Mini-Maglite 3AA LED fault.

[march.brown]

I have a Mini-Maglite 3AA LED torch that I bought less than a year ago ... Serial number is 30000137171 and it was in a sale at a reasonable price ... It worked well for the first few months then the on/off started to give problems. It now doesn't work all the time though if the torch is tapped, it will flicker and then go off again ... It wasn't bought locally so I can't take it back to where I bought it from ... The receipt etc was thrown out several months ago when the torch worked OK.

I just don't trust the torch now as it only works some of the time ... I have Emailed the UK representatives (Burton McCall) a couple of times but to no avail ... I have also Emailed the manufacturers recently and am waiting for a reply.

I have had a look inside but the LED unit doesn't come out, though it rotates freely and moves in and out a few millimetres ... Is there anything that I can do to effect a repair, or is it a Maglite repair job only ?

I have other torches, but I don't like throwing money (or torches) away ... Ideally, I would like this torch to have a fixed focus and a tail push-button ... Failing that, I would just like it to work reliably.

Many Thanks.
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[Scott_T]

I vaguely recall reading a forum post here somewhere about how to fix that, might try googling some here.

 

[march.brown]

I vaguely recall reading a forum post here somewhere about how to fix that, might try googling some here.

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Anyone know the thread/post please ... I can't trust the torch but I don't want to scrap it either ... Many Thanks.
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[se4g4e]

You might try this: http://www.maglite.com/pdf/CustServ/Mini Maglite LED FAQ5222007805552.pdf

Also make sure the battery contacts are clean. Evidently the LED module is not meant to come out of the body.

 

[chmsam]

I did a quick search on the words "minimag led problem" and turned up the following thread among others.

3 watt AA LED Maglite Problem/Question

There are a few things that could be going on and are pretty easy to check.

Simplest things first:

- try brand new batteries. This flashlight/torch will often do what you describe when it needs fresh batteries. For what it's worth, I run mine on lithium AA's with best results.

- inspect the ends on the batteries and the contacts on both the battery spring and the contact at the LED end. Do you see any dark areas at all? If so there is some normal oxidation. Try using a soft eraser (rubber for those in the UK) on a pencil and very gently rub it off.

By the way, the DeOxIt mentioned in the thread in the link above is used to prevent oxidation and improve the quality of the electrical contacts. It is somewhat expensive but I use it on all my flashlights/torches and I think it improves their reliability. Fortunately you do not need to use much.

If it still doesn't work, try some other very simple fixes:

- try to very gently pull on the spring at the tail end. Intermittent contact will give you the problems you are finding.

- on the tail cap are two small metal tabs that are contacts to the body of the flashlight. Inspect these for oxidation as well. If you do not see any or you have cleaned it and there is still has a problem, use very, very gentle effort to pry those out just a tiny bit but no more. Just use your thumbnail for this.

If it were mine, rather than doing anything more than this I'd just ship it off for warranty service.

Hope this helps.

 

[march.brown]

I did a quick search on the words "minimag led problem" and turned up the following thread among others.

3 watt AA LED Maglite Problem/Question

There are a few things that could be going on and are pretty easy to check.

Simplest things first:

- try brand new batteries. This flashlight/torch will often do what you describe when it needs fresh batteries. For what it's worth, I run mine on lithium AA's with best results.

- inspect the ends on the batteries and the contacts on both the battery spring and the contact at the LED end. Do you see any dark areas at all? If so there is some normal oxidation. Try using a soft eraser (rubber for those in the UK) on a pencil and very gently rub it off.

By the way, the DeOxIt mentioned in the thread in the link above is used to prevent oxidation and improve the quality of the electrical contacts. It is somewhat expensive but I use it on all my flashlights/torches and I think it improves their reliability. Fortunately you do not need to use much.

If it still doesn't work, try some other very simple fixes:

- try to very gently pull on the spring at the tail end. Intermittent contact will give you the problems you are finding.

- on the tail cap are two small metal tabs that are contacts to the body of the flashlight. Inspect these for oxidation as well. If you do not see any or you have cleaned it and there is still has a problem, use very, very gentle effort to pry those out just a tiny bit but no more. Just use your thumbnail for this.

