B07EP Electrical Practices - Practical - Print 21 Copies

B07EP
Electrical
Practices
PRACTICAL
EASA PART
66
WORKSHOP SAFTY RULES
1. Eating, drinking, smoking, sleeping are not allowed inside the laboratory.
2. jewelry, ties and clothing which, in the opinion of the Workshop Staff, is
hazardous
must not be worn while working with machinery in the workshop. All users must
wear
full shoes (not sandals) and at least a shirt and full-length trousers. Long hair
must be
held back securely with a head band or a net. Medallions or jewelry hanging from
the
neck must not be worn.
3. The bench is for experimental equipment only. Do not leave coats, sweaters,
briefcases and other irrelevant personal belongings on the bench.
4. Keep your workspace tidy and set aside all equipment and leads that are not
actually
part of the test being conducted.
5. Move around slowly to avoid knocking things over.
6. Make sure that there are at least three persons in the lab all the time.
7. Use the proper power cord and correct fuse. Replace the power cord if it is
cracked or
broken or has any pins missing. Make sure that all devices are using a three-wire
power
cable when powered from a 220V outlet. Use extension cords only when
necessary and
only on a temporary basis.
8. Voltages above 50 V rms ac and 50 V dc are always dangerous. Extra

precautions
should be considered as voltage levels are increased.
9. Always be careful when electricity is applied to the experiment circuit. Some

circuit
elements such as capacitors and inductors may produce high voltages even when
the
power supply voltage is low.
10. Never handle “live” equipment when hands, feet, or body are wet or
perspiring, when
standing on a wet floor or on a metal surface.
11. While manipulating a circuit with an applied voltage or current, put one hand
in your
pocket or behind your back.
12. All accidents, including minor injuries and all hazardous conditions are to be
reported immediately to the workshop Staff or the Director.
I
Contents
Task No. Task Page No.
EPE 1 Wire Stripping & Soldering 1
EPE 2 Joining Wires Together with Solder 3
EPE 3 Soldering Assessment 5
EPE 4 Multimeter Pre-use Checks 7
EPE 5 Safe Measurement of Voltage and Current 11
EPE 6 Continuity Checking 16
EPE 7 Crimp cable to ring tag terminations 20
EPE 8 Contact Crimping 24
EPE 9 Lacing 29
Complete a wiring assignment involving ring tag crimping, 31
EPE 10
contact crimping & insertion and looming.
EPE 11 Heat shrinking & Solder Sleeves 33
EPE 12 Insulation Testing 37
EPE 13 Soldering and de-soldering Techniques. 40
EPE 14 Find faults in simple electrical circuits 45
Wiring assignment that involves a variety of connector 49
EPE 15 types, crimping, soldering bulkhead feed through, loom split
and terminal blocks, including inspection and test.
disassembly/assembly of electrical boards and sub units in 52
EPE 16
aircraft electrical units
Perform removal and installation of components in aircraft 53
EPE 17
(PCB) printed circuit boards.
Perform removal (extraction) and installation (insertion) of 57
EPE 18
plugs and sockets of actual a/c receptacles.
Perform disassembly/assembly of analogue and digital 58
EPE 19
multimeter, inspection and recognize parts.
II
TRAINING WORK INSTRUCTION MANUAL
STANDARD FORMAT-Practical Skills Instruction sheet
PRACTICAL ASSESSMENT TASK
B07EP - Electrical Practices (EPE) - 1
Student Task Brief
INTRODUCTION:
Carry out manual wire stripping operations on equipment wire, airframe wire,
multicore & co-axial cables
TASK:
1- Wire Stripping
PROCESS:
Refer to B07EP - Electrical Practices TASK 1
GUIDANCE:
1. Prepare the required tools for the job.
2. Perform housekeeping upon completing your task.
TOOLS REQUIRED:
1- Stripper
1
Task 1 Wire Stripping & Soldering
Part A
Following the demonstration on wire stripping your first task is to strip a variety of
cable types.
Part B
Following the demonstration on tinning a stripped wire prepare a variety of

cable types to the dimension listed below:
1 cm
Once you have completed a selection of cables and are satisfied that they exhibit a
high standard of workmanship, present them to your lecturer for inspection.
2

