EQUIPMENT FOR ENGINEERING EDUCATION EQUIPMENT FOR ENGINEERING EDUCATION

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ASSEMBLY PROJECTS – MAINTENANCE
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GUNT-CATALOGUE No. 2, “MECHATRONICS“, COVERS THE FOLLOWING PROGRAM GROUPS schools and factories...
...we offer you practice-oriented teaching
More detailed learning content

Engineering Drawing Assembly Projects

Cutaway Models and training systems for your education relating to
Maintenance
Basic principles

Dimensional Metrology
Machinery Diagnosis
Fasteners and Machine Parts Assembly Maintenance Repair
Manufacturing Engineering Automation

PLANNING & CONSULTING · TECHNICAL SERVICE · COMMISSIONING & TRAINING INDUSTRIAL TRAINING AND VOCATIONAL QUALIFICATION
G.U.N.T. Gerätebau GmbH
Fahrenberg 14 phone: +49 40 67 08 54 - 0 web: www.gunt.de Use the
CD catalogue!
Visit
our website
D-22885 Barsbüttel · GERMANY fax: +49 40 67 08 54 - 42 e-mail: sales@gunt.de www.gunt.de
ASSEMBLY PROJECTS – MAINTENANCE

Maintenance is a Key Area in Apprentice Training A Selection of Assembly Exercises

Plant and machinery

should be operational… ch
e r e is mu
...t h NT.
Therefore maintenance is an o r e at GU ing
m ow
essential part of production n t h e foll ow
O
we sh d
and machine management. pages e detaile
o m
you s es.
MT 152 MT 154 GL 430 pl
…not sitting idle You must have: exam
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 MT 156 MT 157 MT 158
more practice-oriented.
This is hands-on tuition in
practice.

MT 140.02 MT 140.01 MT 110.02

MT 180 MT 181 MT 182

MT 183 MT 184 MT 185

3
ASSEMBLY PROJECTS – MAINTENANCE

Learning Concepts Relating to Industrial Maintenance

The maintenance What is maintenance? MAINTENANCE TO DIN 31051

of industrial plant and machinery is a key field of activity for technicians and skilled tradesmen working in mechanical ‘Maintenance’ as defined by German
and electrical engineering. industry standard DIN 31051 is a
Maintenance Inspection Repair
complex field, so the range of teaching
Key area in technical training and training systems we offer in this Maintaining the
required condition
Recording and
assessing the actual
Restoring the
required condition
area is very diverse.
The level of attention devoted to the subject of maintenance by the curricula is therefore high. condition
Cleaning, lubricating, Measuring, testing, Replacing,
adjusting diagnosing correcting
TEACHING AND LEARNING SYSTEMS RELATING TO MAINTENANCE

GUNT-Gerätebau GmbH offers you a wide range of wholly practice-oriented teaching and training systems This theme should be read With the plant shut down With the plant running With the plant shut
in close conjunction with the only, and in accordance and shut down, in down only, based on
relating to technical maintenance with which you can cover essential learning content: with the maintenance accordance with work order and after
GUNT catalogue no. 2 instructions inspection instructions thorough preparation

Use of specific manufacturer’s documentation for Planning and assessing maintenance sequences
maintenance, inspection and repair and steps

Reading and understanding engineering drawings Practical execution and documentation of
maintenance operations
This chapter deals with the process
Familiarisation with machine and system components Testing and commissioning of repaired systems
of familiarisation with component
and their functions, reading and
understanding engineering
Understanding maintenance as the interaction between Assessment of malfunctions, detection of faults
drawings or operating instructions,
inspection, maintenance and repair and familiarisation with technical
terminology and language.
The GUNT training systems are ideally suitable for students’ group working, and of course for project-oriented The assembly exercises can
working methods. 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
LEARNING THROUGH PRACTICE...
MACHINERY
DIAGNOSIS
The teaching systems
familiarise trainees with the
MAINTENANCE 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
The real, industrial
diagnostic steps for preventive
nature of the exercises is higher
maintenance or targeted repair.
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 substan-
tial project work. Demands are
made on technical skills.

... SO THE THEORY IS EASY !

Things don’t have to get this bad It’s possible to do something in time

5
ASSEMBLY PROJECTS – MAINTENANCE

Coverage of the
TZ 200.71 Lever Shears Assembly Kit fundamentals: MT 158 Assembly Exercise: Ball Valve and Shut-off Valve
An Assembly Kit for
introducing a course
Two different valves and
fittings in one assembly kit.
Blades Parts are clearly and
M
Main body
function group
fu perfectly arranged.

