Mechanical Systems > Pneumatic Troubleshooting

Pneumatic Troubleshooting

Course Number: 740

The Pneumatic Troubleshooting textbook is the second of a pair on pneumatics, following the 739 textbook on Basic Pneumatics. After an overview and a chapter on using pneumatic diagrams to understand a system, the textbook describes the installation of components and the maintenance of the system. The chapters that follow describe troubleshooting for all the major components of a typical pneumatic system. The final chapter deals with systems that use a combination of pneumatics and hydraulics.

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This textbook has been recently updated
to include topics lists, objectives, & key terms for every chapter.

Recommended Contact Hours – 15

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Table of Contents

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.

Add Chapters to Your Custom Book

Select Chapter(s):

  •    Chapter 1: Pneumatic Systems
  •    Chapter 2: Pneumatic Diagrams
  •    Chapter 3: Installing Pneumatic Components
  •    Chapter 4: System Maintenance
  •    Chapter 5: System Troubleshooting
  •    Chapter 6: Compressor Troubleshooting
  •    Chapter 7: Valve Troubleshooting
  •    Chapter 8: Cylinder Troubleshooting
  •    Chapter 9: Motor Troubleshooting
  •    Chapter 10: Pneumatic/Hydraulic Systems

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