A common cause of flipper solenoid burn-out is the mushrooming of the
solenoid plunger against the coil stop causing an excess amount of friction
that fails to allow a full stroke. This eventually will keep the high
current winding active because the end of stroke switch won't be fully
exercised. As noted in another tip, if the plunger is mushroomed or has a
flat end, it is necessary to bevel the plunger using a file or grinder. But,
remember, if one plunger has had enough play to mushroom then the chances
are that the rest of the high-powered solenoids are also in need of beveling
to prevent solenoid burn-out.
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