTRUMENT, INC.
1635 S. Sacramento Ave.
P.O. Box 50600
Ontario, California U.S.A. 91761-1083
Website: www.maglite.com
Warranty: Tel: [phone] or
[phone]
Fax: [phone]
E-mail: [email protected]
Sales & Parts:
Tel: [phone] • [phone]
E-mail: [email protected]
©2004 MAG INSTRUMENT, INC.
421-000-447 8/04
Tool has a long
and short pin
end. The long
pins remove the
switch. The short
pins are to install
the switch.
Tool required to
replace the switch
in the Solitaire®.
(included)
STEP 2
Unscrew (counter
clockwise) and remove
the entire HEAD
ASSEMBLY (1)
STEP 1
Unscrew (counter
clockwise) and remove
the entire TAIL CAP
ASSEMBLY (14) and
the battery.
Note: A spare LAMP (8) is
located in the TAIL CAP (20).
STEP 4
Insert the end of the TOOL
(20) with the longest pin
protrusion into the bottom
of the BARREL (10). Rotate
the tool until the two pins
enter the two holes in the
bottom of the LOWER
INSULATOR (13).
STEP 6
You can now remove the
UPPER INSULATOR (8)
from the BARREL (10).
STEP 5
Place the TOOL (20) and
the BARREL (10) on a flat
surface and push down on
the BARREL (10). The
UPPER INSULATOR (8)
will move upward and
separate from the LOWER
INSULATOR (13).
Parts List for Standard Black Solitaire
®
Flashlight
ITEM NO QTY. PART NUMBER DESCRIPTION
1 1 108-000-089 Head Sub-Assembly
2 1 220-000-055 Head, Black
3 1 108-000-067 'O' Ring, Head
4 1 108-000-083 Clear Lens
5 1 108-000-084 Reflector
6 1 LK3A001 Bulb
7 1 108-000-269 Barrel & Switch Sub-Assembly
8 1 * Upper Insulator Receptacle
9 1 108-000-067 'O' Ring, Barrel
10 1 220-000-067 Barrel, Black
11 1 * Lamp Receptacle, Side Contact
12 1 * Lamp Receptacle, Center Contact
13 1 * Lower Insulator Receptacle
14 1 108-000-190 Tail cap Sub-Assembly
15 1 108-000-069 Spring, Tail cap
16 1 108-000-618 Electrical Contact
17 1 108-000-204 Lip Seal
18 1 220-000-156 Tail cap, Black
19 * 108-000-085 Switch Assembly
20 1 112-000-003 Short/Long Pin Tool
Switch Removal
STEP 7
Slowly lift the BARREL
(10) off of the TOOL (20),
the LOWER INSULATOR
(13) should be on the
TOOL (20). If not, tap the
BARREL (10) lightly and
the LOWER INSULATOR
(13) should fall out.
WARNING: Do not allow children to
install or tamper with the lamp.
Protect the lamp from bending or
twisting. If the lamp is installed
improperly or if the leads from the
lamp are twisted so as to contact one
another, this could short circuit the
flashlight and cause heat generation.
STEP 3
Remove the LAMP (6) by
pulling it straight out of
the receptacles.
© 2004 Mag Instrument, Inc. 421-000-447 8/04

Replacement switches come
assembled.
Push down on the lower half of
the SWITCH ASSEMBLY (19),
this will cause the UPPER
INSULATOR (8) to pop up.
To separate the SWITCH
ASSEMBLY (19) prior to
installation, place the SWITCH
ASSEMBLY (19) on the LONG
PIN
TOOL (20) .
Preparing Replacement Switch Assembly
STEP 8
Place the CENTER CONTACT (12)
on the TOOL (20) making sure
the pins of the TOOL (20) are in
the holes of the LOWER
INSULATOR (13).
*Note: make sure the SIDE CONTACT
(11) and CENTER CONTACT (12) are in
the switch.
STEP 9
Insert the TOOL (20) with the
LOWER INSULATOR (13) into the
bottom of the BARREL (10). Push
the TOOL (20) into the BARREL
(10) until it stops at the top of the
BARREL (10).
CENTER
CONTACT (12)
SIDE
CONTACT (11)
STEP 10
While firmly holding the TOOL
(20) and BARREL (10), line up the
pins of the UPPER INSULATOR (8)
with the holes of the LOWER
INSULATOR (13). Push the UPPER
INSULATOR (8) down into the
LOWER INSULATOR (13) until it
presses into place.
STEP 11
Reinstall the LAMP (6) in the
receptacles of the UPPER
INSULATOR (8). Adjust the LAMP (6)
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 (6).
ALL VISIBLE SEALS (3, 9, & 17) SHOULD HAVE A LIGHT COAT OF OIL ON THEM.
IF NOT, LIGHTLY COAT WITH PETROLEUM JELLY (VASELINE®)
STEP 12
Replace the HEAD ASSEMBLY (1)
STEP 13
Before installing the batteries, check
for leakage or corrosion. Reinstall or
replace the batteries, (one/AAA series
alkaline only) install with the positive
(+) end toward the lamp. Reinstall
TAIL CAP (14).
*Note: always make sure the TAIL CAP (14)
is tight for good positive electrical contact.
Tool Required (Included)
STEP 2
Place the TOOL (20) against the
LENS (4).
STEP 1
These are the components of the
HEAD ASSEMBLY (1), HEAD (2),
LENS (4), REFLECTOR (5).
Solitaire®Lens / Reflector Replacement
STEP 3
Apply a hard even pressure on
the
TOOL (20) until the LENS (4)
and REFLECTOR (5) are pushed
out the back of the HEAD (2).
NOTE: The pressure required to remove
the LENS (4) & REFLECTOR (5) will be
considerably more than to replace
them and you will usually destroy the
REFLECTOR (5) upon removal.
STEP 4
To replace the components, first
insert the LENS (4).
Note: You should wear a glove when
replacing the LENS to avoid fingerprints.
STEP 5
Replace the REFLECTOR (5) ,
Place the REFLECTOR (5) into the
opening of the HEAD (2) being
careful not to get fingerprints on
the reflective surface.
STEP 6
Place the TOOL (20) over the rear
portion of the REFLECTOR (5).
Make sure the LENS (4) is
seated evenly.
STEP 7
Push down firmly applying firm
even pressure until the LENS (4)
and REFLECTOR (5) meet the
LENS (4).
Replacing the Switch
WARNING: Do not allow children to install or tamper with the lamp.
Protect the lamp from bending or twisting. If the lamp is installed
improperly or if the leads from the lamp are twisted so as to contact one
another, this could short circuit the flashlight and cause heat generation.
© 2004 Mag Instrument, Inc. 421-000-447 8/04