If it were mine, rather than doing anything more than this I'd just ship it off for warranty service.

Hope this helps.

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Well, I have read and tried all the recommendations on this and the other posts and have used Electrolube wiped over any contact or thread areas having thoroughly cleaned the torch first ... I couldn't see any Oxidation on the LED contact though I cleaned it anyway ... I have tried my freshly charged Eneloops and new Alkaline cells but there was no difference.

It has improved the torch to the extent that it might now be possible to use it as a non-essential light ... It now works more often than before but by no way near to 100%.

I have noticed that when slowly turning it to the off position, the LED goes out but screwing slightly further it goes on again ... Further turning turns it off properly ... When turning it on again, if I go to this 'bad patch', it won't come on, though a quick screw to the OFF position and back to the ON lets it come on most of the time ... It does seem that the fault is the ON/OFF control ... I don't know what type of switch this is and suspect that its contacts need more tension ... As the LED assembly will not come out, I am stuck with a torch that I can't trust 100%.

I suppose that this is a reason to buy more torches.

Many Thanks to you all for taking the time to reply.
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[chmsam]

One other thought and pretty much "grasping at straws," but some batteries differ a tiny bit in length. Don't know if this is still the case or not but many years ago I did run into similar problems as yours with a few of my lights when I used Duracells and a few other brands. For primary cells I now only use either Energizer alkalines or their lithium batteries and have not had any problems since. I don't have eneloops so I can't talk about those.

 

[Robin24k]

Also, try pulling the spring to see if you can extend it (pop it out first). Shake the light, do the batteries rattle a lot?

 

[march.brown]

Also, try pulling the spring to see if you can extend it (pop it out first). Shake the light, do the batteries rattle a lot?

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Done the spring stretch bit early on, plus the metal tabs on the endcap ... Cells definitely don't rattle, they never did before I slightly stretched the spring ... The spring pushes the 3 cells onto the LED contact with a fair bit of pressure, so no problem there ... I assume that turning the head unit allows the LED unit contact to move between the OFF position (where there is no contact made) and ON (where there is a contact made) ... My impression is that there is a poor contact tension giving the intermittent operation of the LED ... When I turn the head to where it should light the torch, a couple of taps on the side of the head will make the lamp flicker or sometimes come on fully.

The LED unit can be shaken up and down very easily (in the body) when the batteries are out and the head/reflector off ... This is why I think that it is a poor contact in the LED sliding unit ... I can't think of anything else to try since I can't take the LED unit out to see if there are any contacts.

Does anyone know how the switch is constructed or how to bypass it ? ... There must be a drawing somewhere, perhaps in the 'Patent' office.

Ideally I would like to bypass the switch and put an endcap switch on it ... The focus could be used as normal or just left in a chosen position.

At the moment, the torch is in my bedroom as I don't trust it enough to put it in general use by my family.
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[Robin24k]

Based on your serial number, you have an early version of the light. I think this is a known problem and there's no way to fix it. You may want to contact Mag's warranty center and arrange a replacement. If possible, making an international call to them at (909) 947-1006 may offer the quickest resolution.

 

[march.brown]

Based on your serial number, you have an early version of the light. I think this is a known problem and there's no way to fix it. You may want to contact Mag's warranty center and arrange a replacement. If possible, making an international call to them at (909) 947-1006 may offer the quickest resolution.

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I assume that the reason it was half price was that it was an early version ... I've just tried it again and it seems to work randomly about 80% of the time ... I know it will work if I shut it off and then on again a couple of times, so I might just leave it as a sort of spare torch and keep it in the desk drawer for when I need a torch less than urgently ... It's a good reason to buy a another torch.

I don't really want to go to the expense of a (perhaps) long international telephone call plus the expense of overseas postage ... It might be better to just put it down to experience.

I have not had any replies to my Emails to Maglite and Burton MacCall as yet.

