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TABLE OF CONTENTS
Preface ...................................................................................................... 2
Troubleshooting Procedure ................................................................... 3
General Notes ........................................................................................... 4
Section I, Litebox Housing Disassembly/Assembly Procedures ......... 5
Section II, Testing/Replacing the Lamp .................................................. 8
Section III, Testing the Litebox Battery .................................................. 9
Section IV, Testing/Replacing the Switch .............................................. 10
Section V, Testing/Replacing the Wiring Harness ................................. 11
Section VI, Testing/Repairing the Printed Circuit .................................. 15
Section VII, Testing and Repairing the Charging System ..................... 18
Appendix I , Identifying and Testing the Power Failure Model ............. 23
Appendix II , Litebox Replacement Parts and Diagram ...................... 24
Appendix III , Testing and Repairing the SL - 40X ................................. 25
Appendix IV , SL- 40X Replacement Parts and Diagram .................... 30
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   Summary of Contents for StreamLight LiteBox

  • Page 1

    Section VII, Testing and Repairing the Charging System ..... 18 Appendix I , Identifying and Testing the Power Failure Model ..... 23 Appendix II , Litebox Replacement Parts and Diagram ...... 24 Appendix III , Testing and Repairing the SL - 40X ......... 25 Appendix IV , SL- 40X Replacement Parts and Diagram ……………..…...

  • Page 2

    LITEBOX SERVICE MANUAL PREFACE The purpose of this manual is to provide the information needed to service the Streamlight Litebox flashlight system. This manual is dated (see front cover). Additions, deletions and changes to this manual will display a later date.

  • Page 4

    If the Litebox can be turned “on” and “off “ and the problem is still elusive the printed circuit board may be malfunctioning. The printed circuit board can be replaced as a module (see Section IV).

  • Page 5

    LITEBOX HOUSING DISASSEMBLY/ASSEMBLY PROCEDURES Disassembly 1. Use a Phillips screwdriver to remove the six screws from the bottom of the Litebox. 2. Separate the top and bottom halves of the housing by pulling them apart. 3. Remove the black rubber gasket.

  • Page 6

    Reassembly 1. Make sure that the battery wires are properly routed (see diagram). a. Press each wire firmly into the proper slot. Note : The battery wires must be properly seated and should not cross one another. b. Lay the foam sheet over the wires before inserting the battery. 2.

  • Page 7

    4. Align the bottom and top halves of the housing. a. The charge connector on the bottom housing should face the rear of the Litebox. b. Make sure that the charge connector wiring is routed through the center channel of the bottom housing.

  • Page 8

    The socket can be adjusted in the spot reflector assembly. 1. Turn the Litebox on and shine it on a wall approximately 10 feet away. 2. Adjust to the desired focus by screwing the socket inward towards the fully seated position or outwards until the point where the socket O-ring starts to leave the surrounding screw shell of the reflector.

  • Page 9

    3. Charge the battery to full capacity in a known good Litebox system. 4. Operate the battery in a known good Litebox and note the run time. a. Run time is the time from when the Litebox is turned on to the point where it becomes no longer usable.

  • Page 10

    1. If the Litebox is not already disassembled refer to Section I for instructions. 2. Slide the printed circuit board out of the slots in the upper Litebox housing. (note: Use caution to avoid bending the LED’s out of place).

  • Page 11

    3. Remove the lamp ring, reflector, and lamp from the lamp head as shown in Section II. A . Inspect and test the wiring harness between the Litebox pc board and the lamp housing. 1. If the wiring is frayed or damaged it should be replaced.

  • Page 12

    C. If the wiring harness does not need to be replaced the Litebox may be reassembled as shown in Section I. Replacing The Wiring Harness 1. Remove the existing wiring harness. A . Remove the lamp ring, reflector, and lamp from the Litebox.

  • Page 13

    C. Route the wiring harness (slip-on connector end) through the opening in the back of the lamp housing. D. Reattach the lamp housing to the Litebox body and secure it in the down position ( the lamp housing should be flush against the Litebox body).

  • Page 14

    (trim the excess portion of the wire tie). H. Solder the lamp leads to the PC board (see Section VI). I. Replace the lamp, reflector and lamp ring. J. Reassemble the Litebox as shown in Section I. - 14 -...