B07 EP - Electrical Practices (EPE) 2
Student Task Brief
INTRODUCTION:
Carry out soldering operations on single core wires forming a variety of joints
TASK:
1- Soldering Joints
PROCESS:
GUIDANCE:
1- Prepare the required tools for the job.
2- Perform housekeeping upon completing your task.
TOOLS REQUIRED:
1- Soldering Iron
2- Solder
3- Stripper
3
Task 2 Joining Wires Together with Solder
Following the demonstration on methods of joining wires together prepare and
join wires together in a variety of methods. Practice doing this until you can
present excellent quality joints to the lecturer.
Lap splice
Hook Joint
Overlapping Joint
Joints should have an even flow

of solder all around with strands
visible but covered; as in the
photograph to the right
4
Student Task Brief
INTRODUCTION:
Complete a simple soldering assessment
TASK:
1- Joining Wires Together with Solder
PROCESS:
GUIDANCE:
TOOLS REQUIRED:
1- Soldering Iron
2- Solder
3- Stripper
5
Task 3 Soldering Assessment
You are to construct the wiring exactly as detailed in the diagram shown
below, all joints are to be soldered. Any colour wire may be used from the
variety supplied for the task.
10mm 60mm 5mm
5mm
10mm
60mm All corner

angles 900
6
Student Task Brief
INTRODUCTION:
Carry out pre-use checks of digital multi-meter
TASK:
1- Pre-use checks
PROCESS:
GUIDANCE:
TOOLS REQUIRED:
1- Multimeter
7
Task 4 Multimeter Pre-use Checks
Introduction:
The pre-use check, as with all test equipment, is an important aspect of their
use. Multimeters are used for a large proportion of their time to measure
voltages and currents, these voltages and currents even at low values can be
lethal! This session will provide generic guidance to enable a decision to be
made if a multimeter is serviceable & safe to use.
Method:
For any test leads to be used inspect the following:
 Completeness and no damage of the insulation

 Loose, bent or missing probes
 Loose, bent or missing connector on multimeter side of the leads
8
For the multimeter check the following
 Casing for any damage including the screen

 Any signs of battery leakage (usually at the rear of the unit)
 Ensure that any selection switches or buttons are secure and can be
operated through their range of movements
 Check all sockets which the test leads connect to for missing parts or
obstructions
 Calibration is in date
Power on checks
Turn the multimeter on and if it is a digital type the screen may self test the
screen, if so ensure the display is correct
Connect the leads to the multimeter, observing red to positive and black to
negative
Set multimeter to Ohms ( Ω )
 Check reading is infinite/open circuit

 Short the probe tips together and check the reading is 0 ohms
Set multimeter to diode ( ) check position
 With probe tips apart check the displayed reading is infinite/open circuit
 Short the probe tips together and check the reading is 0 and tone is
present
Pre-use test completed

9
Task Observation
Clean and safe working environment
X 
Relevant safety precautions observed
Work safely with others
Demonstrate appropriate attitude to flight safety & airworthiness
Check of insulation
Test leads inspected Check of probes
Check of connectors
Casing & screen check
Battery leakage
Buttons & switches check
Multimeter Sockets check
Calibration check
Screen self-test
Leads connected with correct polarity
Zero ohms (short circuit)
Ohms Check
Infinite (open circuit)
Short circuit test (with tone)
Diode Check
Open circuit test
Student declaration as to whether multimeter is OK to use
Task Observation
Clean and safe working environment
X 
Relevant safety precautions observed
Work safely with others
Demonstrate appropriate attitude to flight safety & airworthiness
Check of insulation
Test leads inspected Check of probes
Check of connectors
Casing & screen check
Battery leakage
Buttons & switches check
Multimeter Sockets check
Calibration check
Screen self-test
Leads connected with correct polarity
Zero ohms (short circuit)
Ohms Check
Infinite (open circuit)
Short circuit test (with tone)
Diode Check
Open circuit test
Student declaration as to whether multimeter is OK to use
10
Student Task Brief
INTRODUCTION:
Safe measurement of voltages & current in a simple circuit using a

digital multi-meter assessment
TASK:
1- Safe Measurement of Voltage and Current
PROCESS:
GUIDANCE:
TOOLS REQUIRED:
1- LOCKTRONICS ELECTRICAL EXPERIMENT KIT.

