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Lab 03 - Maintenance Tools
20 points
Last edited 21 days ago by Aditya Satish Musale.
Overview
This lab introduces students to a set of essential measurement and assembly tools used in aviation maintenance: digital calipers, digital multimeters, crimping tools, and torque wrenches. Through hands-on exercises, you will learn how to measure dimensions with precision, test electrical continuity, create reliable wire connections, and properly torque fasteners. Each activity emphasizes accuracy, safety, and good technique, helping you build a foundation in tool use that is critical for quality control, system reliability, and professional practice.
Assignment
Caliper
Figure 1: Digital Caliper
Introduction to Using Calipers
Digital Calipers are precision instruments that measure internal, external, and depth dimensions. They provide quick, accurate digital readouts, making them essential for ensuring proper fit, design accuracy, and quality control. This lab will cover how to read measurements and tips for practical use.
Equipment
Collect the following equipment
Making Measurements
In this section, you will measure the outer diameter, inner diameter, and depth of a socket.
Measurements Table
Item
Item Dimension
Measurement (in)
Measurement (mm)
Image
Notes
3
Outer Diameter
0.85 in
21.7mm
Open
Inner Diameter
0.65 in
16.4mm
Open
Depth
2.08 in
53.5 mm
Open
Questions
Answer the following questions about calipers. Use any resource (AI, Wikipedia, etc.).
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Digital Multimeter (DMM)
Figure 2: Digital Multimeter
Introduction to Multimeters
Digital Multimeters (AstroAI AM33D) are handheld instruments used to measure voltage, current, resistance, and check continuity or diodes. They provide a digital readout and require the user to select the correct range before measuring, making them reliable tools for basic electrical testing.
Equipment
Collect the following equipment
DMM Settings
In this section, you will learn about the different measurement settings available on a DMM, what it measures, and the range and limits.
Setting Name
What it Measures
Range/Limit
Image
500
AC Voltage
0-500V
2000μ
Capacitance
0-2000pF
200m
DC Current
0-200mA
Diode Test
Continuity
N/A
200M
Resistance
0-200M
2000m
DC Voltage
0-2000m
200
DC Voltage
0-200V
There are no rows in this table
Making Measurements
Now it’s time to put the DMM to use by using the continuity settings to learn the pinout of a DA-15 connector. D-subminiature or D-sub connectors are commonly used connectors in the digital signal world, and we will be working with the same connector used in the Believer wing section. Follow the steps below:
DA-15 Pinout Table
DB15
Connector Name
Pin Number
1
Positive Lead
1
2
Positive Lead
2
3
Positive RUD, Positive AIL, Positive ELV
3
4
Negative AIL
4
5
Negative RUD
5
6
Negative ELV
6
7
Negative Lead
7
8
Negative Lead
8
9
Positive Lead
9
10
Positive Lead
10
11
Signal AIL
11
12
Signal RUD
12
13
Sig ELV
13
14
Negative Lead
14
15
Negative Lead
15
There are no rows in this table
Questions
Answer the following questions about DMMs. Use any resource (AI, Wikipedia, etc.).
DMM Ports
Port Name
Port Purpose
COM
Open
VΩmA⎍
Open
10A_MAX_
Open
There are no rows in this table
Crimping
Figure 4: Wire crimper
Introduction to Crimping
Crimp Tools are used to join wires to connectors by compressing (or “crimping”) a metal sleeve around the wire. This creates a secure mechanical and electrical connection without the need for soldering.
Making Crimps
Follow the steps below to remanufacture a servo cable.
Crimp Analysis Table
Wire Gauge
Connector Type
Crimp Tool Slot Setting
Image of Crimp
Inspection
Reflection of Crimp
3
3
3
Open
Open
Open
Questions
[ ]
Torquing
Torque Wrenches are precision tools used to apply a specific amount of torque to a fastener, such as a bolt or nut. They ensure that parts are tightened enough to hold securely without being over-tightened, which can damage components.
Table Assembly
In this section, we will assemble a lab table. Follow the steps below.
Torque Table
Bolt Head Size
Specified Torque Value (LB IN)
Student Torque Setting
Instructor Sign-off
3
40
64
111
Questions
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