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Mag-lite RX3019 Repair Manual

Rechargeable flashlight
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Rechargeable Flashlight System
manual
421-000-438
Mag-Lite
repair
Rechargeable
Flashlight
RX1019/RX1016
RX2019
RX3019
RX4019
RX5019
RX6019
RX7019
Repairs must be performed by Mag Instrument
certified warranty service personnel
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®
Rechargeable Flashlight and/or other Mag-Lite® Rechargeable Flashlight System™
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.
(Ni-Cad)
™
®
MR Rev.1 8/03
1

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Summary of Contents for Mag-lite RX3019

  • Page 1 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® Rechargeable Flashlight and/or other Mag-Lite® Rechargeable Flashlight System™...
  • Page 2 MAINTENANCE AND REPAIR INSTRUCTIONS Rechargeable Flashlight Warnings: Any battery may leak harmful chemicals which may damage skin, clothing, or the inside of the flashlight TO AVOID RISK OF INJURY, DO NOT LET ANY MATERIAL LEAKED FROM A BATTERY COME IN CONTACT WITH EYES OR SKIN. Any battery may rupture or explode if put in a fire or otherwise exposed to excessive heat.

  • Page 3: Troubleshooting

    RECHARGEABLE SWITCH REPLACEMENT Rechargeable Flashlight Tools Required: 1. Barrel Holder 2. Spanner Wrench 3. Multimeter Testing Procedures (Troubleshooting) 1. Bulb 2. Battery 3. Charge Module 4. Converter 5. Circuit Board 1. Bulb a. Verify that you have a good LAMP and BATTERY PACK Probe placement •...
  • Page 4 d. Battery c. Lead Placement Less than 6.00 Red probe on positive button. volts but higher Black lead on flat negative end. than 4.8 volts WARNING: do not touch bare leads indicates battery during test. Very Hot. should be charged longer prior to test.
  • Page 5 U.S.A., STANDARD COMMERCIAL FLASHLIGHT SPECIFICATION FLASHLIGHT OVERALL LENGTH: 12-19/32 in. 319.79 mm BARREL DIAMETER: 1-9/16 in. 39.67 mm HEAD DIAMETER: 2-5/16 in. 58.72 mm WEIGHT WITHOUT BATTERY: 18.0 oz. 510.29 gm WEIGHT WITH BATTERY: 32.0 oz. 907.18 gm * BEAM CANDLEPOWER @ 10 feet / 3.0 meters 40,000 Peak Beam Candlepower * BATTERY LIFE CONTINUOUS ON TIME: 2 hours from full charge...
  • Page 6 STEP 1 STEP 2 Remove TAIL CAP ASSEMBLY(21) Remove the FACE CAP ASSEMBLY (5) (counterclockwise) and BATTERY PACK (22). (counterclockwise). STEP 3 STEP 4 Remove the REFLECTOR (6) from the FACE Remove the SWITCH SEAL (7) by grasping CAP (1). The REFLECTOR (6) unscrews the seal with your thumb and index finger, (counterclockwise) .

  • Page 7: Switch Housing

    STEP 5 STEP 6 Remove the LAMP (11) by pulling straight Lift up the plunger of the barrel holder and up until the pins are clear of the receptacle. insert the flashlight, BARREL (16), first into *Note: It is easier to change the LAMP (11) if the front of the barrel tool holder, lining the you push the HEAD (14) down over the switch hole up with the plunger.
  • Page 8 STEP 9 STEP 10 Insert the SPANNER WRENCH into the back Unscrew (counterclockwise) the CHARGER of the BARREL HOLDER TOOL and match MODULE (15) 2-3 turns. the pins of the holder with the holes in the CHARGER MODULE (15). STEP 11 STEP 12 Lift up the plunger and remove the HEAD Unscrew and remove the CHARGER...

  • Page 9: Meter Settings

    CHARGER MODULE TEST A. METER SETTINGS B. LEAD PLACEMENT Dial should be at 2k Ω ohms. 1. The black lead is on the spring. 1. The black probe in the“COM” Port 2. The red lead is on the outer 2. The red probe in the “V_mA” port. charging ring.
  • Page 10 PROBLEM (cont.) Separate the silver ring and black insulator from the MODULE (15) by inserting your finger nail or a knife blade between the ring After you have removed the silver ring and and the second insulator. The ring is held in insulator ring you will see the flat surface place by the spring loaded diode shown where the rings had been.
  • Page 11 When replacing the ring onto the MODULE Before replacing the plastic insulator note (15) place the ring over the diode pin, push the lip on one side of the insulator ring. down and snap the ring in place. STEP 13 The lip on the insulator ring goes against the Push the HEAD (14) down and over the silver ring so that the flat side will be facing...
  • Page 12 STEP 14 FIGURE 1 REPLACEMENT SWITCH Depress the switch button on the SWITCH (12) and at the same time push the SWITCH The Replacement SWITCH (12) should come ASSEMBLY (12) out the back of the SWITCH with the internal mechanism partially out of HOUSING (9).
  • Page 13 STEP 16 STEP 17 Make sure the SWITCH (12) is seated evenly Push hard on the black plastic portion of the in the SWITCH HOUSING (9). Do not press on SWITCH (12) and it should click into place the black plastic portion of the SWITCH (12) with the push button centered in the switch until you are certain it is seated properly.
  • Page 14 STEP 20 STEP 21 Pull the plunger on the tool holder up and Push the flashlight into the tool holder until place the flashlight, CHARGER MODULE (9) the HEAD (14) stops at the holder. Push the end first into the front of the tool holder. plunger down into the switch hole.
  • Page 15 STEP 25 STEP 24 Push the head down and replace the LAMP Remove the flashlight from the barrel (11) by lining up the pins of the LAMP (11) holder tool. with the two holes in the switch receptacle and apply a straight downward pressure. CAUTION: This bulb is pressurized and CAN SHATTER OR EXPLODE, causing PERSONAL INJURY.
  • Page 16 STEP 28 STEP 29 BULB ALIGNMENT Hold the REFLECTOR (6) down with your thumb as you hold the HEAD (14) with your Before replacing the FACE CAP ASSEMBLY fingers as shown. This allows you to hold (5) check for proper bulb alignment. the REFLECTOR (6) down and turn the HEAD Using a test REFLECTOR (6) place it into the (14) for adjustment.
  • Page 17 STEP 32 Replace the FACE CAP ASSEMBLY (5). R e c h a r g e a b l e F l a s h l i g h t 421-000-438 MR Rev.1 8/03...

