StreamLight Scorpion User manual

30 EAGLEVILLE ROAD •EAGLEVILLE, PA. 19403
www.streamlight.com
SERVICE MANUAL
SCORPION™
This Streamlight service manual is provided "AS IS" and for informational
purposes only.
STREAMLIGHT MAKES NO WARRANTY OF ANY KIND REGARDING THE
INFORMATION CONTAINED IN THIS SERVICE MANUAL. FURTHERMORE,
WE DISCLAIM ALL WARRANTIES AND CONDITIONS WITH REGARD TO
THIS INFORMATION, INCLUDING ALL IMPLIED WARRANTIES AND
CONDITIONS OF MERCHANTABILITY, AND FITNESS FOR A PARTICULAR
PURPOSE. WE ARE NOT LIABLE FOR ANY SPECIAL, INDIRECT OR
CONSEQUENTIAL DAMAGES OR ANY DAMAGES WHATSOEVER, WHETHER
IN AN ACTION OF CONTRACT, NEGLIGENCE OR OTHER TORTIOUS
ACTION, ARISING OUT OF OR IN CONNECTION WITH INFORMATION
AVAILABLE FROM THIS SERVICE MANUAL.
STREAMLIGHT TAKES NO RESPONSIBILITY FOR THE INFORMATION, OR
WHATEVER YOU DO WITH THE INFORMATION. It may not necessarily be
correct, accurate, safe, effective or reliable, and it may not apply to your
specific situation. It is subject to change at any time without notice and
Streamlight reserves the right to make changes and corrections at any
time without notice. Any modifications you make to your Streamlight
product are AT YOUR OWN RISK. You should consult the product’s
operating instructions or a Streamlight authorized service center with any
questions or when selecting and using parts for your Streamlight product.
For products using lithium CR123A cells: WARNING: FIRE, EXPLOSION,
BURN HAZARD - USE ONLY STREAMLIGHT, PANASONIC, SANYO, OR
ENERGIZER CR123A OR DURACELL 123. DO NOT MIX BRANDS OR OLD
AND NEW BATTERIES.
To the maximum permitted by applicable law, in no event will Streamlight,
its affiliates, owners, directors, or officers, be liable for any special,
incidental, indirect, consequential or punitive damages, costs or expenses
whatsoever, including legal fees, arising from or in any way related to the
use of or inability to use the service manual, even if Streamlight or an
authorized representative of Streamlight has been informed, is aware or
should have been aware of the possibility of such damages.
Information contained herein shall be deemed provided in the
Commonwealth of Pennsylvania and shall be subject to Pennsylvania law
and jurisdiction.
This disclaimer and the information contained in this service manual is the
proprietary intellectual property of Streamlight, Inc. No part of this service
manual may be reproduced without Streamlight's written authorization.
(c) Streamlight, Inc. All Rights Reserved.
PART No. 990523
February 2007

TABLE OF CONTENTS
PREFACE..................................................................................... 2
COMPONENT LIST AND CUTAWAY DRAWING......................... 3
TROUBLESHOOTING DIAGRAM................................................. 4
GENERAL NOTES........................................................................ 5
ELECTRICAL TEST OF THE SWITCH ASSEMBLY.................... 6
EXTRACTING THE SWITCH ASSEMBLY................................... 7
SLEEVE REMOVAL/REPLACEMENT (W/O SERVICE KIT) -8
INSERTING THE SWITCH ASSEMBLY....................................... 9
SERVICING THE LAMP HOLDER ASSEMBLY.......................... 10
REPLACING THE LENS.............................................................. 11
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SCORPION SERVICE MANUAL
PREFACE
The purpose of this manual is to provide the information needed to service the Streamlight
Scorpion flashlight system.
This manual is dated (see front cover). Additions, deletions and changes to this manual will
display a later date.
A set of special tools is required for complete servicing and is available as Streamlight Repair
Kit, Part No. 990499.
The Service Kit Includes :
ITEM DESCRIPTION PART No.
(1) Barrel Holder/Sleeve Tool ................................... 850166
(2) Switch Assembly Extraction Pliers ...................... 850169
(3) Lens Removal Tool .............................................. 850168
(4) Snap Ring Pliers .................................................. 750169
(5) Mounting Board and Post .................................... 850167
Additional tools needed are: a multimeter, a screwdriver, a 13/16th socket and a rubber mallet.
