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Lab 03 - Maintenance Tools

20 points

Last edited 40 days ago by Ryan James Pirro.

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.

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Assignment

Caliper

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WhatsApp-Image-2024-10-21-at-10.56.51-3.png

Figure 1: Digital Caliper

Figure 1: Digital Caliper

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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 provide practical tips for use.

Equipment

Collect the following equipment

1 - Digital Calipers

1 - Socket

Making Measurements

In this section, you will measure the outer diameter, inner diameter, and depth of a socket.

Fill in your chosen socket size here:

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Complete the

Measurements Table 2⁠

below.

Measurements Table 2

Measurements Table 2

Item

Item Dimension

Measurement (in)

Measurement (mm)

Image

Notes

Outer Diameter

0.76

Open

Inner Diameter

0.58

14.7

Open

Depth

1.3

Open

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Questions

Answer the following questions about calipers. Use any resource (AI, Wikipedia, etc.).

What is the listed accuracy of the calipers?

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What is the listed resolution of the calipers?

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What is the difference between accuracy and resolution?

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[ ]

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What are two potential sources of systematic/random error?

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[ ]

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Digital Multimeter (DMM)

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Figure 2: Digital Multimeter

Figure 2: Digital Multimeter

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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

1 - Digital Multimeter

1 - Believer DA-15 Cable

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.

Complete the

DMM Settings Table 2⁠

below.

Setting Name

What it Measures

Range/Limit

Image

Voltage(AC)

AC Voltage

500V- AC

DC microAmps

micro-Amperes DC

2000 micro-amps

DC Milliamps

milliamps

1200 milliamps

Continuity Diode test

Continuity and its resistance in Ohms

none

200M

resistance

200 mega-ohms

DC millivolts

DC milli Volts

2000 millivolts

DC Volts

200 Volts

There are no rows in this table

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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 2

DA-15 Pinout Table 2

DA-15

Connector Name

Pin Number

(VCC) DC+

AIL, ELV, RUD

AIL

ELV

RUD

DC-

VCC DC+

AIL

RUD

ELV

DC-

There are no rows in this table

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Questions

Answer the following questions about DMMs. Use any resource (AI, Wikipedia, etc.).

Modern DMMs protect themselves from overcurrent. What electrical safety device provides this protection?

⁠

The DMM has three ports/plugs on the bottom. Complete the table below, explaining what each port is for.

DMM Ports 2

DMM Ports 2

Port Name

Port Purpose

COM

Open

VΩmA⎍

Open

10A_MAX_

Open

There are no rows in this table

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Crimping

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Figure 4: Wire crimper

Figure 4: Wire crimper

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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 2

Crimp Analysis Table 2

Wire Gauge

Connector Type

Crimp Tool Slot Setting

Image of Crimp

Inspection

Reflection of Crimp

Open

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Questions

In aviation applications, why are crimps preferred over soldering?

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[ ]

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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 2

Torque Table 2

Bolt Head Size

Specified Torque Value (LB IN)

Student Torque Setting

Instructor Sign-off

111

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Questions

Why is it important to always return a torque wrench to zero?

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[ ]

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Why is it important to use a torque wrench instead of just “tightening until it feels snug”?

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[ ]

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Deliverables

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Complete the lab assignment.

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