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
– 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.
