Nordson Encore 1096694A User manual

Instruction Sheet
Part 1096694A
E2009 Nordson Corporation
P/N 1096694A
EncorerManual Powder Spray Gun
Trigger Switch Replacement
Preparation 1. Remove the nozzle nut, nozzle, and electrode assembly.
2. Disconnect the powder feed hose adapter, purge air tubing, and air
wash tubing from the gun handle.
3. Disconnect the gun cable from the controller interface module.
Gun Disassembly
1. See Figure 1. Remove the top (M3 x 30) screw (11).
2. Slide the hook (10) off the display module (9).
3. Remove the bottom (M3 x 20) screw (12).
4. Carefully pull the display module away from the gun, then remove the
adhesive support pad and disconnect the trigger switch header.
5. Separate the gun cable/display module connectors (J3).
6. On the display module, carefully clean the switch header mounting
surface and surrounding area with isopropyl alcohol. Allow the surface
to dry completely before connecting the new switch header.
11
12
9
10
J3 Adhesive
Support
Pad
Switch
Header
Figure 1 Display Module Removal

Encore Manual Spray Gun - Trigger Switch Replacement
2
Part 1096694A E2009 Nordson Corporation
7. See Figure 2. Insert a small screwdriver into the recess in the J2 gun
cable/power supply connectors to release the catch and separate the
connectors.
8. Remove the M5 x 10 nylon screw (24) from the gun body.
J2
24
Figure 2 Disconnecting Cable/Power Supply and Removing Gun Body Screw
9. See Figure 3. Grasp the handle in one hand and the gun body in the
other. Press the thumbs of each hand together while pulling in opposite
directions to gently separate the gun body from the handle.
Figure 3 Gun Body Removal
10. See Figure 4. Remove the elbow (13) from the inlet tube (23).
11. Remove the two M3 x 20 screws (12) from the handle base (22).
12. Pull the base away from the handle about 25-50 mm (1-2 inches).
23
13
12
22
Figure 5 Base Removal

Encore Manual Spray Gun - Trigger Switch Replacement 3
Part 1096694A
E2009 Nordson Corporation
13. See Figure 6. Carefully pull the ground pad (27) away from the handle,
starting with the bottom and rotating it up and away.
27
Figure 6 Ground Pad Removal
14. See Figure 7. Separate the right and left handles (25, 26).
15. Remove the main trigger, settings trigger, and trigger actuator (16, 17,
18) from the right handle half.
16. Remove the trigger switch (15) from the right handle half.
27
25
26
17
16
18
15
Figure 7 Separating Handle Halves and Trigger Switch Removal

Encore Manual Spray Gun - Trigger Switch Replacement
4
Part 1096694A E2009 Nordson Corporation
Gun Assembly
New Trigger Switch Installation
1. Remove the adhesive liner from the new trigger switch.
2. See Figure 8. Install the trigger switch (15) on the mounting flat of the
right handle (25), using the locator tabs and bottom flat to orient the
switch. Press firmly on the switch to secure it in place.
3. Install the actuator (18) and settings trigger on the main trigger (17),
noting the orientation of the settings trigger (16) gusset. Slide the
triggers over the trigger pivot pin on the right handle half.
15
18
17
16
25
Gusset
Pivot Pin
Locator Tabs
Bottom Flat
Figure 8 Trigger Switch Installation Steps 1-3
Assembly 1. Align the right and left handle hex pins with their mating sockets and
press the handles together.
2. See Figure 9. Feed the cable (28) connectors into the bottom front of
the handle, then slide the inlet tube (23) through the tube guides while
routing the cable (28) out the top of the handle. Leave the base about
1.5-2 inches from the bottom of the handle.
3. Route the 4-mm clear tubing from the gun body through the handle and
connect it to the barbed fitting (20) in the base, if previously
disconnected.

