The powerswitch actuator is a very small piece in comparison to the rest of the marker, but it is very important that its function and purpose is understood. The actuator is a transparent piece of plastic that is housed in the rear of the frame. When you turn the marker on by pushing the button at the back of the frame, you're actually pushing on the back of the actuator itself.
When you push the actuator forward, it in turn presses and actuates the tiny microswitch located on the upper circuit board. This is what turns the marker on and off, toggles between eye modes, and performs whatever other function different boards (aftermarket boards) may involve.
The secondary function of the powerswitch actuator is to provide a lightpipe for the marker's indicator LED. A lightpipe in this situation is a transparent piece of material that is used to transfer light from a source to a different destination. In this case, the lightpipe transfers blue light from the LED on the upper circuit board out the back of the frame.
The actuator is held in place by a steel roll pin in the frame. The switch has two small magnets on one end; these serve to attract the steel pin that holds it in. This allows the switch to "bounce" back at you after you release it, without the use of springs. Both magnets are required for the actuator to function smoothly; if one is missing, the actuator will often have difficulty resetting itself. If both are missing, the actuator may tend to push the powerswitch on the board when not needed, and will also cause "switch bounce" issues with it as well (in much the same way that a trigger switch bounces).
Removal of the powerswitch actuator is not required for any task, unless the frame is full of dirt or debris which must be thoroughly cleaned out. To remove the actuator, simply tap out the roll pin using a hammer with a metal punch, nail, or any other small object. You shouldn't worry too much about scratches in this area, since the grip panels will cover much of it.
Powerswitch Versions:
There are currently two versions of pwoerswitches in Shockers. The older version was used until early 2004, when it was replaced by the newer, current version. Older version is "cloudy" and larger in shape, whereas the current version is more transparent and smaller. Shown in the picture above is the current powerswitch actuator.
Wire Harness Disassembly & Reassembly:
Located between the two circuit boards is a harness of 10 small wires with a male plug connector at each end. This is referred to as the wire harness in almost all applications. Its purpose is to connect the upper and lower circuit board; it is required for the marker to function.
For simplicity, I will say each of the wires must be intact for the marker to function fully. Technically, this is somewhat untrue, since if you don't have Vision then three of the wires aren't used, and it's also true that one of the wires is actually completely unused altogether, but I won't go into details here (see the section for the upper circuit board for technical specifications).
The main factor to keep in mind regarding the wire harness is that it must be installed into its plugs even and straight across all 10 pins. it is possible to bend the small pins inside the connector, which results in some part of the upper board not functioning (basically preventing the marker from working correctly, in some way).
Frame/Body Reassembly:
One of the most universally-known assembly quirks about the Shocker is that you must take care to pull the wire harness away from the powerswitch when reassembling the frame to the body. If you fail to keep the wire harness clear from the actuator, it may accidentally get caught and pinned between it and the circuit board. When this happens, the powerswitch [component on the circuit board] is almost always broken, and would then need to be repaired or replaced (requires soldering or sending the circuit board out for the repair).
If you have damaged your powerswitch, follow the link at the bottom of the page for instructions on how to repair it yourself (moderate/advanced soldering experience is required).
When assembling the frame onto the body, I would suggest following these steps to ensure a smooth reassembly. Pictures follow each numbered step below.
1. While the frame and body are separated, connect the wire harness to the upper board.
2. Align the frame with the solenoid and pull them together. Don't push the frame all the way up against the body, though.
3. Pull the wire harness out of the way of the powerswitch actuator.
4. Once the wire harness is out of the way, push the frame up against the body and screw it down using the two frame screws.
5. Once tightened, plug the harness into its connector on the lower circuit board. You can do this while the board is installed in the frame, or not. Be sure to insert the harness evenly (see the above wire harness).
Below is a demonstrational video to show the above process.
Frame assembly, high-res (24-MB)
Frame assembly, high-res (10-MB)
Overview:
· The powerswitch actuator is the button you press to turn the marker on and off.
· The powerswitch actuator is magnetic and resets itself after being pushed, as if a spring were pushing it back.
· The powerswitch actuator doesn't need to be removed for normal maintenance.
· A collection of wires connect the two circuit boards, this is known as the wire harness.
· Caution must be taken when reassembling the frame. The wire harness must not be pinched between the actuator and the board, or damaged parts will result.
Related Links:
· Powerswitch actuator manual scan (Shocker SFT only)
· Powerswitch repair
· SFT upper circuit board
· NXT upper circuit board
