Troubleshooting & Maintenance in Pneumatics

Troubleshooting & Maintenance in Pneumatics

This course is designed as an introduction to fault-finding and maintenance in pneumatic and electropneumatic systems, and how to avoid common mistakes and inefficiencies. It provides a comprehensive overview including the identification of components, reading and understanding pneumatic/electropneumatic circuits and systematically identifying faults. The content will improve your approach to maintenance and efficiently dealing with breakdowns.

Practical sessions provide you with the opportunity to put theory into practice. Simulating common problems helps you understand the reasons behind, and consequences of, real-life situations. Our aim is to ensure an effective transfer of learning to obtain the skills needed.

Target Group
All personnel involved with the maintenance, production, design, installation, operation and servicing of industrial pneumatic equipment and control systems.


  • Systematic fault-finding diagnosis and remedy.
  • Compressed air preparation and maintenance.
  • Air service units and maintenance.
  • Poor air preparation, condensation, blocked filters and consequences.
  • Correct use of valves, cylinders.
  • Identifying components on the machine and in circuit diagrams.
  • Reading circuit diagrams efficiently for effective trouble-shooting.
  • Faults in pneumatic circuits with PLCs in the system.
  • Intermittent pressure drops, reasons and consequences.
  • Relationship between force & pressure, correct use of regulators.
  • Relationship between speed and flow, correct use of one-way flow
    control valves.
  • Stopping cylinders in mid-position and issues.
  • Sensors and correct adjustments.
  • Sequence analysis and fault finding with PLC.
  • Vacuum generators and performance.
  • What causes vacuum pressure drop?
  • Faults on vacuum systems, reasons and consequences.
  • Safe working practice.
  • Common mistakes, reasons and remedies.


Fundamentals of pneumatics

Training Outcomes

  1. Follow a logical approach to fault finding
    Enables participants to establish the root cause of the problem quickly and avoid costly downtime.

  2. Eliminate unnecessary checks and replacement of parts
    Establishes the root cause quickly and avoids unnecessary component replacement costs.

  3. Reduce mean time to repair
    Be able to fix faults faster, get machines up and running quicker, therefore reducing downtime.

  4. Interpret pneumatic / electro-pneumatic circuit diagrams, chase faults more efficiently
    Understand the importance of using a circuit diagram as an aid to fault-finding.

  5. Maintain pneumatics systems in good condition
    Conduct proactive maintenance tasks to extend mean time between failures.

  6. Approach breakdowns systematically to find the root cause of the problem
    Enables the engineer to find the cause of the failure and prevent reoccurrence.

  7. Understand component functionality to establish if components are faulty or not.
    Avoids the unnecessary swap-out of healthy components during breakdown scenarios.

  8. Make correct adjustments to optimise system performance
    Improves output quality, efficiency and lifetime of the machine.

  9. Understand the relationship between pressure and flow
    Solve machine performance issues, what to check and adjust, in order to maximise efficiency and productivity.

  10. Deal with intermittent pressure drops/fluctuations
    Understand how the distribution of air can affect the performance of production lines/machines and how to check for this.

  11. Explain common mistakes/faults and the causes/consequences
    Enables the sharing of good practice within the production team to reduce common issues.

  12. Understand the importance of safe practices
    Identify potential hazards and perform safe practice during the fault-finding proceedures.

N.B Course contents are only a guide and will be covered as far as time permits.

Courses take place over two days and are available in-house or at one of our national training centres. Practical exercises are used throughout the whole course.

To discuss this seminar in more detail please contact us on on 01604 667068 or alternatively, e-mail







On request Northampton
  650,00 GBP Add selected date to your order basket



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01604 667068

World Skills