StreamLight LITEBOX Bedienungsanleitung

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

- 1 -

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.

A set of tools 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 (610) 631-0600

Phone (800) 523-7488

FAX (610) 631-0712

7:00 a.m.-5:00 p.m. EST

- 2 -

GENERAL NOTES

Troubleshooting Note

A troubleshooting diagram is provided (page 3) to help enable a repair technician to isolate and

repair electrical problems which can arise. The diagram describes a condition and suggests the

underlying cause. Repair procedures are provided in the chapters indicated in the solution

blocks. The troubleshooting procedure does not attempt to isolate individual components.

Instead it suggests replacement of modules or assemblies such as the printed circuit board, the

battery, the switch, etc. Occasionally problems may arise which are not included in the

troubleshooting procedure. In these cases a thorough physical inspection may reveal a broken

wire, cracked or damaged circuit board, or some other mechanical damage which results in an

apparent electrical problem. 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). If the problem remains elusive the Litebox and all of its available

components (including the mounting rack and plug-in wall charger) should be returned to

Streamlight for factory service.

The Red and Green Charge Indicators

The Litebox is equipped with two LED’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 the green LED should turn “on”. If the red LED remains lit for more than

24 hours the charging circuit must be tested and replaced or repaired as necessary

(see section VI).

Additional Information

Important Note : When mounting or repairing the charge rack Do Not Use anaerobic thread

locking compounds (Loc-tite, etc). Chemical reactions caused by the curing of these compounds

destroys the molded plastic and will void the factory warranty.

Caution : Adjustment of the controls on the printed circuit board within the Litebox should be

performed only within the guidelines established in this manual. Improper adjustment may result

in serious damage to the system and may cause physical injury. Damage caused by improper

settings may require extensive repair at the factory.

The plugs and sockets may be cleaned with contact cleaner (make sure it is plastic safe) to

minimize corrosion. Silicone grease may be used to improve contact and retard corrosion. Make

sure that the power is disconnected and lightly spread a small amount on each connector plug

pin.

- 4 -

SECTION I

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.

4. Disconnect the battery leads and remove the battery.

- 5 -

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. 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 upper housing.

- 6 -

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.

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 –

SECTION II

TESTING/REPLACING THE LAMP

1. Remove the black rubber lamp ring from the lamp housing.

note : A flat blade tool can be used to help pry the black rubber ring from the housing.

2. Pull the lamp/reflector assembly from the lamp housing.

3. If the lamp is the sealed beam type disconnect the slip-on connectors from the lamp blades.

a. Test the bulb by placing a multimeter into the continuity position and place one lead on

each lamp contact (a beep indicates a good bulb).

b. Replace the bulb if necessary.

c. The wattage of the bulb is shown on the back of the lamp in the second printed data line.

1. Example “ 6V 8W 01-28-96 1720” - the 2nd group of characters (8W) indicates the

wattage (8 watts).

2. A clear lens is a spotlight pattern (“S“); a waffled lens is a flood pattern (“F”).

4. If the lamp is the new style with a plastic reflector and screw-in bulb(s) follow the

instructions below.

a. Test the bulb(s) by unscrewing the plastic threaded bulb socket from the plastic reflector.

1. Pull the old bulb straight out from the socket.

2. Use a multimeter in the continuity position and place a meter lead on

each bulb lead (a beep indicates a good bulb).

b. Bulb replacement

1. 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. 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. Note : The focus should be attained

somewhere between the two limits described (try 1/4 turn out from the fully seated

position).

5. Place the reflector assembly into the lamp housing.

a. Try to dress the wires away from one another.

b. The reflectors need to be aligned so that the key on the reflector fits into the recesses on

the lamp housing.

c. There are two key positions on the plastic reflector assembly which allow the flood pattern

to be adjusted to either a wide or a tall pattern.

6. Replace the black rubber lamp ring.

note : A flat blade tool can be used to help pry the black rubber ring onto the lamp housing.

- 8 -

SECTION III

TESTING THE LITEBOX BATTERY

1. Disassemble the Litebox as shown in Section I.

2. Remove the battery from the Litebox.

a. Carefully disconnect the battery leads.

b. Slowly pull the battery from the Litebox housing and remove the foam pad.

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.

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 cells should be replaced.

5. Install the battery and reassemble the Litebox as shown in Section I.

- 9 -

Lamp Option Run Time Charge Time (AC) Charge Time (DC)

8.00 hrs. 24.0 hrs. 15-24 hrs.

8 watt spot/flood 3.50 hrs. 24.0 hrs.

20 watt spot/flood 15-24 hrs.

SECTION lV

TESTING/REPLACING THE SWITCH

Testing the Switch

1. Disassemble the Litebox and disconnect the battery as shown in Section I.

Note : Make sure that the battery leads are disconnected from the battery.

2. Slide the printed circuit board outward from the upper Litebox housing.

a. Slide the board out far enough to access the solder pads where the switch leads are

connected.

b. Use care to avoid bending the leads of the LED’s mounted on the underside of the board.

3. Place a multimeter into the continuity position.

4. Place one lead on each of the solder pads marked “S 1”.

5. Depress the switch 8 times (4 on/off cycles).

6. The multimeter should indicate continuity for the 4 “on” cycles.

a. If continuity is indicated as above the switch is functional.

1. Slide the printed circuit board back into the upper Litebox housing.

(note: Make sure that the LED’s are aligned with their respective openings).

2. Reinstall the battery and reassemble the Litebox as shown in Section I.

b. If continuity is not indicated as described the switch needs 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 is an integral part of the boot).

4. Desolder the switch leads from the solder pads marked “S 1” and discard the old switch.

5. Obtain a new switch (P/N 400157).

a. Cut the leads to 4” in length.

b. Strip and tin 1/4” from the end of each lead.

6. Solder the leads of the switch to the printed circuit board at the solder pads marked

“S 1”. (note: Either lead to either pad.)

7. Install the new switch in the opening in the upper Litebox housing.

8. Use the switch boot tool to secure the switch boot and integrated lock ring in place.

(note: Do not overtighten the switchboot as it may prevent the switch from turning "on".)

9. Slide the printed circuit board back into its slots in the upper Litebox housing.

(note: Make sure that the LED’s are aligned with their respective openings.)

10. Install the battery and reassemble the Litebox as shown in Section I.

- 10 -

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