2- ELECTRICAL CONNECTING BOARD.
3- ELECTRICAL CONNECTING CABLES.
4- DMM
5- Different Resistance value
6- Power Supply Unit
11
Task 5 Safe Measurement of Voltage and Current
Build the circuit shown below:
1K
+ ve
B
PSU
1K
10 volts
C
1K
D
Connect the circuit as shown with a resistance values (R) of 1KΩ; ensure that
the power supply remains switched off.
Calculate the voltage at points A through to D if measured with respect to

earth and write in table 1.
Calculate the circuit current at points A through to D and record in table 2
Voltage Measurements:
Voltages should always be measured in relationship to a reference, in the

majority of cases it will be earth or the negative line, the Digital Multi Meter
(DMM) will need to be placed across the circuit (in parallel). To measure in a
safe manner the following process should be carried out:
Pre use check of the DMM
 Set the DMM to a scale which will accommodate the voltage you
expect. If you do not know what the voltage is set to the highest range.
 When connecting the probes to circuits only one hand should be used.
This reduces the chance that you can bridge the circuit with your body.
Using this method you can measure voltages without having to keep
turning the circuit off and then back on.
12
 Always connect the negative lead first to the circuit
 Connect the positive lead to the point to be measured
 If more than one voltage is to be measured then the positive lead can
be moved, again with only one hand, to other test points.
Negative
lead first
PSU
Then
Positive
lead
PSU
Method
Turn on the power supply and adjust for an output voltage of 10V. (Note that
the gauge on the power supply is not accurate, the actual output voltage will
need to be set with the DMM.) Measure the voltages at points A through to D
and record in table 1
Turn off the power supply and DMM
Results
Voltages
Point Calculated Measured
A
B
C
D
Table 1
13
Conclusions:
For what reasons do you think the voltages measured in table 1 are different
to the calculated values
Current Measurement:
In order to measure currents a circuit needs to be physically broken and the

multimeter inserted at that point to bridge the break. In order to measure in a
safe manner the following process should be carried out:
Pre use check of the DMM
 Set the DMM to a scale which will accommodate the current you
expect. If you do not know what the current is then set to the highest
range. If measuring currents the multimeter leads will need
repositioning where they attach to the DMM to the current position
 Ensure the circuit is turned off and measure the current at point A
 Break the circuit and insert the multimeter to break the gap ensuring
the polarity of the DMM leads are correct with the circuit polarity
 Turn the circuit on
 Take the measurement and record in table 2; if the reading is small the
DMM meter scale may need to be changed to obtain an accurate
reading. Before changing the DMM settings or re-positioning leads the
circuit will need turning off.
 Repeat for points B, C and D
PSU
14
Currents
Point Calculated Measured
A
B
C
D
Table 2
Conclusions:
For what reasons do you think the currents measured in table 2 are different
to the calculated values
15
Student Task Brief
INTRODUCTION:
Carry out continuity checks of cable assemblies and determine

serviceability
TASK:
1- Troubleshooting
PROCESS:
GUIDANCE:
TOOLS REQUIRED:
1- DMM
2- Multicore Cable
16
Task 6 Continuity Checking
Continuity testing means making sure that something is continuous ie not
broken. For example, copper tracks on PCBs or wires in cables should not be
open circuit but continuous.
In the
diagram, when
the two leads of the DMM are
connected to the two ends of the same wire in a
cable loom, the DMM should indicate ‘0’ ohms if on a resistance setting or ‘0’
and a tone on the diode checking position (may indicate a small resistance
reading due to cable resistance/length).
It important to note that when continuity checking that there should be no

