StreamLight LITEBOX, Service Manual

Page 1: ...ction 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...

Page 2: ...ls including a Philips screwdriver pliers and a multimeter are required to service the Litebox Additional tools which are available 1 Switch boot tool Streamlight P N 450074 2 Strain relief tool Streamlight P N 450075 Lamp may be changed without special tools For additional information and or assistance contact STREAMLIGHT INC Repair Department 1030 West Germantown Pike Norristown Pa 19403 Phone 6...

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Page 4: ...ED s which light to indicate the mode which the charging circuit is in The red LED indicates that the battery is being charged The green LED indicates that the charging cycle is complete and the battery is at maximum capacity The LED s can warn of malfunctions within the charging circuitry The red LED should turn off completely twenty four 24 hours or less after the charge cycle is initiated and t...

Page 5: ...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 4 Disconnect the battery leads and remove the battery 5 ...

Page 6: ...he foam sheet over the wires before inserting the battery 2 Place the battery onto the bottom housing a The positive battery terminal must face toward the lamp holder see diagram b Use a pair of needle nose pliers to connect the leads to the battery terminals red to positive black to negative Note The positive terminal is marked with a red patch and a sign 3 Fit the black rubber gasket onto the up...

Page 7: ...gh the center channel of the bottom housing c Remove the slack from the charge connector wiring by drawing any excess wire to the component side of the printed circuit board see illustration 5 Place the top and bottom halves of the housing together and make sure that they mate fully with the black rubber gasket 6 Insert the six screws into the bottom and tighten them until they are snug 7 ...

Page 8: ...Replacement bulb information voltage and wattage is printed on a label located on the back of the reflector assembly 2 Replace the bulb by aligning the pins with the holes in the socket and seat the bulb firmly 3 Wipe off any fingerprints from the bulb with a tissue and alcohol 4 Screw the socket back into the reflector assembly a The socket can be fully seated in the flood reflector assembly b Th...

Page 9: ... the point where it becomes no longer usable b Nominal run times are 8 hours for the 8 watt bulb and 3 5 hours for the 20 watt bulb c Normal intensity and short run time is usually an indication that a battery is suffering from sulfation d Low intensity and normal run time is usually an indication that a battery has one or more shorted cells e Batteries which exhibit signs of sulfation or shorted ...

Page 10: ... to be replaced according to the instructions below Replacing the Switch 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 3 Use the switch boot tool P N 450074 to remove the switch boot and integrated lock ring note The lock ring i...

Page 11: ...wires for continuity a Place a multimeter in the continuity position b Place one of the meter leads on any of the lamp lead connectors located at the lamp head 1 If the leads are color coded place the other meter lead onto the corresponding PC board solder pad position see illustration a The meter should indicate continuity b Repeat the above procedure for each lamp lead B If the test of the leads...

Page 12: ... D Use wire cutters to cut the wiring harness strain relief base where it passes through the Litebox housing see illustration E Desolder and remove the lamp leads from the PC board F Discard the old wiring harness 2 Install the replacement wiring harness 2 wire P N 450053 or 3 wire P N 450054 A Route the wiring harness slip on connectors first through the opening in the Litebox body B Place the st...

Page 13: ...d 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 E Place the wire tie P N 450073 through the anchor located on the interior of the lamp holder and wrap it around the wiring harness do not tighten the wire ...

Page 14: ...tension on the wiring harness and draw the wire tie snug to secure the harness in place 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: ... Place the positive meter lead on the red battery lead 2 Place the negative meter lead on the black battery lead 3 The meter should read between 7 1 and 7 4 volts a The green LED should be on b The red LED should be off 4 Keep the multimeter connected to the battery leads a Place a 15 ohm 10 watt resistor across the battery leads b The multimeter should read between 6 65 and 6 95 volts c The green...

Page 16: ... switch 6 Desolder the lamp leads which are included on the new PC board a For Standard and Power Failure model Liteboxes solder the existing lamp leads to the new PC board at the pads marked L 1 see illustration b For Dual Filament and Dual Bulb model Liteboxes solder the existing lamp leads to the new PC board as follows 1 Solder the green and white lamp leads to the solder pads marked L 1 2 Sol...

Page 17: ...ell where the switch is located b Install the power input connector in the bottom housing of the Litebox 1 Place the power input connector slot side up through the rear opening in the bottom housing and snap the connector into place 2 Secure the connector in place with the retaining screw 3 Remove the slack from the wire between the connector and the printed circuit board by pulling the wire from ...

