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How to Operate and Repair the Nova 5000 Flashlight

Introduction

The Nova 5000 flashlight is known for its durability and its simplistic design. The Nova
5000 was created to be user friendly flashlight making it easy to use and maintain. The Nova
5000 has LED bulbs powered by batteries. Its single mode setting allows the Nova 5000 to
produce a high powered light beam. The high density polycarbonate used in the cases allows
for long lasting durability. The precise manufacturing provides an airtight seal making the
Nova 5000 dust and water resistant in normal use. Proper use and repair of this product will
lead to a consistent and reliable performance. These instructions will detail how to properly
use and repair the Nova 5000 flashlight. Repair instructions will be provided after operating
instructions. No special knowledge or skills are required.

Caution

Lithium-Ion batteries can be dangerous and lead to serious harm if; shorted, overheated,
disassembled, exposed to fire or high temperatures (above 212 F). This flashlight produces a
high-powered beam of light and if turned on in a container or in clothing then the flashlight
may; overheat, damage surrounding materials, and/or damage the flashlight. This may cause
surrounding materials to catch on fire. Remove batteries from the flashlight and replace them
when the light is dim or unusable. Always make sure to place the batteries in the correct
orientation. If not, this may cause shortages. Never use old batteries or mix them with new
batteries. If instructions are not followed, may cause personal injury and/or property damage.

Operation Overview

The Nova 5000 includes two D sized batteries. When the endcap from the flashlight is turned
and removed, the battery cavity will be seen. Inserting the two batteries will supply the
flashlight with electricity and will allow the user to operate the flashlight. After insertion of
the batteries, the endcap is then screwed on tightly to the bottom of the flashlight. Operation
of the flashlight is as simply as pressing the button to turn the flashlight on, and then pressed
once again to turn it off. (Reference Picture 1)

(Reference Picture 1: Product Components)

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Equipment and Materials Needed For Operation

Two Size D Batteries

Nova 5000 Flashlight

Operation Instructions

To Insert/Replace Batteries:

1. Remove endcap. Remove the endcap from the bottom of the flashlight by turning it
counterclockwise until it detaches from the body of the flashlight. (Figure 1)

2. Put in batteries. Insert two size D batteries. Insert both batteries with the side labeled
+ facing towards the head of the flashlight. (Figure 2) Caution: make sure they face
the correct way.

3. Reinstall endcap. Reinstall the endcap back onto the flashlight by facing the threaded
end of the cap towards the threads on the flashlight. Then turn it clockwise until it is
tight. (Figure 3)

Operation:

1. Turn the flashlight on. Press the button located near the center of the flashlight. The
button will stay down when the flashlight is turned on. (Figure 4) (Be sure to have the
batteries inserted in the properly and the endcap is screwed on tightly.)
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2. Turn the flashlight off. Press the button (from step 1) again. The button will stick up
from the body when the flashlight is off. (Figure 5)

Repair Overview

Even though the Nova 5000 flashlight is very durable, there will be times when a repair is
needed. Whether it is the LED bulb that burns out or the glass lens cracks, repairing the Nova
5000 is as simple as unscrewing the old bulb or lens and replacing it with a new one.

Equipment and Materials Needed

New LED Bulbs
New Glass Lens

Repair Instructions

Replacement of the LED Bulb:

1. Removed the batteries. Turn the endcap counterclockwise until the endcap comes
off the body. Once the endcap is off take out the batteries and set them aside for
reinsertion. (Figure 6)
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2. Remove the lens. Take the front lens off of the bulb assembly by turning the
polycarbonate ring surrounding the lens, counterclockwise until the lens comes off.
(Figure 7)

3. Remove the LED case. Grab the case surrounding the LED bulbs and turn it
counterclockwise until the LED case comes off. (Figure 8)

4. Remove the LED bulb. Gently grab the LED bulb and twist in a counterclockwise
motion until the bulb comes off. (Figure 9)

5. Put in the new LED bulb. Take the new LED bulb and place it on top of the hole on
the LED holder. Turn the bulb in a clockwise motion until the bulb is tightly seated.
(Figure 10)

6. Put back on the LED case. Take the loose LED case and place it around the new
LED bulb. Turn the case in a clockwise motion until it is seated tightly. (Figure 11)
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7. Put back on the lens. Take the loose lens and place it on top of the LED case. Turn
the lens in a clockwise motion until it is tightly seated. (Figure 12)

8. Put back in batteries and endcap. Take the batteries and insert them back in with
the + facing towards the head of the flashlight and turn the endcap in a clockwise
motion to put back on the endcap. (Figure 13) Caution: make sure they face the
correct way.

Replacement of the lens:

1. Removed the old lens. Take off the old lens by grabbing the polycarbonate ring
surrounding the glass lens, and turn it counterclockwise until it comes loose. (Figure
14)

2. Put on new lens. Take the new lens and place it on top of the LED case. Turn the
new lens in a clockwise motion until it is seated tightly against the case. (Figure 15)
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Conclusion

Turning on and off the flashlight is as easy as pressing the button once for on and twice for
off. You can replace the batteries and insert them by taking off the endcap and putting the
batteries in, but make sure the face the end labeled +. Repairs can be done by taking apart
the flashlight and by replacing the damaged part. The simplistic design makes it easy for
reassembly.

Troubleshooting/Follow-up Advice

If there are any issues with your flashlight, the best way to try to fix it would be to check the
connections between; the batteries and/or the LED bulb to the bulb holder. If there are further
issues please contact us at (425)-596-0589 or email us at NovaCorp@flashlight.net.