StreamLight SURVIVOR Setup guide

REPAIR INSTRUCTION
SURVIVOR LED
®
SURVIVOR LED ATEX
®
This Streamlight manual is provided "AS IS" and for informational purposes only. It is
intended as a guide for the maintenance and repair of common problems specific to the
product.
STREAMLI HT MAKES NO WARRANTY OF ANY KIND RE ARDIN THE INFORMATION
CONTAINED IN THIS MANUAL.
STREAMLI HT 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 application. It is subject to change at any
time without notice. Any modifications you make to your Streamlight product are AT
YOUR OWN RISK. Always 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: WARNIN : FIRE, EXPLOSION, BURN HAZARD -
USE ONLY STREAMLI HT, PANASONIC, SANYO, OR ENER IZER CR123A OR DURACELL
123. DO NOT MIX BRANDS OR OLD AND NEW BATTERIES.
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.
December 2011
Page 1 of 14

SURVIVOR LED-REPAIR INSTRUCTIONS
I Troubleshoot (Reference Section VI Appendix A /Troubleshoot)
CAUTION: LED Radiation (RG-2)-Do not stare into the beam May be
harmful to eyes
1) The Survivor LED features a top mounted push button switch
Check switch for proper operation:
• Push switch until click on to test “on” function
• Push and hold the switch for one second to dim
• Push and hold the switch two seconds to activate the “strobe” mode
• Push switch until click off to test “off’ function
2) If light does not turn on or operates for only a short period of time at high
intensity, check the battery
• If using an Alkaline Battery Pack, replace the batteries Remove the
battery pack from the light Depress the tabs on the outside edges of the
battery pack and pull the two halves apart Replacement batteries should
be new alkaline 1 5V of the same type Observe the polarity indicated in
the tray Re-assemble Re-test light
Note: See product ratings for specific batteries for use in hazardous
locations
• If using a rechargeable Battery, p/n# 90130, place light in charger for at
least 15 minutes, the red LED charge indicator should light If LED on
charger does not light, remove battery Check the condition and date
code of the battery Check output voltage; should be between 1 2V and
4 8V Use a multi-meter to test for continuity between battery negative
spring and battery negative output terminal If open, replace battery
(Reference-Figure 1– Part 4B, Test between points shown)
Note: When new, the battery should yield 160-180 minutes of continuous run
time Should the performance have decreased significantly with age or use, it
is recommended to replace battery for optimum performance
3) If light still does not function properly; reference Repair Instruction
Section II
Page 2 of 14 DEC 2011

SURVIVOR LED-REPAIR INSTRUCTIONS
II LED MODULE ASSEMBLY-REPLACEMENT
A Disassembly
1) Release latch on Battery Door Assembly (Item 3) and remove Battery
Carrier Assembly (Item 4A or 4B)
ATEX ONLY: Remove Insert Screw (Item 5) to release latch on Battery
Door Assembly (Item 3) Body will have Insert
Note: Only remove Battery Retaining Pin (Item 7) if replacement of
Battery Door assembly (Item 3) is required
2) Remove Face Cap Assembly (Item1) Replace Facecap O-ring (Item 2) as
required
Note: If lens or reflector requires replacement, reference Section III
Figure 1
Page 3 of 14 DEC 2011
1
2
5
3
6
4A
4
B
1
3
7
1
2
1
1
8
9
1
4
1
0
15
Test
Test

SURVIVOR LED-REPAIR INSTRUCTIONS
II LED MODULE ASSEMBLY-REPLACEMENT
A Disassembly (cont’d )
3) Inspect Battery Door Assembly (Item 3) for damage or corrosion If
replacement is required, remove assembly by pressing out the Battery
Retaining Pin (Item 7) from body and battery door assembly Replace
Battery Door Assembly as required
4) Remove Pin (Item 8) from Belt Clip (Item 9) and Double torsion Spring
(Item 10) Remove (2) Self Tapping Screws (Item 11) and Clip Bracket
(Item 12) from body Note the orientation of the Clip Bracket when
removed Retain these items for reassembly Replace as required
5) Slide LED Module Assembly (Item 13) from Body Assembly (Item 15)
6) Remove Switch Spacer (Item 6) and retain for re-assembly
7) Replace Valve (Item 14) if missing
B Reassembly
P/N #90556-Survivor Clip Replacement Tool Kit required for re-assembly
1) Insert Switch Spacer (Item 6) onto LED Module Assy
(Picture 1-Arrow A)
2) Insert replacement LED Module Assembly (Picture 1-Arrow B) into
body Align with belt clip mounting holes on back-side of body
Picture 1
Page 4 of 14 DEC 2011
B
A