Page 18: ... a reading between 13 and 22 volts and there should be no indication of reversed polarity 6 If the voltage or polarity is wrong replace the charger 7 Do not attempt to repair the AC charger Testing For DC Input Power DC 1 System cigarette plug 1 Connect the DC 1 charger plug to its power source power point cigarette lighter outlet etc 2 Place a multimeter into the DC Volts position 3 The voltage s...

Page 19: ... 3 The meter should show the supply voltage 12 to 15 volts a If there is no voltage or reverse voltage check the wiring between the rack and the supply also check any in line fuse b If the supplied voltage is higher than 15 volts or lower than 12 volts an alternate source should be used Testing the Charge Rack 1 Connect the charge rack to its power input source 2 Place a multimeter in the DC volts...

Page 20: ...e Rack Both versions of the charge rack disassemble the same way The charge rack is held together by two push retainers located on the bottom of the rack 1 Use a pointed tool to remove the push retainers from their mounting posts 2 Insert the tool as shown in the illustration and pry the push retainers up and off of their mounting posts 3 Remove the existing wiring harness Note Replace the direct ...

Page 21: ...d connection where the wire is connected to the board this location is marked with a b Place the negative lead onto the soldered connection marked c The meter should read between 13 and 22 volts and a should not precede the reading B If an AC wall transformer is not available the charging connector can be checked by placing the multimeter into the continuity position 1 Test the positive input a Ho...

Page 22: ... 2 Unsolder the two leads of the charging harness from the rear of the PC board a Clean the mounting holes thoroughly b Discard the old charging harness 3 Route the wire of the new charging harness P N 450028 through the hole on the back of the PC board the side without the components 4 Solder the white striped positive lead to the solder pad marked on the PC board 5 Solder the black negative lead...

Page 23: ...s most component positions filled some examples are Q5 C4 Q4 CR10 and R14 R17 Testing a Power Failure Litebox 1 First remove the Litebox from its charging rack and verify that the lamp is working 2 If the lamp works switch the Litebox off 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...

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Page 25: ...continuity position 2 Place the red meter lead on one of the bulb leads 3 Place the black meter lead on the other bulb lead 4 The meter should beep and indicate continuity 3 If the meter does not indicate continuity the bulb will need to be replaced a If the SL 40 was equipped with a sealed beam bulb it will need to be upgraded with the PAR 36 Lamp Retrofit Kit P N 40107 1 The kit contains 3 lamp ...

Page 26: ...to the negative battery terminal Note Always use a fusible link P N 400307 between the negative lead and the negative battery terminal Note It is very important that proper polarity is observed Reversed wiring may cause permanent damage to the SL 40 c Tape the connections securely in place with 3 4 strapping tape d Place the positive end of the battery into the rear opening of the flashlight and s...

Page 27: ...ly separate the two halves of the body e Remove the rubber footpads at the bottom of the flashlight and place them aside 6 Inspect the wires to make sure that none of them are disconnected or broken and replace them as necessary 7 Use the switch boot tool P N 450074 to remove the switchboot and integrated lock ring 8 Desolder the switch leads from the circuit board The replacement switch is P N 40...

Page 28: ...it is open a Use a multimeter set to the lowest ohms position 1 Place the black lead on either one of the resistor leads 2 Place the red lead on the other resistor lead 3 The meter should read close to zero approx 5 ohms 4 If the meter indicates an open condition the resistor will need to be replaced b If a multimeter is not available a jumper wire can be placed across the resistor leads 28 1 Appl...

Page 29: ... the voltage regulator is properly oriented label side toward you pin 1 is the pin on the left c Align the leads of the new voltage regulator with the holes in the circuit board d Solder the three pins of the voltage regulator in place e Test the voltage regulator as described in B 1 2 above Note If the voltage regulator still fails to perform reassemble the light as below and send it to Streamlig...

Page 30: ...00130 1 SWITCH BOOT 400266 SCREW PACKET BODY 8 1 400157 SWITCH W BOOT 400307 FUSIBLE LINK ASSY 9 1 400258 REAR COVER ORANGE W FOOT 400179 KIT 2 PIN PLUG INCLUDES 400258 1 REAR COVER BIEGE W FOOT PARTS FOR RACK AND LIGHT 10 1 400254 BODY R H ORANGE 400256 BODY R H BEIGE CHARGERS 22311 120V AC STANDARD 11 1 400255 BODY L H ORANGE 21725 230V AC STANDARD 400257 BODY L H BEIGE 22051 12V DC 1 W LIGHTER ...

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