12 --- Some Common Electrical Problems. This Section Applies to Custom 18/30,
Custom 30/30, Super 30/30, Custom 30/40-Mechanical, and Super 30/40-Mechanical Machines. Does Not Apply to Hydraulic Machines Super 30/40HD and Super 36/75.
Trouble-Shooters need to Understand that SAF's were made for over 40 Years with
Many Variations in Electrical Wiring, Electrical Components, and Mechanical
Components. You need to Understand how it Works & a Maintenance Manual with
Electrical Schematic to do any Trouble-Shooting. Manual has Trouble-Charts & Theory.
As a Rule, an Electrical Device Fails in 1 of 2 Ways;
--- It "Shorts" or "Short-Circuit" meaning Very-Low or No-Resistance.
--- It "Opens" or "Open-Circuit" meaning Very-High or Infinite-Resistance.
--- Or It is Broken or Misadjusted or Miss-Wired or is Wrong Repacement Part.
12A --- Fuse Blows when you Try to Punch in Single or Nibble Mode. Caused by Shorted Punch Solenoid Coil or wiring, Normal Coil Resistance is about 15 Ohms.
12B --- No Punch in Single or Nibble Mode.
--- Caused by Open Punch Solenoid Coil, Normal Coil Resistance is about 15 Ohms.
--- Caused by Broken-Wire "Open" going to the Punch-Piston & Solenoid Coil.
--- Caused by Tool Handle Lock-Switch or Lock-Switch Wiring being Broken or Open.
--- Caused by Broken or Open Switch in Footswitch or Wiring to switch.
12C --- Machine Will Punch with Tool Handle Open and NOT Locked-In.
--- Caused by Tool Handle Lock-Switch being Shorted or By-Passed.
12D --- Punches OK in Nibble, but Blows Fuse 4FU and won't Punch in Single Mode.
--- Caused by Control Relay CR1 Coil Short, Normal Resistance about 250 Ohms.
--- Caused by Shorted-Wiring To or From Single Switch, 1LS, 2CR, 1CR Coil.
12E --- Punches OK in Nibble, No Punch in Single. Some Causes;
--- Limit Switch LS1 Open. LS1 is Normally-Open & Closes when Activated!
--- Limit Switch LS2 Open. LS2 is Normally-Closed & Opens when Activated!
--- LS3 Switch Shorted, Normally-Closed But Held-Open Contacts Shorted-Closed
--- Control Relay CR1 Failed or Coil Open, Coil About a Couple Hundred Ohms.
--- LS1 or LS2 Wired Wrong. LS1 is Normally-Open, LS2 is Normally-Closed
on most Later Machines, but Normally-Open on VERY EARLY 1960's Machines
which also did Not have LS3 Double-Punch Prevent Switch!
--- Wrong Switches used, Switches Miss-Wired, or Switches Misadjusted.
12F --- Varying Short to Normal Stroke in Single, Normal Operation in Nibble.
--- Limit Switch LS1 Short. LS1 is Normally-Open & Closes when Activated!
--- Oil Level Improperly Set WITHOUT using Correct Dipstick & Setting-Procedure
--- Too-Thick Oil in Punch-Head as Too-Thick Oil does NOT flow Back & Forth
Fast enough through the Bottom of Piston when Valve is Open.
12G --- Starts Nibbling when Punch in Single Mode, must Turn-Off Machine to Stop.
--- Limit Switch LS2 Short. LS2 is Normally-Closed & Opens when Activated!
12H --- Fuse 4FU Blows as Punch Ram starts to move down in Single or Nibble.
--- Caused by Burned-Out & Shorted Solenoid Coil, or Wiring to Solenoid Coil
--- Caused by Control Relay CR2 Coil Short, Normal Resistance About 2000 Ohms
12i --- Machine continues to Punch in Single as long as Foot Petal is Depressed.
--- LS3 Switch Shorted, Normally-Closed But Held-Open Contacts Shorted-Open
--- Caused by Control Relay CR2 Open, Normal Resistance is About 2000 Ohms.
12J --- No Punch in Single, but Nibble Punches Without Depressing Footswitch.
--- Limit Switch LS3 Short. Note! Early Machines do Not have this LS3 Switch
which was Added to Eliminate Possibility of Double Punching in Singe-Punch Mode.
12K --- Constant Nibble Punching in Single Mode, Normal Operation in Nibble Mode.
--- Caused by Limit Switch LS3 Open.
12L --- 1 Punch at Power-On in Single or Punching in Nibble
without depressing Footswitch. --- Caused by Shorted Footswitch or Wiring
12M --- 3-Phase Power Fuses Blow. Caused by;
--- Wrong A.C. voltage to machine or motor & transformer not wired to correct voltage
--- Bad (Shorted) Press-Drive Motor
--- Stalled Motor from Bad Crankshaft Bearings or from Old Hardened Grease
--- Shorted / Melted Step-Down Transformer. Caused by Wrong A.C. Voltage to
Machine or Big-Loads Plugged-In to 120 VAC Machine Power Socket, like a
Cooling Fan. This Power-Socket was made ONLY for a 60 Watt Work-Light!
Note! Very Early 1960's Machines WITHOUT FRONT--LS3 Switch had LS2 Switch on
Right-Flywheel wired Normally-OPEN. Later Machines had Wiring Changed with
Front-LS3 Switch ADDED and LS2 Switch on Right-Flywheel wired Normally-CLOSED.
LS1 Switch on Left Flywheel has Always been wired Normally-OPEN.