EQUIPMENT FOR ENGINEERING EDUCATION

EQUIPMENT FOR ENGINEERING EDUCATION

Eq

me
uip

ASSEMBLY PROJECTS MAINTENANCE

nt

g
erin
ine
g
n
E
on
for
cati
Edu

our ge
t
a
k
loo
ran
a
t
c
e
u
v
d
Ha
te pro embly
e
l
p
com g to Ass
ce
n
a
n
n
e
i
t
relat ts Main .
e
c
Proje much mor
onics
r
t
...and
a
h
Mec
e
h
t
r
Ask fo ue.
g
catalo

inin
al Tra

IC
N
O
R
T
ECHA
n

iscipli

Interd

chnic
ary Te

rs

ginee

s En
tronic

echa

orking

Metalw

s
Trade

M
rades
ical T

tr

Elec

You educate apprentice tradesmen in technical

schools and factories...
...we offer you practice-oriented teaching
and training systems for your education relating to

Engineering Drawing

Basic principles

Cutaway Models
Dimensional Metrology
Fasteners and Machine Parts
Manufacturing Engineering

More detailed learning content

GUNT-CATALOGUE No. 2, MECHATRONICS, COVERS THE FOLLOWING PROGRAM GROUPS

Assembly Projects
Maintenance
Machinery Diagnosis

Assembly

Automation

PLANNING & CONSULTING TECHNICAL SERVICE COMMISSIONING & TRAINING

G.U.N.T. Gertebau GmbH

Fahrenberg 14
D-22885 Barsbttel GERMANY

phone: +49 40 67 08 54 - 0
fax: +49 40 67 08 54 - 42

Maintenance

web: www.gunt.de
e-mail: sales@gunt.de

Use the
CD catalogue!

Visit
our website
www.gunt.de

INDUSTRIAL TRAINING AND VOCATIONAL QUALIFICATION

Repair

ASSEMBLY PROJECTS MAINTENANCE

Maintenance is a Key Area in Apprentice Training

A Selection of Assembly Exercises

Plant and machinery

should be operational

ch
is mu
e
r
e
h
...t
NT.
at GU ing
e
r
o
m
ow
e foll ow
h
t
n
O
we sh
d
pages e detaile
m
o
you s es.
pl
exam

Therefore maintenance is an
essential part of production
and machine management.
not sitting idle

You must have:

MT 152

MT 154

GL 430

Strategies and methods

in place
Qualified and trained staff
GUNT supports you with
our proven teaching systems
regarding Assembly Projects
and Maintenance. Our service
will help you to make the
education of your staff much
more practice-oriented.

MT 156

MT 157

MT 158

This is hands-on tuition in

practice.

MT 140.02

MT 140.01

MT 180

MT 183

MT 110.02

MT 181

MT 184

MT 182

MT 185

ASSEMBLY PROJECTS MAINTENANCE

Learning Concepts Relating to Industrial Maintenance

The maintenance

What is maintenance?

of industrial plant and machinery is a key field of activity for technicians and skilled tradesmen working in mechanical
and electrical engineering.

Maintenance as defined by German

industry standard DIN 31051 is a
complex field, so the range of teaching
and training systems we offer in this
area is very diverse.

Key area in technical training

MAINTENANCE TO DIN 31051

Maintenance

Inspection

Repair

Maintaining the
required condition

Recording and
assessing the actual
condition

Restoring the
required condition

Cleaning, lubricating,
adjusting

Measuring, testing,
diagnosing

Replacing,
correcting

With the plant shut down

only, and in accordance
with the maintenance
instructions

With the plant running

and shut down, in
accordance with
inspection instructions

With the plant shut

down only, based on
work order and after
thorough preparation

The level of attention devoted to the subject of maintenance by the curricula is therefore high.

TEACHING AND LEARNING SYSTEMS RELATING TO MAINTENANCE

GUNT-Gertebau GmbH offers you a wide range of wholly practice-oriented teaching and training systems
relating to technical maintenance with which you can cover essential learning content:

Use of specific manufacturers documentation for

maintenance, inspection and repair

Planning and assessing maintenance sequences

and steps

Reading and understanding engineering drawings

Practical execution and documentation of

maintenance operations

Familiarisation with machine and system components

Testing and commissioning of repaired systems

Understanding maintenance as the interaction between

inspection, maintenance and repair

Assessment of malfunctions, detection of faults

The GUNT training systems are ideally suitable for students group working, and of course for project-oriented
working methods.