Encore Manual Spray Gun - Trigger Switch Replacement 5
Part 1096694A
E2009 Nordson Corporation
28 28
Clear tubing
23
Tube Guides 22 20
Figure 9 Handle Assembly
4. See Figure 10. Hook the ground pad (27) behind the locator tabs and
rotate the ground pad into position against the handles.
5. Attach the base (22) to the handles with the two M3 x 20 screws (12).
Hand tighten the screws only.
22 12
27 Locator Tabs 27
Figure 10 Installing Ground Pad and Base
6. Make sure the power supply is correctly installed in the gun body, with
the gun body rib between the mating grooves on the power supply.
Press on the end of the power supply to ensure that the contact in the
end is seated against the contact tip in the gun body.
Align Ribs and Grooves
Figure 11 Power Supply Installation
7. See Figure 5. Make sure the O-ring is installed on the inlet tube (23).
Install the elbow (13) onto the end of the inlet tube.
8. See Figure 12. Position the lower edge of the bulkhead cover (8)
behind the handle screw boss, then rotate the top of the cover forward
until it snaps into place on the handle.

Encore Manual Spray Gun - Trigger Switch Replacement
6
Part 1096694A E2009 Nordson Corporation
9. Feed the power supply connector through the top opening in the
bulkhead cover (8).
10. Route the trigger switch header and gun cable connectors through the
bottom opening in the bulkhead cover.
11. Connect the gun cable J2 connector to the power supply J2 connector.
8Screw Boss Trigger
Switch Gun Cable
J3 Display
Connector
Power
Supply
J2 Connector
Gun Cable
J2 Power
Connector
Figure 12 Handle Assembly Steps 8-10
12. See Figure 13. Make sure the outlet powder tube (14) is installed in the
gun body. Align the gun body with the handle and slide them together,
engaging the internal ribs of the gun body with the tabs in the handle.
13. Install the M5 x 10 flat head nylon screw (24) into the gun body to
secure it to the handle.
14
13
Internal Ribs
Handle Tabs
24
Figure 13 Gun Body and Handle Assembly

Encore Manual Spray Gun - Trigger Switch Replacement 7
Part 1096694A
E2009 Nordson Corporation
14. With your finger or a wooden dowel, align the inside end of the outlet
powder tube (14) with the elbow (13) then push on the tube to seat it in
the elbow.
15. See Figure 14. Install the display module as follows:
a. Make sure the display module switch mounting surface is clean and
dry. Clean old adhesive off with isopropyl alcohol and dry before
connecting the new switch.
b. Remove the two adhesive liners from the connector side of the
trigger switch header.
c. Align the trigger switch header with the display module receptacle
and push on the header to connect it. Apply even pressure on the
header to seal it tightly against the display module.
d. Remove the liner from the new adhesive support pad and install it
over the trigger switch header. Apply even pressure on the support
pad to secure and seal it to the display module.
e. Connect the display module and gun cable J3 connectors together.
f. Gently fold the trigger switch ribbon cable and display module cable
into the gun, and install the display module onto the gun.
g. Secure the module with the bottom (M3 x 20) screw (12).
h. Slide the hook (10) onto the display module and secure it with the
top (M3 x 30) screw (11).
11
12
9
10
Adhesive
Support Pad J3
Switch
Header
Adhesive
Liners
Figure 14 Display Module Installation

Encore Manual Spray Gun - Trigger Switch Replacement
8
Part 1096694A E2009 Nordson Corporation
16. Install the electrode assembly, nozzle, and nozzle nut.
17. Connect the purge air tubing, air wash tubing, and powder feed hose
adapter and hose to the gun.
18. Connect the gun cable to the controller interface module.
19. Turn on the interface and check the gun functions.
Trigger Switch Kit
Part Description Note
1096671 KIT, trigger switch, Encore A
NOTE A: Kit includes new adhesive support pad.
Issued 6/09
Original copyright date 2009. Encore, Nordson, and the Nordson logo are registered trademarks of Nordson Corporation.