MAG-LITE® Switch Repair C and D Cells

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Switch Assy. | Head Sub-Assy 'C','D' | Barrel Sw. Sub-Assy 'C','D'

Tailcap Sub-Assy 'C','D' | Battery Leakage

Switch Replacement Unscrew and remove entire Tailcap Assembly (17) Remove Batteries. (See notice regarding Battery Leakage) Unscrew and remove entire Head Assembly. Remove Lamp (11) by unscrewing Retaining Cap (10). A spare lamp is located in the tailcap. Use 'C' or 'D' end of the Spanner Wrench (25) to unscrew and remove Retaining Ring (12). Remove Switch Seal (15) by grasping with thumb and index finger, buckle and pull to extract. Switch Button (A) must be in the down (depressed) position. Insert Proper Hex Wrench (23) for 'C' (24) for 'D' into the Switch Button (A), through the switch and into the Set Screw (22). Back out set screw three turns to release from pocket in barrel. (See Switch Assembly (13)) Remove Switch Assembly (13) from lamp end of barrel. A wooden rod or battery may be used to dislodge switch. Install Retaining Ring (12) over small end of New Switch (13). Switch Button (A) must be depressed. (See Switch Assembly (13). Center Switch Button (A) over switch port hole in Barrel (16). Tighten Set Screw (22) into pocket in barrel. Switch may have to be rocked slightly to assure proper alignment. Set Screw (22) must be tight for electrical contact. Align Switch Retaing Ring (12) with threads in Barrel (16). Rotate ring counter-clockwise several turns to align with threads in barrel before tighting (Clockwise) firmly against switch assembly. Replace Switch Seal (15) by bowing it slighty with thumb and index finger to get it started into hole of barrel. Push all outside edges of seal into barrel hole. Warning: The Bulb Spring (B) in the end of the switch assembly must not be caught behind the plastic wall. If it is use Small Hex Wrench (23) to realign spring to pass through hole in plastic wall (See Switch Assembly). Reinstall the lamp and retaing cap. Press on the lamp several times. It should move back and forth freely against Spring (B) without binding. Wipe smudges from lamp with a clean soft cloth. Lightly lubricate all 'O' Rings Seals and Threads with clean motor oil or petroleum jelly (Vaseline). See Maintenance and Inspection to complete assembly.

Reflector, Lens and Seal Replacement To repace the Face Cap 'O' Ring (3), Lens (4) Remove the Face Cap (2). Lightly lubricate new 'O' Ring before installing. The Reflector Parabola (5) cannot be satisfactorily cleaned without scratching or marring the delicate coating. Therefore a new reflector should be installed. Make sure the Face Cap (2) is screwed firmly on the Head (7). If not, the Reflector (5) will rotate when spot to flood cam follower rides on cam area on small end of reflector.

Maintenance and Inspection All Seals (3)(6)(8),(14),(20), and all threads should have a light coat of oil or petroleum jelly applied every 6 months. Check batteries for leaks or corrosion every 3 months. install positive (+) end toward lamp. Heavy Duty Alkaline batteries perform best with Mag-Lite® lamps. Bright metal surfaces on Tailcap (21) and Barrel (16) must be free from any foreign substance that could impair electrical continuity.