This theme should be read

in close conjunction with the
GUNT catalogue no. 2

LEARNING THROUGH PRACTICE...

This chapter deals with the process
of familiarisation with component
and their functions, reading and
understanding
engineering
drawings or operating instructions,
and familiarisation with technical
terminology
and
language.
The assembly exercises can
be conducted in relatively short
periods of time (within lesson
units) and do not as yet require any
particular technical experience.
Fault diagnosis and maintenance
measures are not yet central to the
training systems.

ASSEMBLY
PROJECTS

MACHINERY
DIAGNOSIS

MAINTENANCE

The real, industrial

nature of the exercises is higher
than in the Assembly Projects.
Typical maintenance methods and
testing procedures are offered
as learning content. Some of the
exercises take a lot of time to
complete and amount to substantial project work. Demands are
made on technical skills.

The teaching systems

familiarise trainees with the
specific methods of monitoring
plant /machinery condition, such
as the early detection of bearing
or gear damage. We work
primarily with vibration analysis
methods
which
constitute
diagnostic steps for preventive
maintenance or targeted repair.

... SO THE THEORY IS EASY !

Things dont have to get this bad

Its possible to do something in time

ASSEMBLY PROJECTS MAINTENANCE

Coverage of the
fundamentals:
An Assembly Kit for
introducing a course

TZ 200.71 Lever Shears Assembly Kit

MT 158 Assembly Exercise: Ball Valve and Shut-off Valve

Two different valves and
fittings in one assembly kit.

Blades

Parts are clearly and

perfectly arranged.

M
Main
body
function group
fu
Sh
Shear
body
function group
fu

Workpiece

St
Stop function
gr
group

Operating
principle of lever
shears

The assembly kit

Lever shears function groups

Interdisciplinary teaching
possibilities.
Learning in a small
team is an effective learning
format.
Excellent instructional
materials, including a CD,
for printing and presentation.

spindle

Function group

Partial function

Movement

Main body

Carries, supports and

guides all other parts

None

Stop

Sets the length to be

cut off

None

Shear body

Transmits the shearing

force to the workpiece

Rotary & linear

motion

Learning Objectives / Experiments

23
2
17

8
18

11
17

Assembly step 1 (Main body) Parts required for assembly

Pos.

Name

Pos.

Name

Main body

17

Cheese head screw

Bearing flange

18

Cheese head screw

Lower blade

23

Paralell pin

11

Base plate

Introduction to technical drawing:

reading and understanding technical
drawings
three-plane views
sectional views
drawing types
3D views
parts lists
dimensioning
surface finish and tolerance specifications
differentiation between standard and
production parts
material specifications

sealing body

Exercises can be conducted

in a classroom no workshop
environment necessary.

seating ring
valve box

Assembly exercises can be

conducted in relatively short
periods of time (within lesson
units).
Comprehensive and wellstructured instructional
material will impress you.

Grinding of the seat

of a flatseat valve

Learning Objectives / Experiments

Design and function of a ball valve
Design and function of a valve
Assembly and disassembly, including for
the purposes of maintenance and repair
Replacing components (e.g. seal)

Planning and execution of simple

assembly operations:
planning and describing work sequences
assessing results

Comparison of 2 different valves and

fittings
Reading and understanding engineering
drawings and operating instructions

Measurement exercises:
length measurements
angle measurements

Leak testing (together with hydraulic

valves and fittings test stand MT 162)

Manufacturing methods:
operational examples of handmade production and production on machine tools
Replacement parts available according to part lists and drawings