power applied to the circuit; it may cause damage to the test equipment.
When checking a long cable the leads may not reach, so one of the two
methods on the following page may be used. It is also worth noting that long
cables may exhibit a small resistance due to their length, this should be
factored into the judgement of a cable’s serviceability.
17
Shorting link
Aircraft skin
Shorting link
Aircraft skin
18
Method:
 Carry out pre-use checks on the multimeter
 Isolate the cables to be tested
 Perform a continuity check on the cables using an appropriate method

and decide if they are serviceable from the test performed
Results:
Note down the results of the cables you test in this space
19
Student Task Brief
INTRODUCTION:
Crimp cable to ring tag terminations
TASK:
1- Crimping
PROCESS:
GUIDANCE:
TOOLS REQUIRED:
1- Stripper
2- PIDG Crimping Tool
3- Terminals
4- Butt Splice
20
Task 7 PIDG Crimping

Prior to carrying out any crimping, pre-use checks should be carried out of the
termination equipment. This should include serviceability, calibration and a
functional test.
Preparing to Crimp
The tool should first of all be set up for the cable by carrying out ‘pull off’
checks. A crimp of a suitable size for the wire being used should be inserted
in to the tool and an unstripped length of the wire to be used inserted into the
crimp body, then in one smooth action the handles drawn together until the
ratchet releases. Then the pull off check can be carried out on the
termination.
This should begin at setting number 3 on the

tool, should it fail the ‘pull off’ ed here check then move
Wire insert
the insulation setting pins to position 2 and so
on.
Uncrimped
Insulation
setting pins
Position 3
Position 2
Position 1
Following this the next step is to prepare the cable to the correct stripped
length, there should be no damage to the strands and the conductor end
should be long enough to be visibly protruding from the crimp barrel exit.
Do not touch the stripped wire as this will contaminate the joint.
Then insert the crimp into the tool, insert the cable into the crimp and carry out
the crimping action.
Following termination a joint should be checked for security and conformity.
A similar procedure should be carried out when crimping ‘butt splices’, here
though the conductor should be visible in the centre of the splice through the
viewing window.
Butt splice indent

aligned with guide
Part A
Following your practical lesson on PIDG crimping you are to prepare and
crimp 4 cables to the following dimensions:
20 cm
Part B
Once Part A has been completed to the lecturer’s satisfaction take one 10cm
length of wire and cut it in half, then rejoin it using a butt splice
22
General Information
Student Task Brief
INTRODUCTION:
Crimp cables to contacts and insert/extract in connectors
TASK:
1- Crimping
PROCESS:
GUIDANCE:
TOOLS REQUIRED:
1- Stripper
2- Contact Crimping
24
Task 8 Contact Crimping

General Information
AF8 tool wire crimp range from 12 AWG to 26 AWG

The tool has a double action ratchet; it cannot be opened without completing
a cycle
Retainer Ring
Retainer Ring
Indenter
Selector Index
Selector Knob
Installation of Positioner
 The AF8 tool must be in the open position

 Press the turret trigger latch which releases turret to indexing position
 Place turret head assembly onto the retainer ring, ensuring socket
head screws align with tapped holes
 Tighten socket head screws using 9/64 inch hex key
 Select correct colour code on turret head positioner for crimp by
rotating to index mark
 Press positioner into position
 Set selector knob on AF8 tool to wire gauge size
being used
Index Mark
Positioner
Identification
Colour Code
Turret Trigger Latch
CAUTION – tool handle must be in the open position whenever turret is being installed,
removed or released; otherwise damage may occur to turret head or crimp tool
Gauging Instructions
“Go” Gauging
 Set the tool selector knob to information detailed on the gauging tool
 Operate the tool to fully closed position
 Maintain firm hand pressure on the tool handles
 Insert the “Go” gauge end into the crimping indenter jaws
 The gauge must pass freely between indenter tips
Indenter
“No-Go” Gauging
 Set the tool selector knob to information detailed on the gauging tool
 Operate the tool to fully closed position
 Maintain firm hand pressure on the tool handles
 Insert the “No-Go” gauge end into the crimping indenter jaws
 The gauge may partially enter the indenter opening but must not pass
completely through the opening
Indenter
CAUTION – no attempt should be made to forcibly push the gauge through, damage may result to the tool
and/or gauge. Never attempt to crimp the gauge!
Wire/contact Insertion Instructions
 Ensure that the  Insert the contact