	Figure 2 Tailcap Sub, Assy 21) 200-000-038 - TAILCAP 'D' 16) 200-000-013 - BARREL 2D 17) 000-000-000 - TAILCAP SUB-ASSY 'D' 21) 200-000-038 - TAILCAP 'D' 20) 400-000-005 - 'O' RING, TAILCAP 'D' SIZE 19) 400-000-047 - BULB PROTECTOR 'C' & 'D' 11) 107-000-088 - LAMP, 2 CELL KRYPTON 18) 400-000-009 - SPRING, TAILCAP 'D' SIZE
	Figure 1 Head Sub, Assy 8) 400-000-004 - 'O' RING, C BARREL 7) 200-000-044 - HEAD 'D' SIZE 7) 200-000-047 - HEAD 'C' SIZE 6) 400-000-001 - 'O'RING, HEAD 5) 400-000-041 - PARABOLIC REFLECTOR 4) 400-000-008 - CLEAR LENS 3) 400-000-002 - 'O' RING, FACE CAP 2) 201-000-157 - FACE CAP 1) 000-000-000 - HEAD SUB ASSY, 'D' 1) 000-000-000 - HEAD SUB ASSY, 'C'
Barrel Switch Sub Assembly 'C', 'D' 09) 000-000-000 - BARREL AND SWITCH SUB ASSY 'D' 09) 000-000-000 - BARREL AND SWITCH SUB ASSY 'C' 15) 400-000-024 - SWITCH SEAL UNIVERSAL 14) 400-000-003 - 'O' RING 'D' BARREL 13) 100-000-003 - SWITCH SUB ASSY. 'D' SIZE 13) 100-000-004 - SWITCH SUB ASSY. 'C' SIZE 12) 400-000-049 - RETAINING RING 'D' 12) 201-000-127 - RETAINING RING 'C' 11) 107-000-088 - LAMP, 2 CELL KRYPTON 11) 107-000-092 - LAMP, 3 CELL KRYPTON 11) 107-000-096 - LAMP, 4 CELL KRYPTON 11) 107-000-100 - LAMP, 5 CELL KRYPTON 11) 107-000-104 - LAMP, 6 CELL KRYPTON 10) 200-000-057 - BULB RETAINER 08) 400-000-004 - 'O' 'C' BARREL 07) 200-000-044 - HEAD, 'D' SIZE 06) 400-000-001 - 'O' RING, HEAD	(Cont.) 16) 200-000-013 - BARREL 2D 16) 200-000-014 - BARREL 3D 16) 200-000-015 - BARREL 4D 16) 200-000-016 - BARRLE 5D 16) 200-000-016 - BARRLE 6D 16) 200-000-019 - BARREL 2C 16) 200-000-020 - BARREL 3C 16) 200-000-021 - BARREL 4C 16) 200-000-022 - BARREL 5C 16) 200-000-023 - BARREL 6C 25) 000-000-025 - SPANNER WRENCH 'C' & 'D' *A) 000-000-000 - SWITCH BUTTON
	Switch Sub Assembly 13) 100-000-003 - SWITCH SUB-ASSY 'D' SIZE 13) 100-000-004 - SWITCH SUB-ASSY 'C' SIZE 16) 000-000-000 - BARREL (SEE ABOVE) 22) 000-000-000 - SET SCREW 'D' 22) 000-000-000 - SET SCREW 'C' 23) 000-000-023 - HEXAGON WRENCH 'C' 24) 000-000-024 - HEXAGON WRENCH 'D' _A) 000-000-000 - SWITCH BUTTON _B) 000-000-000 - BULB SPRING

Important notice regarding battery leakage. THE FLASHLIGHT WARRANTY OF MAG-INSTRUMENT, INC. DOES NOT COVER BATTERY LEAKAGE.

Important notice regarding battery leakage. The flashlight warranty of Mag Instrument does not cover battery leakage. Upon removal of the flashlight tailcap, if you observe any form of battery leakage, corrosive deposits that could destroy metallic components, then you should consider following. Most reputable battery manufactures gaurnantee their batteries against leakage. In their gaurnantee they advise leaving the batteries in the apparatus and returning the entire unit to their consumer affairs department for evaluation and consideration of replacing the batteries and the apparatus. (In this case the entire flashlight) Please do not return your flashlights to Mag-LiteŽ because we do not perform the service of forwarding the flashlight to the battery manufacturer. If you don't recognize a battery leakage problem and you do send your flashlight to Mag-LiteŽ. We will send you written notification that battery damage has occured and request you advise us what to do with the flashlight. Please note at this point the batteries have usually been removed and discarded. Therefore the battery manufacturer cannot determine if their batteries caused the damage or if another battery manufacturer batteries caused the damage and their gaurantee becomes void.