Sh
Shear body
Workpiece function group
fu

Operating St
Stop function
principle of lever gr
group
shears

The assembly kit

Lever shears function groups
Interdisciplinary teaching spindle
possibilities. Function group Partial function Movement
sealing body
Main body Carries, supports and None Exercises can be conducted
Learning in a small guides all other parts in a classroom – no workshop seating ring
team is an effective learning Stop Sets the length to be None
environment necessary.
format. cut off valve box
Shear body Transmits the shearing Rotary & linear Assembly exercises can be
Excellent instructional force to the workpiece motion conducted in relatively short
materials, including a CD,
periods of time (within lesson
for printing and presentation.
units).
Learning Objectives / Experiments
Comprehensive and well-
Introduction to technical drawing: Grinding of the seat
structured instructional
23 reading and understanding technical of a flatseat valve
material will impress you.
2 drawings
17 three-plane views
sectional views
drawing types
3D views
parts lists Learning Objectives / Experiments
3 dimensioning Design and function of a ball valve
surface finish and tolerance specifications Design and function of a valve
differentiation between standard and
Assembly and disassembly, including for
8 production parts
the purposes of maintenance and repair
18 11 material specifications
Replacing components (e.g. seal)
17 Planning and execution of simple
assembly operations: Comparison of 2 different valves and
planning and describing work sequences fittings
Assembly step 1 (Main body) – Parts required for assembly assessing results Reading and understanding engineering
Measurement exercises: drawings and operating instructions
length measurements Leak testing (together with hydraulic
Pos. Name Pos. Name
angle measurements valves and fittings test stand MT 162)
2 Main body 17 Cheese head screw
3 Bearing flange 18 Cheese head screw Manufacturing methods:
8 Lower blade 23 Paralell pin operational examples of handmade pro-
11 Base plate duction and production on machine tools
Replacement parts available according to part lists and drawings

7
ASSEMBLY PROJECTS – MAINTENANCE
MT 186 Assembly & Maintenance Exercise: Gear Pump
Installing the driven shaft Mounting the wearing discs
2 3
1 assembly project
5
13
21
20
22
Components included in the assembly kit
Learning Objectives / Experiments
Design and function of a gear pump
and its components
Assembly and disassembly for
maintenance and repair purposes
Replacing components (e. g. seals)
Troubleshooting, fault assessment
Planning and assessment of
maintenance and repair operations
Reading and understanding
engineering drawings and operating
instructions
MT 140.02 Assembly Exercise: Piston Compressor
Students studying the assembly
The classic
An assembled compressor, to the right individual
parts, exploded view in the background
Crankcase, crankshaft, oil distribution ring
Learning Objectives / Experiments
Design and function of a compressor
Reading and understanding engineering
drawings
Familiarisation with components and
assemblies, their design features and
functions
Dimensioning exercises, gauging of parts
Work planning, particularly planning
and presentation of the assembly process
Familiarisation with assembly aids
and jigs
Assembly exercises: component and
complete unit assembly
Analysis of faults and damage, in
conjunction with maintenance and
repair steps
Material selection criteria
In conjunction with MT 140.01:
Functional testing of the assembled
compressor
9
ASSEMBLY PROJECTS – MAINTENANCE
MT 110.02 Assembly Exercise: Spur Wheel / Worm Gear Mechanism
A totaly hands-on
Assembly Exercise
An example of
assembly section
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
Design and function of a multistage
gear combination
Reading and understanding engineering
drawings
Familiarisation with component and
assemblies, their design features
and functions
Dimensioning exercises, gauging of parts
Work planning, particularly planning
and presentation of the assembly
process
Familiarisation with assembly aids
and jigs
Assembly exercises: component and
complete unit assembly
Analysis of faults and damage, in
conjunction with maintenance and
repair steps
Material selection criteria
In conjunction with MT 172:
Left hand: single parts of the gear Functional testing of the assembled
Right hand: fully assembled multistage gear gear unit
MT 190 Assembly Project: Materials Tester
Build your own
materials tester
This is the assembly kit...
Learning Objectives / Experiments
Reading and understanding
technical documentation
Planning and execution of
assembly operations and
sequences
Familiarisation with machine
elements and components
Commissioning and checking of a
materials tester following assembly
Planning, execution and
assessment of maintenance
operations
Fault analysis: Troubleshooting,
fault assessment and repair
After assembly:
Tensile test of metallic specimens
Recording of stress-elongation
diagrams
Brinell hardness test
...and this is the result
11
ASSEMBLY PROJECTS – MAINTENANCE

MT 210 Assembly & Maintenance Exercise: Refrigeration HL 960 Assembly Station: Pipes and Valves and Fittings
1 Fully hermetic compressor
10 2 Filter dryer
11 3 Sight glass with humidity indicator
12 4 Delivery side manometer
5 HP (high-pressure) pressure switch Practically oriented
13 8
6 LP (low-pressure) pressure switch assembly of piping and
14 7
7 Intake side manometer system installations
15 6 8 Cooling chamber with evaporator
5 and fan 2
4 9 Thermostat
Maintenance
3 10 Expansion valve Repair
2 11 Assembly panel
12 Solenoid valve
1 ...it is difficult to
13 Condenser with fan 1
imagine a more hands-on
14 Service valves training system
15 Electrical switch box

