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Pneumatic Systems Maintenance

Course Number: 740

This course is the second of a pair on pneumatics, following Course 739, Pneumatic Equipment. After an overview and a lesson on using pneumatic diagrams to understand a system, the course describes the installation of components and the maintenance of the system. The lessons that follow describe troubleshooting for all the major components of a typical pneumatic system. The final lesson deals with systems that use a combination of pneumatics and hydraulics.

Chapter 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.

Chapter 2: Pneumatic 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.

Chapter 3: Installing Pneumatic 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.

Chapter 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.

Chapter 5: System Troubleshooting

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.

Chapter 6: Compressor Troubleshooting

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.

Chapter 7: Valve Troubleshooting

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.

Chapter 8: Cylinder Troubleshooting

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.

Chapter 9: Motor Troubleshooting

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.

Chapter 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.