conductor is and prepared
visible through wire into the
the crimp viewing turret positioner
hole
 Squeeze handles
 Ensure the gap together until
between wire crimp tool ratchet
 Select the  Strip the wire of releases
correct insulation insulation and
wire/contact crimp top is
minimal  Inspect crimped
combination  Trim the joint for correct
exposed formation
conductor to the
correct length
 Insert wire into

the contact
Contact Assembly Insertion Instructions
28
Student Task Brief
INTRODUCTION:
Carry out lacing on cable looms
TASK:
1- Lacing
PROCESS:
GUIDANCE:
TOOLS REQUIRED:
1- Lacing Cords
2- Cables Assembly
29
Task 9 Lacing
Following the practical lesson on lacing you are to lace the cable from task 9,
below are pictures detailing the lacing knots to be used:
Start it off
like this
Between start and finish

do it like this, remember
evenly spaced!
Finish it like this …………

this
Using the cables from task 9 form them into a laced loom, begin lacing 2 cm
from the PIDG crimp end and space your knots 1 cm apart finishing 3 cm from
the rear of the plug.
Student Task Brief
INTRODUCTION:
Complete a wiring task involving, ring tag crimping, contact crimping &
insertion, and looming
TASK:
1- Stripping
2- Crimping
3- Contact Insertion
4- Looming
PROCESS:
GUIDANCE:
TOOLS REQUIRED:
1- Stripper
2- Crimping Tool
3- Contact Crimping
4- Lacing Cord
31
Task 10 Termination & Lacing Assessment
Student ………………………
Grading
Area Marks awarded for Maximum Awarded
Correct tooling used 10
PIDG Formation of crimp body (2) 8
Conductor of suitable length shape (2) 8
Correct tooling used 10
Contacts Formation of crimp joint (2) 8
Conductor/insulation length (2) 8
Correct length and spacing 10
Lacing Correct knots 10
Correct lay of cables & Ident 8
Total mark awarded %
Lecturer Post Assessment Actions

Hardcopy FAP submitted
Student database updated
32
Student Task Brief
INTRODUCTION:
Apply heat shrink and solder sleeves to cables
TASK:
1- Apply Heat Shrink and Solder Sleeve
PROCESS:
Refer to B07EP - Electrical Practices TASK 11 A & B
GUIDANCE:
TOOLS REQUIRED:
1- Stripper
2- Heat Shrink
3- Solder Sleeve
4- Heat Gun
33
Task 11-A Heat shrinking

Part A
Following your practical demonstration lesson prepare 3 lap spliced cables

using different cable types; then apply suitable heatshrink to them. The heat
shrink should cover the joint and extend 5mm either side
Part B
Once you have shown the lecturer your cable from ‘Part A’ and they are
satisfied with your workmanship you may now take your cable from task 10,
remove the lacing and apply heatshrink to the cable. The heat shrink should
begin 3cm after the plug and end 3cm before the rear of the PIDG crimps
34
Task 11-B Solder Sleeves
 Coax. cable
 Cable stripped
 Earth fly lead

prepared and
tinned
 Earth fly lead laid

onto stripped co-ax
 Solder sleeve slid

over cable
assembly
 Cable assembly
and solder sleeve
in position
Heat
 Heat applied to
assembly
 Solder should be
melted, cable
undamaged from
heat application
Following the demonstration on using solder sleeves prepare an assembly
using the detailed cable and to the following dimensions
26 AWG Raychem 55 type
7mm
Sub miniature Coax.
10mm
36
Student Task Brief
INTRODUCTION:
Carry out insulation checks on cables & assemblies
TASK:
1- Testing and inspection.
PROCESS:
GUIDANCE:
TOOLS REQUIRED:
1- Insulation Tester
37
Task 12 Insulation Testing
The purpose of this type of testing is to check the insulating properties of, in
the main, cables. Before beginning an insulation test on a system, the
following generic preparations should be made, details of which will depend
on the installation concerned. It should be noted though those maintenance
procedures for the particular type of aircraft should be followed as damage is
easily created by incorrect insulation testing techniques
 The aircraft and any external supply should be disconnected
 Circuit breakers should be closed, where applicable
 Power selector switch should be switched to the position appropriate to