Fully assembled MT 210 unit

Learning Objectives / Experiments

Reading and understanding technical Service technician at work
documentation
Planning and execution of assembly
operations and sequences
06/2007
06/2007

HL 960
ASSEMBLY STA
Learning Objectives / Experiments
Making piping connections as per HL 960 4.4.2
TION PIPES
AND FITTINGS
ASSEMBLY STA
TION PIPES
AND FIT
Flange con
nections and
seals - Sub
-section “A” Design and function of valves and
system diagram Worksheet
2, Page 4 -
TINGS Sub-section
“A”
The followin
the complet
g connecting
e piping sys
Solution to
elements are
task 2.3
required to
assemble the
fittings, piping elements and system
tem:
Electrical installation as per circuit diagram Items:

48
sections into

components

07
Germany 06/20
30 27
Commissioning and checking of a 49
Planning of piping and system

07
Germany 06/20
A 4
1

refrigeration unit following assembly

üttel,
installations according to specification,

GmbH, Barsb
3

üttel,
(in conjunction with ET 150.01)
GmbH, Barsb
2
e. g. a process schematic

.T. Gerätebau
31

.T. Gerätebau
B
Familiarisation with the function of 3
Selection of components and drafting

rved G.U.N
rved G.U.N

5
the components of a refrigeration

All Rights Rese

C of requirement lists
All Rights Rese

system and of the complete system

E
A flang
ge con nection in our
piping system
is made up
of the followin
Technically correct preparation and
Leak testing at expansion valve Fault analysis: troubleshooting, fault D
32
Item

1
Quantity

2
Name
Steel flange
Standard /
Catalogue
g parts:

execution of system assembly

2
1 EN 1092-1

assessment and repair

Flat seal
3
8 DIN 2690 /
Washer Klingersil
4
5
4
4 Hexagon head
Nut
screw
ISO 7090
ISO 4014
Reading and understanding
Planning, execution and assessment of Note:
48 25
35 33
ISO 4032
engineering drawings and technical
To go beyo
nd assembly

maintenance operations piping syste

parts:
m (with flang
25 - x 1
of sections
e connectio
and 48 -
A, B, C, D
ns), we also
x 2.
and E to crea
need the follo
te the com
plete
wing additiona 4 Basic inform
documentation
l ation on pipes an

Maintenance, repair,
d control fittin
gs

In conjunction with ET 150.01: 7 Solutions

18
Operational testing of the constructed
troubleshooting of Evacuation and filling of refrigeration
90

systems (in conjunction with suitable

a refrigeration system units Two examples
T l ffrom our comprehensive
h i training documentation water supply and disposal)
...totally practice-oriented

13
 ASSEMBLY PROJECTS – MAINTENANCE

The Instructional Material will Impress You

Tasks and solutions Complete set of drawings

06/2007

HL 960
ASSEMBLY ST
ATION PIPES
11/2008 AND FITTINGS
Worksheet
4, Page 4 -
Solution to
MT 182 task 4.5
ASSEMBLY
AND MAINT ENANCE EXER
4.5 Explain the
06/2007 CISE: SCREW standard de
PUMP fitting: Shut- signation
off valve DN of the follow
15 / PN16 ing control
HL 960 Worksheet
ASSEMBLY ST 9, page 4
ATION PIPES Procedure
AND FITTINGS for assemblin V lve DIN 33
Va
Worksheet g the screw 56 - 15 PN16
2, Page 4 - pump

007
Solution to - 2 A 02 A
The following task 2.3

Germany 06/2
connecting Pump housing
the complet elements are (1)
e piping sys required to
tem: assemble the
Items: sections into Cast iron typ
e: EN-GJL-
250