Lamp and batteries may be changed without special tools.
For additional information and/or assistance contact:
STREAMLIGHT, INC.
Repair Department
30 Eaglevile Rd.
Eagleville, Pa. 19403
Phone [phone]
Phone [phone]
FAX [phone]
7:00 a.m.-5:00 p.m. EST
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GENERAL NOTES
The lithium batteries should be replaced when troubleshooting the Scorpion. Remove the
batteries from the flashlight by unscrewing the head from the body.
The Scorpion uses a high output xenon bi-pin light bulb.
DO NOT TOUCH A HOT BULB. Allow the bulb to cool
before handling. The bulb is under high internal pressure.
ALWAYS WEAR SAFETY GLASSES WHEN HANDLING
THE BULB. To change the bulb unscrew the head of the
flashlight from the barrel. Firmly grasp the burned out bulb
and pull it from the lamp holder assembly. A spare bulb is
located in the base of the lamp holder assembly. To
access the spare bulb turn the lamp holder assembly over
so that the battery contact/cover is facing upwards. Remove the battery contact/cover by prying it
upwards (see diagram). The spare bulb is located in the recessed area in the center of the lamp
holder assembly. Turn the lamp holder assembly over so that the bulb side is up. There are four
holes visible in the bulb side of the lamp holder assembly. The pins of the bulb mount in the two
holes which have square metal contacts abutting them
(see diagram). Carefully align the pins of the new bulb
with the contact holes in the lamp holder. Push the bulb
into the lamp holder. Use care to make sure that the pins
are straight and that the bulb is firmly seated in place.
Occasionally the battery contact spring on the switch will
become detached from the switch assembly. A quick
inspection can be made to confirm that the spring is in
place. Remove the head of the flashlight and remove the
batteries. The spring should be visible in the switch end of
the barrel. Use a small screwdriver to ensure that the
spring is firmly attached. If the spring has detached the
switch should be replaced (See page 7,8,9).
The connection between the end of the barrel and the contact ring on the lamp holder assembly
must be clean and free of corrosion. Keep the end of the barrel clean and free from grease or
other deposits.
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ELECTRICAL TEST OF THE SWITCH ASSEMBLY
1. Unscrew the head of the flashlight from the barrel.
2. Place a multimeter into the continuity position.
3. Place one meter lead into the barrel and make contact with the spring terminal at the
base of the switch (see illustration).
4. Place the other meter lead onto the exposed metal thread of the barrel.
5. Cycle the switch.
a. The meter should indicate continuity (or give an audible beep) when the switch
is cycled into the “on” position.
b. The meter should read “over range” (no audible signal) in the “off” position.
c. Cycle the switch at least eight times.
d. If the switch fails at any time during the testing it should be replaced.
(See: Extracting the switch assembly p. 7)
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EXTRACTING THE SWITCH ASSEMBLY
1. Unscrew the head from the flashlight barrel.
2. Remove the rubber barrel sleeve:
(See page 8 If no Service Kit is available.)
a. Screw the threaded end of the barrel into the barrel holder/sleeve tool (P/N:850166).
b. Place one hand on the rubber sleeve and slowly apply air pressure to the barrel
holder/sleeve tool. (If using a Service Kit Compressor the push-button switch is used
to regulate the air pressure.)
CAUTION: STAND CLEAR WHEN REMOVING THE BARREL SLEEVE. A
SUDDEN BUILD-UP OF AIR PRESSURE CAN CAUSE THE SLEEVE
TO SLIDE FREE OF THE BARREL WITH UNEXPECTED FORCE.
c. Slowly guide the sleeve from the barrel. Retain the sleeve.
d. Unscrew the barrel from the barrel holder/sleeve tool.
3. Place the barrel over the mounting board and post assembly (P/N:850167) with the
threaded end of the barrel down and the switch end up.
4. Insert the tips of the switch removal pliers (P/N:850169) into the cupped retaining clips
on either side of the switch.
a. Apply pressure to the handles of the switch removal pliers to draw the retaining clips
toward the center of the switch. (See illustration next page.)
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CAUTION: KEEP FINGERS FROM BETWEEN THE HANDLES OF THE PLIERS.
b. Apply downward pressure to the barrel with your free hand.
c. The switch will slide upwards and free from the barrel. Discard the switch.
