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SunBell: Port cover repair

Required tools

  • Screwdriver: Torx T5

  • Screwdriver: Torx T6

  • Knife

  • DC Port cover

  • USB Port Cover

Step 1

Unscrew lamp casing

Using a Torx T6 screwdriver, carefully remove the 3 screws at the bottom of the case.

Screws are small and light, so make sure to place them in a safe spot to avoid losing them.

Step 2

Open the plastic casing

Carefully separate the two parts of the plastic casing. Make sure not to pull too fast as there is a battery cable still keeping the two parts together.

Step 3

Pull battery out from bottom casing

Gently pull out the battery.

If the battery is locked very tight, pull firmly but with care not to damage the cables.

Avoid using sharp tools such as pliers, which may damage or break the cables to the battery. This is a safety hazard!

DO NOT use sharp edge tools to pull battery out.

Step 4

Disconnect battery from electronics board

If your lamp's battery has a connector:
The connector consists of a socket soldered to the electronics board (PCB) and a plug attached to the battery cables. Using your fingers, gently pull the plug out of the socket. (Pulling on the entire connector might lead to breaking the solder.)

If your lamp's battery cables are soldered directly to the electronics board (PCB), there is no connector:
Continue to the next step, and be careful not to bridge the two ends of the battery with any metallic item.

You might find silicon glue around the connector; remove it by simply pulling the connector away.

Step 5

Unscrew electronics board.

Using a Torx T5 screwdriver, remove the 2 screws from the board. One or both might be hidden behind the black foam piece.

Screws are small and light, so make sure to place them in a safe spot to avoid losing them.

Step 6

Lift up electronics board

Carefully pry up the PCB using a knife or a flathead screwdriver. Once you can see its edges, you can use your fingers to lift and rotate it to expose its underside.

Be careful not to pull too far/hard, as the circuit board is soldered to two more wires underneath.

Step 7

Install the new plastic cover.

Using pliers or your fingers, remove from the bottom of the case any remaining material from the damaged cover.

Insert the narrow part of the new cover in the hole of the casing top. Push it in, and with the help of pliers, pull the narrow portion of the cover until it snaps in place and is well secured.

Try lightly pulling the cover to make sure it is correctly installed.

Step 8

Reassemble the lamp

Reverse each step from steps 5 to 1 to reassemble the lamp.