Barsbüttel,
48 (lamellar gra
phite cast iro
n)
30 27 Valve piston
and

au GmbH,
49 valve spring Design an
008

d features
y 06/2007

(8, 17) type code 02 based on

Germany 11/2

.N.T. Geräteb
büttel, German

Direct flow
Set screw type, straig
ht upper
Barsbüttel,

(6) section and

flange conne

erved G.U
ction
GmbH, Bars

Cast iron
Gerätebau,

All Rights Res

31 Valve cover
(7)
au

B Nominal pre
.
.N.T. Geräteb

rved, G.U.N.T

ssure

O-ring Nominal dia

meter
erved G.U

(19)
All rights rese

C DIN no. for

shut-off val
All Rights Res

ves
Sealing ring
(15) Name
E

32 Safety was
D her
(16)

Seal
(11)
7 Sol
oluutio
tionnss
48 25
Note: 35 33
To go beyond 103
piping system
parts:
assembly of
(with flange
sections A,
connection
B, C, D and
E to create
7 Solutions Prepared exercises and The core of the teaching
25 - x 1 s), we also the comple
need the follo te
and 48 -
x 2. wing addition
al
136
worksheets help to focus on material is a complete set of
7 Solutions
the learning task so the drawings conforming to
90 students work efficiently. standards. In addition to the
Of course there is a assembly drawing with
recommended solution for parts list, you will find all
every exercise. manufacturing drawings of
the individual parts.
So you are able to produce
your own parts, or have them
manufactured for you.

10/2008

MT 184
ASSEMBLY
10/2008 AND MAINTE
NANCE EXERCIS
E: PISTON PUM

The complete material on CD (PDF) Fundamental principles

MT 184 P
ASSEMBLY 2.1 C
Classification
06/2007 AND MAINTE and categori
NANCE EXERCIS principle
p sation of pum
E: PISTON PUM p types base
HL 960 P d on operating
2.4.4 Pumps are
P
ASSEMBLY STA Operating fluid-flow mac

presented in detail
TION PIPES characteristi to say, they hines which
4.4.2 AND FITTINGS cs of multiple ensure that dictate how

The complete instructional material is Flange conn

Sub-section
ections and

“A”
seals - Sub
-section “A”
Operation of
and in man
fications
i .
multiple pum
y cases esse
ps simultane
ntial in orde
interacting

ously in a
r to conform
pumps

system is quite
common,
In practice,
purpose, such
pur
pumps are
as
flow takes plac
often named
fitters can more milk pumps or cooling
fitte
processes
e within syste
ms.
after the liquid
operate - that

they pump
is

to extreme easily identify pumps. How or their

operating spec

delivered in hardcopy form in a clearly If mult

mu iple pum to ththeir operating their design ever, technicia
i- ns and

The basic principles and technical descrip-

ps are conf principle. when they
pumps p are conf igured in para are named
igured in serie llel, the deliv according
ery rate is incre

ny 10/2008
are adde
ad d toge s (one behi
ther. nd the othe ased. If
r), the deliv
ery heads

arranged folder. Fluid-flow mach

tions are professionally illustrated with lots

ttel, Germa
ines
ny 06/2007

8
Germany 10/200
Machines

Barsbü
ttel, Germa

(Machine drive Engines

of graphics, photos and clear text.

4 sa

Additionally you receive the complete

1 flowing medi (Flowing medi

Gerätebau,
um) um

Barsbüttel,
Fig. 2.25 Pumps drives mach
ine)
GmbH, Barsbü

Parallel config
3 uration Turbines
Fig. 2.26
Series config

ed, G.U.N.T.
uration Positive-displac

Gerätebau,
The pump

material as PDF-files. It includes all texts,

ement
industry has

The pages are suitable for printing out or

2 pumps
number of made use (Medium conve Centrifugal
o designs of these prop pumps
Gerätebau

accordingly. erties and displaceme

yed by (A gyro cause
developed s

All rights reserv

Multi-flow nt device) centrifugal

ed, G.U.N.T.
pumps achi a forces to act
high heads. eve high deliv on the medi
ery rates, mult

graphics and drawings. That way you can

um)
ed G.U.N.T.

i-stage pum

using with a video projector.

3 ps achieve Oscillating
Rotating

All rights reserv

Self-priming
Self-priming Normally primin
(Displac
lacement g
5 (Not carrying Self-priming
All Rights Reserv

device m (Displacem gas,

moves ent (Carrying gas,

conveniently print or present. device rotate pumping from

back an
and forth s in low pumping from
the pump body) level restricted) low
along an axis) level possible)

A flange conn Piston pump

pu s
ection in our Gear pump
piping syste Diaphragm s Centrifugal
m is made pumps pumps
up of the follo Screw Side-channel
Item
Quantity
wing parts: pumps Multi-stage
pumps
Name centrifugal
1 pumps
2 Standard / Inline pump
Steel flange Catalogue Fig. 2.1 s
2 P
Pump types
1 EN 1092-1
Flat seal
3
8 DIN 2690 /
Washer Klingersil
4 Fig. 2.27
4 ISO 7090 Mult
Multi-flow pump
Hexagon head , sectional
5 screw view and delive Fig. 2.28 2 Technolo
4 ISO 4014 ry principle Multiple-sta gical princip
Nut ge pump, sectio le s of pumps
ISO 4032 view and delive nal
ry principle
2 Technolo 4
gical princip
le s of pumps

4 Basic info 20
rmation on
pipes and c
o ntrol fittings

18

15