SLEEVE REMOVAL/REPLACEMENT (No Kit)
Remove the head from the barrel of the flashlight. Remove the batteries. Remove the old
sleeve by cutting it with a sharp knife. Clean the barrel if necessary.
Spread a light coating of diluted liquid soap on the inside of the replacement sleeve
(p/n:850011). Make sure to spread the soap deeply into the sleeve. Place the threaded end of
the barrel onto a solid surface with the switch pointing upwards. Start the sleeve onto the switch
end of the barrel and work it downward. Continue to urge the sleeve downward until it seats fully
against the switch end of the barrel. There should be approximately ½" of barrel thread visible
when the sleeve is properly seated. Rinse any excess soap away and allow the barrel to dry
(overnight).
After the light has been allowed to dry thoroughly, reinsert the batteries and reattach the head of
the flashlight to the barrel.
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INSERTING THE SWITCH ASSEMBLY
1. Grasp the barrel with one hand and place it threaded end down onto a solid surface.
2. Obtain a new switch assembly (P/N: 850018) and inspect it to make
sure that the positive contact spring is present (see illustration at right
and note on page 5).
3. Place the switch assembly spring side down into the open end of the
barrel opposite the threaded end.
4. Push the switch into the barrel with your thumb.
5. Continue the downward motion until the retaining clips snap into the
internal groove of the barrel. Use care as it is possible to push the
switch too far down into the barrel. The switch can become difficult
or impossible to depress if the switch is incorrectly positioned. If the
switch has traveled past the groove it is possible to push the switch
back upwards by pushing it from the threaded end of the barrel. Push
the switch back up until the retaining clips snap into place.
6. Screw the threaded end of the barrel into the barrel holder/sleeve tool.
7. Apply air pressure to the barrel. (When using the Service Kit Compressor the push-button
switch is used to regulate the air pressure.)
8. Place the open end of the barrel sleeve over the switch end of the barrel.
9. Guide the barrel sleeve onto the barrel and make sure that the closed end of the
sleeve becomes fully seated on the switch end of the barrel.
10. Maintain hand pressure on the barrel sleeve and turn the air compressor off.
11. Unscrew the barrel from the barrel holder/sleeve tool.
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THE LAMP HOLDER ASSEMBLY
1. Remove the head from the barrel.
2. Place the head assembly lens down onto a flat surface.
3. Grasp the white lamp holder assembly and remove it from the head.
4. The bulb can be checked while it is still in the lamp holder.
a. Place the multimeter into the continuity position.
b. Place one lead on the circular metal battery contact opposite the bulb.
c. Place the other lead onto the outer focus spring contact ring.
1. If there is continuity the bulb and lamp holder are functional.
2. If there is no continuity insert a new bulb and retest as in 4a,b, and c above.
a. If the new bulb corrects the problem no further action needs to be taken.
b. If the new bulb does not correct the problem replace the lamp holder assembly.
5. To reassemble place the head lens down on a flat surface.
6. Insert the lamp holder and bulb into the head bulb first.
7. Place functional batteries into the barrel and screw the head onto the barrel.
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REPLACING THE LENS
Lens Removal
1. Remove the head from the barrel.
2. Remove the lamp holder from the
head.
3. Grasp the head and hold it so that the
lens is facing upwards.
4. Hold the Scorpion lens removal tool
(P/N:850168) in the other hand and rest
the base of the tool on a solid surface
(the tool can also be paced in a fixed
vise).
5. Align the opening in the head with the
pin portion of the lens removal tool and
pass the removal pin through the hole
in the base of the reflector.
6. Apply downward pressure to the head
and the lens will pop free of the retainer.
CAUTION : ALWAYS WEAR SAFETY GLASSES. KEEP CLEAR OF THE LENS TOOL
AND LENS WHEN APPLYING PRESSURE.
Lens Replacement
1. Place the head of the flashlight on a flat
surface with the reflector facing upwards.
2. Take a replacement lens, remove the protective film,
and place it so that it is flat across the open end of
the head.
3. Place a clean smooth ended 13/16” socket
(max. OD. 1.120”) onto the lens and center the
socket in the head.
4. Strike the socket with a rubber mallet.
5. Continue to strike the socket until the lens
seats in the head.
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