  • Page 15

    1. Disassemble the Litebox as shown in Section I. 2. It is important to determine that the power input charging connector is functioning properly. Refer to Section VIl, Testing the Litebox Charge Connector. Do not reassemble the Litebox; follow the testing instructions below.

  • Page 16

    3. Remove the switch. a. Remove the switch boot and integrated lock ring with the switch boot tool. b. Slide the switch free from its mounting hole. 4. Pull the PC board out of its slots in the housing. 5. Desolder the lamp leads and discard the old PC board and switch. 6.

  • Page 17

    7. Align the LED’s with their respective openings. 8. Slide the PC board back into the slots in the upper Litebox housing. a. Route any excess switch and lamp wiring into the well where the switch is located.

  • Page 18

    The Litebox charging rack is available in two configurations. Both systems have a two pin connector located at the rear of the charge rack which provides charging power to the Litebox. The difference between the two systems is the way which external power is delivered to the charge rack.

  • Page 19

    4. If there is no continuity (complete circuit) the DC-1 should be replaced. Direct Wire and DC-2 Systems 1. DC-2 system testing (system does not have a rack and utilizes the Litebox input connector). a. Connect the DC-2 to a known good 12 volt source.

  • Page 20

    e. If the meter does not indicate continuity the interior wiring harness should be replaced. B. Charge racks with permanently wired input power should be disconnected from their input source. 1. Place a multimeter into the continuity position. 2. Place one lead on the positive power input lead (red stripe). 3.

  • Page 21

    Testing the Litebox Charge Connector 1. The Litebox charge connector should be tested to make sure that it is functional. 2. Disassemble the Litebox and remove the battery as shown in Section I. 3. Test the connector and wiring by one of the following methods.

  • Page 22

    Note : Make sure to align the LED’s with the openings in the housing. 9. Route the input connector wire through the open grid in the bottom of the housing. 10. Install the battery and reassemble the Litebox as shown in Section I. - 22 -...

  • Page 23

    3. Connect a wall charger directly (no charge rack) to the Litebox. a. If the charger is not plugged into a wall outlet the Litebox should turn on with full intensity. b. Plug the wall charger into a working wall outlet; the Litebox should turn off.

  • Page 25

    APPENDIX III TESTING AND REPAIRING THE SL - 40X This section includes information to repair the SL - 40 series flashlights. A multimeter and Phillips screwdriver will be needed to perform most repairs and troubleshooting. Some repairs may require the use of a soldering iron. Testing/Replacing the Lamp 1.

  • Page 26

    2. Adjust to the desired focus by screwing the socket in to the fully seated position or outwards until the point where the socket O-ring starts to leave the surrounding screw shell of the reflector. Note : The focus should be attained somewhere between the two limits described (try 1/4 turn out from the fully seated position).

  • Page 27

    3. Remove the lamp from the flashlight as described in Testing/Replacing the Lamp 4. Test the switch. a. Place a multimeter in the continuity position. 1. Place one meter lead on the negative battery lead. 2. Touch the other meter lead to either of the lamp leads. 3.

  • Page 28

    If the lamp is functional, the battery tests properly, the switch is operational and the charging system is working, but the flashlight fails to operate or the LED fails to light there may be a problem with the circuit board inside the flashlight. 1.

  • Page 29

    Note: If the voltage regulator still fails to perform reassemble the light as below and send it to: Streamlight, Inc. Repair Department 1030 W. Germantown Pike Norristown, Pa. 19403 Testing/Repairing the Charger System See Section VI of the SL-45 Litebox manual (p. 12) for charger testing and repair information. - 29 -...

  • Page 30

    SL - 40 REPLACEMENT PARTS ITEM QTY PART NO. ITEM PART NO. DESCRIPTION 40107 KIT, PAR 36 LAMP RETROFIT 400176 PLUG ASSY.- 4 PIN P.F. (LAMP RING & SPACERS) 400175 PLUG ASSY - 2 PIN STANDARD 40117 KIT, PAR 36 LAMP RETROFIT, BEIGE 900079 L.E.D.

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