SURVIVOR LED-REPAIR INSTRUCTIONS
II LED MODULE ASSEMBLY-REPLACEMENT
B Reassembly (cont’d )
3) Install Clip Bracket with (2) mounting Screws (2) as shown (Picture 2),
fastening to LED Module Assembly Tighten firmly
4) Insert Double Torsion Spring inside the clip bracket with the legs of the
spring flat against the bracket and pointing towards the top of the
housing Align the holes of the spring with the holes in the bracket
(Picture 3)
Picture 2 Picture 3
5) Place angled tool from kit against the two legs of the spring and against
the Clip Bracket (Picture 3)
Page 5 of 14 DEC 2011
SPRING

SURVIVOR LED-REPAIR INSTRUCTIONS
II LED MODULE ASSEMBLY-REPLACEMENT
B Reassembly (cont’d )
6) Place belt clip over spring Aligning slot in tab (A) with bridge (B) on
spring (Picture 4)
Picture 4
7) While holding the angled tool, push the Clip down and forward against
the angled tool until the holes in the clip line up with the holes in the
spring (Picture 5)
Picture 5
Page 6 of 14 DEC 2011
PUSH PUSH
A
B

SURVIVOR LED-REPAIR INSTRUCTIONS
II LED MODULE ASSEMBLY-REPLACEMENT
B Reassembly (cont’d)
8) While holding the belt clip in position, insert the tapered pin tool (from
kit) through the holes on the belt clip and spring until it is flush with the
clip (Picture 6)
Picture 6 Picture 7
9) While holding the belt clip in position, replace the tapered pin from kit
with the Belt Clip Pin (Item 8) The pin should be flush with the belt clip
(Picture 7)
Picture 8 Picture 9
10) Clip should spring back if installed properly (Picture 8 and 9)
Page 7 of 14 DEC 2011

SURVIVOR LED-REPAIR INSTRUCTIONS
II LED MODULE ASSEMBLY-REPLACEMENT
B Reassembly (cont’d)
11) Inspect and lubricate o-ring (item 2) Clean and/or replace lens as needed
Note: Reference Section-III for replacement
Picture 9 Picture 10
12) Install Face Cap Assembly Tighten until seated firmly against body
(Picture 9)
Note: Clean and/or replace lens as needed (Reference Section III)
13) Check the Battery Pack (Reference Section II 2)and insert into the body in
the proper direction Key on battery door should align with key slot on
battery (Picture 10)
Page 8 of 14 DEC 2011
KEY SLOT-BATTERY
K
E
Y

SURVIVOR LED-REPAIR INSTRUCTIONS
II LED MODULE ASSEMBLY-REPLACEMENT
B Reassembly (cont’d)
Picture 11
14) Close and secure hinged Battery Door Assembly Applying pressure to
door will ease fastening latch (Picture 11)
ATEX ONLY: Re-install Insert Screw once Battery Door Assembly is
secure (see arrow) Threaded insert installed in body at factory
(not shown)
14) Test light Check switch for proper operation:
• Push switch until click on to test “on” function
• Push and hold the switch for one second to dim
• Push and hold the switch two seconds to activate the “strobe” mode
• Push switch until click off to test “off’ function
Page 9 of 14 DEC 2011
SCREW-ATEX ONLY

SURVIVOR LED-REPAIR INSTRUCTIONS
III LENS AND REFLECTOR- REPLACEMENT
NOTE: P/N #905055-Survivor LED Lens Installation/Removal Tool-Required
Picture 1 Picture 2
1) Remove Facecap Assembly from flashlight (not shown)
2) Insert Facecap Assembly (Picture 1-Item B), threaded side up, into Base
(Picture 1-Item A)
3) Insert 3/16” Diameter Pin (Picture 1-Item C) through the opening on the
back of the reflector until it rests on the lens Using a hammer, knock out the
Lens from the Facecap Assembly
4) Remove Facecap Assembly from Base Replace reflector or o-ring if
required
5) Insert the Facecap Assembly into the base with the reflector side up (Picture
2-Item B)
Page 10 of 14 DEC 2011
B
D
E
C
A
B

