Pneumatic Troubleshooting

Lesson 1 - Pneumatic Systems

Topics:

Air supply system; Reciprocating and rotary compressors; Cooling; Compressor maintenance; Air-line filters and lubrication

Learning Objectives:

– Explain the operation of linear actuators-cylinders-in a typical pneumatic circuit.
– Describe the various types of compressors and how they work.
– Define intercooling and aftercooling.
– Describe basic preventive maintenance procedures for compressors.
– List the components of an effective delivered-air system and explain how they work together.
– Describe the three main types of air-line lubrication.

Lesson 2 - Pneumatic Schematic Diagrams

Topics:

Schematic symbol construction; Diagramming an air supply; Simple pneumatic systems; Timing and safety circuits; System schematics

Learning Objectives:

– Explain the different types of symbols used in pneumatic schematic diagrams-how they are constructed and what they show.
– Describe the operation of timing and safety circuits.
– Analyze the schematic diagram of a fluid-power system.

Lesson 3 - Installation of System Components

Topics:

Compressor intakes and foundations; Aftercoolers; Receivers; Dryers; Pipe installation and support; Tubing and hose fittings; System installation

Learning Objectives:

– Describe the proper installation of the compressor and its auxiliaries.
– Describe the installation of aftercoolers, receivers, and dryers.
– Explain the correct procedures for installing pipes, tubes, and hoses in pneumatic systems.
– Describe the installation of control valves, solenoid coils, and cylinders.

Lesson 4 - System Maintenance

Topics:

Control system maintenance; Cylinder maintenance; Tool maintenance; Logs and records; Automatic recorders and recording charts

Learning Objectives:

– Explain the concept of planned maintenance.
– Describe the basic procedures for maintaining the compressor and other important components in a pneumatic system.
– Describe the maintenance of industrial control circuit components.
– Explain the proper maintenance of pneumatic tools.
– Discuss the various types of maintenance logs and explain what kind of information is recorded in each.

Lesson 5 - Determining System Failures

Topics:

Locating troubles; Operations manual; Checking the air supply; Troubleshooting valves and actuators; Interlocks; Final adjustments

Learning Objectives:

– List, in proper sequence, the steps to be taken in troubleshooting a pneumatic system.
– Name and describe the five important parts of every pneumatic system's operations manual.
– Describe procedures for troubleshooting the actuator.
– Explain how to check control valves, sequence valves, and interlocks.

Lesson 6 - Troubleshooting Air Compressors

Topics:

Compressor cooling, lubrication, and valves; Crankcase ventilation; Piston rings; Bearings; Control systems; Troubleshooting

Learning Objectives:

– Describe methods of cooling and lubricating reciprocating compressors.
– Explain the proper maintenance of compressor valves.
– Identify problems associated with the control system of a compressor.
– Describe the basic maintenance requirements of rotary, vane, rotary-screw, and centrifugal compressors.

Lesson 7 - Troubleshooting Control Valves

Topics:

Checking manual overrides, circuit sequence, and solenoids; Improper sequence and valve shifting; Control timing; Lubrication problems

Learning Objectives:

– Outline how to isolate a control malfunction in a pneumatic circuit.
– Explain how to troubleshoot a nonstarting or nonoperating circuit, improper sequencing of the circuit, and miscellaneous problems related to the   equipment.– Describe the proper procedures for checking electric solenoids.– Explain how to check for problems related to valve shifting, control timing, and lubrication.

Lesson 8 - Troubleshooting Cylinders

Topics:

Cylinder construction; Checking for correct size, clogged filters, frozen air lines, and cylinder misalignment; Worn packings and seals; Controls

Learning Objectives:

– Define the different types of pneumatic cylinders.
– Describe the construction of a typical cylinder.
– Describe the proper procedures for troubleshooting cylinders, including checking for misalignment, worn packings, and adequate air pressure.
– Explain general installation techniques for cylinders and accessories.

Lesson 9 - Troubleshooting Air Motors

Topics:

Checking for sufficient air; Contamination; Lubrication; Air motor abuse; Hose and clamp maintenance; Vane and piston motors

Learning Objectives:

– Explain how to check for sufficient clean air when troubleshooting an inoperative air motor.
– Explain how to keep hoses, clamps, and couplings in good condition.
– Describe the operation and maintenance of vane, radial piston, and axial-piston air motors.

Lesson 10 - Pneumatic/Hydraulic Systems

Topics:

Air-oil tanks; Pressure boosters; Hydraulic control; Pneumatic cushioning; System interlock; Pneumatic servos; Troubleshooting

Learning Objectives:

– Explain why and how compressed air and hydraulic pressure are combined.
– Describe the role of boosters in pneumatic/hydraulic systems.
– Explain how single-pressure and dual-pressure booster systems work.
– Describe the advantages and disadvantages of combined air-oil cylinders.
– Explain how pneumatic and hydraulic actions can be interlocked.
– Discuss the proper troubleshooting procedures for air-oil systems.