ASSEMBLY PROJECTS MAINTENANCE

MT 186 Assembly & Maintenance Exercise: Gear Pump

Installing the driven shaft

Mounting the wearing discs

MT 140.02 Assembly Exercise: Piston Compressor

Students studying the assembly

Crankcase, crankshaft, oil distribution ring

The classic
assembly project

1
5
4

Learning Objectives / Experiments

13

Design and function of a compressor

21

Reading and understanding engineering

drawings

20
22

Familiarisation with components and

assemblies, their design features and
functions

Components included in the assembly kit

Learning Objectives / Experiments

Dimensioning exercises, gauging of parts

Design and function of a gear pump

and its components

Work planning, particularly planning

and presentation of the assembly process

Assembly and disassembly for

maintenance and repair purposes

Familiarisation with assembly aids

and jigs

Replacing components (e. g. seals)

Assembly exercises: component and

complete unit assembly

Troubleshooting, fault assessment

Analysis of faults and damage, in

conjunction with maintenance and
repair steps

Planning and assessment of

maintenance and repair operations
Reading and understanding
engineering drawings and operating
instructions

Material selection criteria

An assembled compressor, to the right individual
parts, exploded view in the background

In conjunction with MT 140.01:

Functional testing of the assembled
compressor

ASSEMBLY PROJECTS MAINTENANCE

MT 110.02 Assembly Exercise: Spur Wheel / Worm Gear Mechanism

MT 190 Assembly Project: Materials Tester

Build your own
materials tester

A totaly hands-on
Assembly Exercise
An example of
assembly section

This is the assembly kit...

Practical exercise assembling

a modern industrial gear unit,
using simple tools and jigs
Broad scope of learning
presenting interdisciplinary
problems
Comprehensive and
well-structured instructional
material

Learning Objectives / Experiments

Learning Objectives / Experiments

Design and function of a multistage

gear combination

Reading and understanding

technical documentation

Reading and understanding engineering

drawings

Planning and execution of

assembly operations and
sequences

Familiarisation with component and

assemblies, their design features
and functions

Familiarisation with machine

elements and components

Dimensioning exercises, gauging of parts

Commissioning and checking of a

materials tester following assembly

Work planning, particularly planning

and presentation of the assembly
process

Planning, execution and

assessment of maintenance
operations

Familiarisation with assembly aids

and jigs

Fault analysis: Troubleshooting,

fault assessment and repair

Assembly exercises: component and

complete unit assembly

After assembly:

Analysis of faults and damage, in

conjunction with maintenance and
repair steps

Tensile test of metallic specimens

Material selection criteria

Brinell hardness test

Recording of stress-elongation
diagrams

In conjunction with MT 172:

Left hand: single parts of the gear
Right hand: fully assembled multistage gear

Functional testing of the assembled

gear unit

...and this is the result

11

ASSEMBLY PROJECTS MAINTENANCE

MT 210 Assembly & Maintenance Exercise: Refrigeration

10
11
12
13

14

15

1
2
3
4
5
6
7
8

5
4
3
2
1

9
10
11
12
13
14
15

HL 960 Assembly Station: Pipes and Valves and Fittings

Fully hermetic compressor

Filter dryer
Sight glass with humidity indicator
Delivery side manometer
HP (high-pressure) pressure switch
LP (low-pressure) pressure switch
Intake side manometer
Cooling chamber with evaporator
and fan 2
Thermostat
Expansion valve
Assembly panel
Solenoid valve
Condenser with fan 1
Service valves
Electrical switch box

Practically oriented
assembly of piping and
system installations

Maintenance
Repair
...it is difficult to
imagine a more hands-on
training system

Fully assembled MT 210 unit

Learning Objectives / Experiments

Reading and understanding technical
documentation

Service technician at work

Planning and execution of assembly

operations and sequences
HL 960

ASSEMBLY STA

TION PIPES

ASSEMBLY STA

nections and

AND FIT

Sub-section

Germany 06/20
07

30

27

-section A

07
Germany 06/20

4
3
2

All Rights Rese

rved G.U.N
.T. Gertebau

GmbH, Barsb
ttel,

GmbH, Barsb
ttel,

rved G.U.N
.T. Gertebau
All Rights Rese

3
5

A flang
ge con

nection in our

E
Item

32

Quantity

2
3
4

Planning, execution and assessment of

maintenance operations
Evacuation and filling of refrigeration
units

Design and function of valves and

fittings, piping elements and system
components

seals - Sub

31

Fault analysis: troubleshooting, fault

assessment and repair

In conjunction with ET 150.01:

AND FITTINGS

49

Maintenance, repair,
troubleshooting of
a refrigeration system
...totally practice-oriented

TION PIPES

Flange con

48

Commissioning and checking of a

refrigeration unit following assembly
(in conjunction with ET 150.01)

Leak testing at expansion valve

4.4.2

TINGS
Worksheet
2, Page 4 Solution to
The followin
task 2.3
g connecting
elements are
the complet
required to
e piping sys
assemble the
tem:
sections into
Items:

Electrical installation as per circuit diagram

Familiarisation with the function of

the components of a refrigeration
system and of the complete system

Learning Objectives / Experiments

06/2007

HL 960

06/2007

Making piping connections as per

system diagram

48
Note:

25
35

1
8

piping system

is made up

of the followin

g parts:

Name

Standard /
Catalogue
EN 1092-1

Steel flange
Flat seal

DIN 2690 /

Washer

Hexagon head

Nut

screw

Klingersil

To go beyo
nd assembly
of sections
piping syste
A, B, C, D
m (with flang
and E to crea
e connectio
parts:
te the com
ns), we also
25 - x 1
plete
need the follo
and 48 wing additiona 4 Basic inform
x 2.
ation
l

on pipes an
d

Selection of components and drafting

of requirement lists
Technically correct preparation and
execution of system assembly
Reading and understanding
engineering drawings and technical
documentation

ISO 7090
ISO 4014
ISO 4032

33

Planning of piping and system

installations according to specification,
e. g. a process schematic

control fittin
gs

7 Solutions
18

90

Two examples
T
l ffrom our comprehensive
h
i training documentation

Operational testing of the constructed

systems (in conjunction with suitable
water supply and disposal)

13

ASSEMBLY PROJECTS MAINTENANCE

The Instructional Material will Impress You

Tasks and solutions

Complete set of drawings

06/2007

HL 960

MT 182

Worksheet

ASSEMBLY
AND MAINT

ENANCE EXER

06/2007

PUMP

Worksheet

ATION PIPES

2, Page 4 -

AND FITTINGS

Solution to
The following
task 2.3
connecting
elements are
the complet
required to
e piping sys
assemble the
tem:
sections into
Items:

9, page 4
Procedure
for assemblin
g the screw
pump

Germany 06/2
007

ASSEMBLY ST
Worksheet

4.5

CISE: SCREW

Pump housing
(1)

48

All rights rese

rved, G.U.N.T
.

All Rights Res

erved G.U
.N.T. Gerteb
au

31

Valve piston
and
valve spring
(8, 17)

erved G.U
.N.T. Gerteb
au GmbH,

49

Solution to

AND FITTINGS

task 4.5

Explain the
standard de
signation
fitting: Shutof the follow
off valve DN
ing control
15 / PN16

V lve DIN 33
Va

56 - 15 PN16

- 2 A 02 A

Cast iron typ

e: EN-GJL250
(lamellar gra
phite cast iro
n)

Set screw
(6)

Design an
d features
based on
type code 02
Direct flow
type, straig
ht upper
section and
flange conne
ction
Cast iron

All Rights Res

27

Gertebau,
Barsbttel,
Germany 11/2
008

GmbH, Bars
bttel, German
y 06/2007

30

4, Page 4 -

Barsbttel,

HL 960

ASSEMBLY ST

ATION PIPES

11/2008

Valve cover
(7)

Nominal pre

ssure

Nominal dia

O-ring
(19)

meter

DIN no. for

Sealing ring
(15)

shut-off val

ves

Name

E
32

Safety was
(16)

her

Seal
(11)

7 Sol
olu
utio
tion
nss

33

To go beyond
assembly of
sections A,
piping system
7 Solutions
B, C, D and
(with flange
E to create
connection
parts:
the comple
s), we also
25 - x 1
te
need the follo
and 48 wing addition
x 2.
al
136

The core of the teaching

material is a complete set of
drawings conforming to
standards. In addition to the
assembly drawing with
parts list, you will find all
manufacturing drawings of
the individual parts.
So you are able to produce
your own parts, or have them
manufactured for you.

Of course there is a
recommended solution for
every exercise.