  • Page 18: Circuit Board Replacement

    RECHARGEABLE SYSTEM CIRCUIT BOARD REPLACEMENT R e c h a r g e a b l e F l a s h l i g h t MR Rev.1 8/03 421-000-438...
  • Page 19 ITEM NO# PART NUMBER DESCRIPTION 109-000-485 CHARGER CRADLE ASSEMBLY 405-000-025 SPRING CLAMP 105-000-021 CIRCUIT BOARD ASSEMBLY 405-000-028 SCREW, CIRCUIT BOARD #6X5/16 405-000-103 FIBER WASHER 405-000-047 SCREW, BASE PLATE #6X3/4 405-000-096 BASE PLATE 108-000-440 CHARGER BRACKET 108-000-437 110 VOLT AC CONVERTER 108-000-438 12 VOLT DC CORD W/CIG.
  • Page 20 CHARGER TESTS Tests should be performed to determine the problem area prior to replacing the circuit board. CONVERTER TEST CONVERTER METER READING LEAD REPLACEMENT 1. Dial is at V-20 volts. 1. Place the leads, Red & Black into the pin 2.

  • Page 21: Circuit Board

    CIRCUIT BOARD CIRCUIT BOARD LEAD REPLACEMENT METER READING 1. Red lead on the front pin or pin closest to Should be between 0.20 and head portion of charger. 0.24 Amps. 2. Black lead on the rear pin ADDITIONAL CHARGER TESTS Short the pins out using one of the tester Put the flashlight in the CHARGER (1) probes, paper clip etc.
  • Page 22 STEP 1 STEP 2 Remove CHARGER BRACKET (8) by pushing Remove the CHARGER BRACKET (8) from in on the chrome button and at the same the from the BASE PLATE (7). time pulling up on the edges of the CHARGER BRACKET (8). STEP 3 STEP 4 Remove the BASE PLATE (7) from the...
  • Page 23 STEP 5 STEP 6 Remove the INSULATOR WASHER (5) that is Unscrew the CIRCUIT BOARD SCREW (4) around the CIRCUIT BOARD SCREW (4) head. (counter-clockwise). STEP 7 To remove the CIRCUIT BOARD ASSEMBLY (3), it may be necessary to apply gentle STEP 8 pressure under the board with a screw Lift the CIRCUIT BOARD ASSEMBLY (3) out of...
  • Page 24 STEP 9 REPLACING THE CIRCUIT BOARD - STEP 10 The SPRING CLIP (2) will probably pop out, if not, leave the SPRING CLIP (2) in the Before installing the new CIRCUIT BOARD CHARGER CRADLE (1). (3), test it to make sure the board is good. Plug the board into a power converter and touch the two spring loaded pins on the board together, the LED should light if the...
  • Page 25 STEP 12 STEP 13 Insert one end of the CLIP (2) into one of the Push the CLIP (2) into the CHARGER openings, bow the CLIP (2) and insert the CRADLE (1) and hold it with your thumb. other end of the CLIP (2) into the other opening.
  • Page 26 Make sure the red LED is showing fully in the Make sure the two contact pins are in the rear hole of the CHARGER CRADLE (1). two pin holes in the CHARGER CRADLE (1) and are protruding above the surface. STEP 16 STEP 17 Place the FIBERWASHER (5) Over the head of...
  • Page 27 STEP 18 STEP 19 Replace the CHARGER BRACKET (8). Replace the 4 BASE PLATE SCREWS (6). The full head of the center screw must be fully visible. R e c h a r g e a b l e F l a s h l i g h t 421-000-438 MR Rev.1 8/03...
  • Page 28 Mag® flashlights include Nos. 2,687,693; 2,074,795 and 1,808,998. ©2003 MAG INSTRUMENT, INC. The Mag-Lite® Rechargeable Flashlight System™ is covered by one or more pending patent applications and U.S. Patent Nos. 4,286,311; 4,388,673; 4,527,223; and Des. 263,170; and by foreign patents.

This manual is also suitable for:

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