Step 1 Intermittent ON/OFF Push Button Fault, Push Button Repair, Mini Square Chinese Flashlight

• High power LED Mini flashlight, that stopped working after accidentally ending up in the washing machine. Stopped illuminating. Dried out, but did not respond properly to the ON / OFF button.
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Step 2



• The flashlight does not have screws, so for disassembly requires prying on the sides with a cutter or knife .
• The case is put together with glue, so it has to be forced to separate, by breaking the plastic inside a little, since it was heat-sealed at the factory.
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Step 3
• View of the very simple internal composition; separated into 3 parts, rechargeable battery, PCB board with mini USB socket and push button, LED board.
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Step 4
• After performing various tests, a fault was seen in the button, a jumper on the 2 terminals of the button makes the LED board light up correctly: the problem is located in the 2 internal contacts of the button.
• I tried without success, just to rule out that possibility, re-soldering the 2 connections of the button, but there was no improvement.
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Step 5
• Therefore, the 2nd repair option, (since I don't have a suitable replacement button) is to apply "ELECTRONIC CLEANER" contact cleaner copiously while simultaneously sliding the button from one side to the other to try to clean the interior contact.
• Subsequently, canned air was applied (Air canister on the right for cleaning keyboards) by means of which the inside of the button and the PCB were dried.
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Step 6
• Once the PCB and the switch were dry, it was repeatedly tested, responding perfectly, so the flashlight was reassembled.
• BE CAREFUL WITH THE BATTERY the truth is, it gave me a scare, during assembly; it became very hot in a few seconds because one of its terminals was short-circuited with the aluminum sheet of the LED, so to protect the terminals I chose to place protective insulating tape (Orange) covering the 2 terminals.
• In order not to apply force in the re-assembly. A piece of black rubber was cut from the LED plate. (blue arrow)
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Step 7
• Since the two halves were fused together, during assembly and we forced it open; we must make sure that the lid is correctly positioned and apply a little silicone onto the lid before assembling it, so that it dries properly and remains perfectly closed.
• END of the Guide.
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