10/2008

MT 184

ASSEMBLY

10/2008

The complete material on CD (PDF)

MT 184

HL 960
4.4.2

The complete instructional material is

delivered in hardcopy form in a clearly
arranged folder.

2.4.4

ASSEMBLY STA

TION PIPES

Flange conn

ections and

AND FITTINGS
-section A

NANCE EXERCIS

E: PISTON PUM

ttel, Germa

Fig. 2.26

Series config

uration

The pump
industry has
made use
number of
o designs
of these prop
accordingly.
erties and
developed
Multi-flow
a
pumps achi
eve high deliv
high heads.
ery rates, mult
i-stage pum
ps achieve

A flange conn

ection in our

Item

Quantity

3
4
5

piping syste

m is made

Flat seal

Hexagon head
Nut

Fig. 2.1

Catalogue

DIN 2690 /
screw

Klingersil

Fig. 2.27

ISO 7090
ISO 4014

Mult
Multi-flow pump
, sectional
view and delive
ry principle

ISO 4032
2 Technolo

4 Basic info
rmation on
pipes and c
o

Oscillating
Self-priming
(Displac
lacement
device m
moves
back an
and forth
along an axis)

EN 1092-1

Washer

4
4

Positive-displac
ement
pumps
(Medium conve
yed by
displaceme
nt device)

wing parts:

Standard /

Steel flange

Machines
(Machine drive
sa
flowing medi
um)
Pumps

Piston pump
pu s
Diaphragm
pumps

up of the follo

Name

gical princip
le

Fig. 2.28

Multiple-sta
ge pump, sectio
nal
view and delive
ry principle

Fluid-flow mach
ines

Gertebau,
Barsb

uration

All rights reserv

Parallel config

E: PISTON PUM

d on operating
Pumps are
P
fluid-flow mac
hines which
to say, they
dictate how
ensure that
processes
flow takes plac
operate - that
e within syste
In practice,
is
pumps are
ms.
often named
purpose, such
pur
after the liquid
as
they pump
fitters can more milk pumps or cooling
fitte
or their
pumps. How
easily identify
ever, technicia
to th
their design
their operating
ns and
when they
principle.
are named
according

ed, G.U.N.T.

Fig. 2.25

3
2

NANCE EXERCIS

p types base

AND MAINTE

C
Classification
and categori
principle
p
sation of pum

ny 10/2008

Sub-section

2.1

AND MAINTE

Operating
characteristi
cs of multiple
interacting
Operation of
pumps
multiple pum
ps simultane
and in man
ously in a
y cases esse
system is quite
ntial in orde
fications
i
r to conform
.
common,
to extreme
operating spec
If mult
mu iple pum
ips are conf
igured in para
pumps
p are conf
llel, the deliv
igured in serie
ery rate is incre
are adde
s (one behi
ad d toge
ased. If
nd the othe
ther.
r), the deliv
ery heads

seals - Sub

Gertebau,
Barsbttel,
Germany 10/200
8

Additionally you receive the complete

material as PDF-files. It includes all texts,
graphics and drawings. That way you can
conveniently print or present.

ASSEMBLY

06/2007

All rights reserv

ed, G.U.N.T.

90

103

ny 06/2007

7 Solutions

Prepared exercises and

worksheets help to focus on
the learning task so the
students work efficiently.

ttel, Germa

35

GmbH, Barsb

Note:

25

All Rights Reserv

ed G.U.N.T.
Gertebau

48

2 Technolo

gical princip
le

P
Pump types

Centrifugal
pumps
(A gyro cause
s
centrifugal
forces to act
on the medi
um)

Rotating
Self-priming
(Displacem
ent
device rotate
s in
the pump body)

Gear pump
Screw
pumps

Engines
(Flowing medi
um
drives mach
ine)
Turbines

Normally primin
g
(Not carrying
gas,
pumping from
low
level restricted)

Centrifugal
pumps
Multi-stage
centrifugal
pumps
Inline pump
s

Self-priming
(Carrying gas,
pumping from
low
level possible)

Fundamental principles
presented in detail
The basic principles and technical descriptions are professionally illustrated with lots
of graphics, photos and clear text.
The pages are suitable for printing out or
using with a video projector.

Side-channel
pumps

s of pumps
4

s of pumps
20

ntrol fittings
18

15