SURVIVOR LED-REPAIR INSTRUCTIONS
III LENS AND REFLECTOR- REPLACEMENT (cont’d)
6) Remove any particles from Reflector with compressed air Insert the
reflector into the Facecap until it is seated flat in the groove in the Facecap
7) Install the O-Ring in the groove above the Reflector and into the Facecap
Note: If replacement O-Ring is used, it may be necessary to stretch the O-
Ring slightly so it properly seats into groove
8) Remove protective film from lens and remove any particles with compressed
air Place Lens (Picture 2-Item D) on top of Facecap Assembly
9) Place Top of tool (Picture 3-Item E) on top of lens (Picture 4-Item E)
10) Using a hammer, drive the Top of tool downward until Lens is seated
(Picture 4-Note arrow)
11) Inspect the Lens and O-Ring to make sure they are both seated properly
Picture 3 Picture 4
Page 11 of 14 DEC 2011
E

SURVIVOR LED-REPAIR INSTRUCTIONS
IV Parts List
ITEM QTY PART # DESCRIPTION
1) 1 90547 Face Cap Assembly-Old Style (Note A)
1 90557 Face Cap Assembly-New Style (Note B)
2) 1 905046 Face Cap O-Ring
3) 1 905027 Battery Door Assembly
4A) 1 90542 Alkaline Battery Carrier Assembly
4B) 1 90130 Battery Pack Assembly-Zone 2
5) 1 905074 Screw, Insert (ATEX ONLY)
6) 1 905089 Spacer, Switch
7) 1 900042 Pin, Battery Retaining
8) 1 900310 Pin
9) 1 900307 Clip
10) 1 900309 Double Torsion Spring
11) 2 905029 6-32 x ½ PHP, SS, Self Tapping
12) 1 905009 Bracket, Clip
13) 1 905076 LED Module Assembly-Old Style (Note A)
905082 LED Module Assembly-New Style (Note B)
14) 1 670015 Valve
15) 1 N/A Body Assembly (Note C)
Note A: ITEM 1-P/N# 90547-Face Cap Assembly includes the following items:
Qty 1 900303 Face Cap
Qty 1 900304 Lens
Qty 1 903059 SL-90X O-Ring Lens
Qty 1 905034 Reflector-Old Style
Important: Must be used with P/N#905076/LED Module Assembly-Old Style
Note B: ITEM 1-P/N# 90557-Face Cap Assembly includes the following items:
Qty 1 900303 Face Cap
Qty 1 900304 Lens
Qty 1 903059 SL-90X O-Ring Lens
Qty 1 905083 Reflector –New Style
Important: Must be used with P/N#905082/LED Module Assembly-New Style
Starting with Bodies with Serial Number 216821 Survivor LED
And Serial NumberA014945 Survivor LED ATEX
Page 12 of 14 DEC 2011

SURVIVOR LED-REPAIR INSTRUCTIONS
IV Parts List (cont’d)
Note C: ITEM 15-Body Assembly including body, switch boot and threaded insert
ATEX Only are non-serviceable items Lights requiring
replacement body assemblies must be returned to the factory for
replacement
Reference Tools required:
P/N # 90556-Survivor LED Belt Clip Installation Tool (Reference Section II)
P/N # 905055-Survivor LED Lens Installation/Removal Tool (Reference Section III)
IV Contact Information
To find the nearest Authorized Service Center go to:
http://www.streamlight.com/support/authorized-service-centers.aspx
For Customer Service Contact: Streamlight Inc
30 Eagleville Road
Eagleville, Pa 19403-3996
[phone]-Local
[phone]-Toll Free
[phone]-Fax
cs@streamlight com
www streamlight com
Page 13 of 14 DEC 2011

SURVIVOR LED-REPAIR INSTRUCTIONS
V Appendix A /Troubleshoot
Page 14 of 14 DEC 2011