Busch + Müller Toplight 2C permanent battery replacement

Saw the lamp along the ultrasonic welding seam with a fine saw (e.g. Japanese saw).

A total of four straight cuts must be made

Saw carefully so that the electronics or the battery do not get damaged

The housing should fall apart into two halves after sawing

Pull the old battery out of the socket

The plug may be relatively tight in the socket. Simply wiggle it until it can be pulled out or use pliers

Under the black foil there are two Li-Io cells in AAA size.

At the two outer ends are the negative terminals, which are connected with a metal clip

Remove the round stickers and the long metal clip

Remove the cables including the socket

Buy 2x ICR10440 with solder tag

(The batteries used here are ICR10440; 3,7V each 320mAh with Z-solder tag)

Put the batteries with the positive side to each other and solder the lugs

Now solder the red connection cable

The outer solder lugs are soldered to the sheet metal (paper clip as soldering aid).

The black connection cable is also soldered to the sheet metal

Stick the yellow adhesive tape on the open contacts

Stick the circular red stickers on the outer positive terminals again

Fix the new battery pack with insulating tape.

Plug the power connector into the socket of the board

Insert the board into the black housing with the USB socket pointing downwards

Put on the reflector

To make the housing watertight again, the previously sawed seam must be glued together with a gap-filling adhesive. This can be done for example with Sikaflex

Apply glue carefully along the contour (e.g. Sikaflex)

Make sure that the LEDs and the switch remain clean.

Close the housing and let the glue harden.

Clip the lamp into the holder