Series 300: Mechanical Systems
Course 310: Pneumatic Troubleshooting
Covers pneumatic systems, schematic symbols and diagrams, installing system components, planned maintenance, system diagnosis, and troubleshooting. Includes maintenance of air compressors, control valves, air motors, electrical components, and hybrid systems.
TPC Training Systems is authorized by IACET to offer 1.0 CEUs for this program.
Lesson 1 - Pneumatic Systems
Air supply system; Reciprocating and rotary compressors; Cooling; Compressor maintenance; Air-line filters and lubrication
- 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
Schematic symbol construction; Diagramming an air supply; Simple pneumatic systems; Timing and safety circuits; System schematics
- 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
Compressor intakes and foundations; Aftercoolers; Receivers; Dryers; Pipe installation and support; Tubing and hose fittings; System installation
- 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
Control system maintenance; Cylinder maintenance; Tool maintenance; Logs and records; Automatic recorders and recording charts
- 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
Locating troubles; Operations manual; Checking the air supply; Troubleshooting valves and actuators; Interlocks; Final adjustments
- 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
Compressor cooling, lubrication, and valves; Crankcase ventilation; Piston rings; Bearings; Control systems; Troubleshooting
- 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
Checking manual overrides, circuit sequence, and solenoids; Improper sequence and valve shifting; Control timing; Lubrication problems
- 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
Cylinder construction; Checking for correct size, clogged filters, frozen air lines, and cylinder misalignment; Worn packings and seals; Controls
- 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
Checking for sufficient air; Contamination; Lubrication; Air motor abuse; Hose and clamp maintenance; Vane and piston motors
- 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
Air-oil tanks; Pressure boosters; Hydraulic control; Pneumatic cushioning; System interlock; Pneumatic servos; Troubleshooting
- 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.