Many Thanks for taking the trouble to reply to my posts.
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[Robin24k]

Have you tried contacting [email protected]? That's where I email (usually get a reply in one business day), and they've dispatched me a replacement reflector for one of my lights yesterday.

Here's something to try...insert the batteries and push on the batteries a bit. If the LED module is moving around, that should tighten it.

The LED module does come off (somebody mentioned the method to me in another thread, they swapped the module between an AA light and a D light), and the method involves pushing the metal inside the plastic ring straight down.

 

[march.brown]

Have you tried contacting [email protected]? That's where I email (usually get a reply in one business day), and they've dispatched me a replacement reflector for one of my lights yesterday.

Here's something to try...insert the batteries and push on the batteries a bit. If the LED module is moving around, that should tighten it.

The LED module does come off (somebody mentioned the method to me in another thread, they swapped the module between an AA light and a D light), and the method involves pushing the metal inside the plastic ring straight down.

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Have written to the Email address that you have given me and will post replies if they are forthcoming from Maglite.

Many Thanks.
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[march.brown]

Not certain why, but -----

The torch has improved and is now working almost every time ... It is on my bedside table and I test it several times a night ... I will try leaving it in the car as I need a back-up torch there ... I will probably keep the Saik SA-8 as the main torch ... I am a bit paranoid about not having a useable torch in the car.

When the Mini-Mag doesn't work first time, it only takes a couple of twiddles to get it to work again ... So it might be OK in the car with three AA Hybrios in it.

I will have to think about it first though.
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[Robin24k]

Doesn't that always seem to happen when you want to bring your car in for warranty service?

 

[march.brown]

Just had an Email to send the torch back for repair or replacement.

 

[Robin24k]

Will they send a replacement out to the UK? If so, sending it back to them might be worth it if you use a bubble mailer and send it first class...

 

[march.brown]

Will they send a replacement out to the UK? If so, sending it back to them might be worth it if you use a bubble mailer and send it first class...

I wrote to [email protected] and their UK representitives Burton McCall.

I had an Email from Burton McCall Ltd.

Burton McCall Ltd
163 Parker Drive
Leicester
LE4 0JP

They offered to repair or replace as necessary ... I don't mind which as long as the problem is solved ... The 3AA LED is a nice size for leaving in the kitchen/bedroom for emergency use ... My Wife only needs to be able to find the candles and matches if the power goes off or to look behind stuff to see where the dog has hidden things ... It is surprising where a six pounds Yorkie can hide things.

When the torch is repaired, it will mean that there is one less to buy.

I am aiming for one torch in each room though I wouldn't include the bathroom and cloakroom, plus one in the car plus an everyday carry ... That means eight would be needed ... We have six already plus one in the post, so I only need one plus a spare maybe.

There is no rush to get another torch now, but in the future I will be forced to get another ... Maybe if funds (or the Wife) permit I will get a better one ... One that will meet with the approval of flashaholics ... None of my present torches seem to suit the real flashaholics.

People will probably say that if that is what I want then it's OK ... Maybe they don't have the same financial constraints as some of us pensioners ... Or maybe they are in dangerous jobs or situations where they need a 100% reliable torch plus of course the mandatory back-up torch ... I only have to walk into the next room if one fails ... If the car torch fails then my every-day-carry (single AA) would be in my pocket.

I will report on the repaired / replacement when it arrives.

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[Robin24k]

That's great to hear! Good luck with the replacement.

For me, personally, Maglites are good enough. Better than average and still within reasonable price (especially when on sale when I got them). I don't need anything too special or high end.

 

[march.brown]

Today my brand new Maglite (in grey) arrived by Recorded Delivery ... I sent numerous E-mails to Burton McCall to see if they had in fact received my torch, but to no avail ... Then eventually I had the E-mail saying that a replacement was being sent ... So if you are having trouble with your Maglite, based on my personal experience with Burton McCall, you will have to wait a month or so for a reply to your E-mails ...

Anyway, the replacement arrived well packed and is now in service as the "Kitchen" torch ... My Wife prefers single mode torches. .. Now if only I could get a tail-switch she would be even happier.
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