that required for normal in-flight operation
 All switches in the circuit concerned should be ‘on’, dimmer-switches

should be set at the minimum resistance position and micro-switches
operated to the ‘on’ position
 All items of ancillary equipment which are supplied by the system

concerned should be disconnected. This includes all rotary equipment
(eg. generators, motors, actuator units, etc.) radio equipment,
capacitors, semiconductors, voltage regulator coils, electrical
instruments, fire extinguishers, etc.
38
 In cases where the insulation resistance with the items connected is
not less than 2 mega ohms, the disconnection may be made by the
earth lead, leaving the item connected to the circuit.
NOTE: Bonded earth connections to the airframe structure should, if possible,

remain undisturbed for the purpose of these tests.
 Components such as cut-outs and relays which are normally open

should have their terminals bridged to ensure continuity of the circuit,
and disconnected leads for suppressors should also be bridged for
similar reasons. Where s suppressor cannot be bridged, and plug and
socket connections are used, the capacitors should be discharged
before the circuit is re-connected, otherwise arcing and burning of the
pins may occur. Items in series which are disconnected should also be
bridged so that part of the circuit is not omitted
 Co-axial cables have a capacitive effect when subjected to an

insulation resistance test so they need to be discharged prior to being
reconnected into circuit to prevent damage to delicate circuits
 Immediately after an insulation test, functioning checks should be made

on all the services subjected to the test. If the insulation test or
subsequent functioning test should reveal a fault, the fault should be
rectified and the insulation and functioning tests should be repeated in
that sequence on the affected circuits.
Pre-use Check of Insulation Testers
There are a variety of insulation testers in use so specific instructions on their

pre-use checking will not be given, however generic ones can
 Physical condition of the tester
 Calibration validity
 Condition of any testing leads used
 Self-test of meter/leads
o Looking for reading hi resistance and low resistance

Practical Task
Now test a selection of the cables provided using an insulation tester

39
Student Task Brief
INTRODUCTION:
Carry out soldering and de-soldering operations on components, connectors,

tags and posts
TASK:
1- Soldering and De-Soldering Techniques
PROCESS:
GUIDANCE:
TOOLS REQUIRED:
1- Soldering Iron
2- Solder
3- Sucker
4- Electronic components
5- Connectors and Tags.
40
Task 13 De-soldering Techniques
De-soldering operations are as important as soldering; a poorly de-soldered joint may

damage components and cause subsequent soldered joints to be of a poor quality.
There are 2 main ways to de-solder joints, both use a soldering iron, they are:
 Vacuum pump or solder sucker

 De-solder braid
During this practical session you will de-solder items using the first method.
Following your lecturers demonstration you are to carry out the presented de-
soldering tasks.
SOLDERING PROCEDURES
1- Be extremely careful and solder in an appropriate location. Always solder in a well-

ventilated area, using breathing and eye protection. Make sure to prop up the iron when it is
on but not in use. Irons can start fires quite easily by burning into your workbench.
 Seven to twelve inches of space should be between the electronic components and
your face, or it may jump into your eyes. Solder may splatter.
2- "Tin" the solder. Melt a small blob of solder on end of the soldering iron. This process is
called tinning and it helps to improve heat flow from the iron to the lead and pad, keeping the
board safe from the heat.
 Carefully place the tip (with the blob) onto the interface of the lead and pad. The tip or
blob must touch both the lead and the pad.
 The tip of the soldering iron should not be touching the non-metallic pad area of the
PCB, or any of the fibreglass area surrounding. This area can be damaged by
excessive heat.
3- Feed the solder onto the interface between the pad and lead. Flux from the solder wire
is only active for about one second maximum after melting onto the joint as it is slowly
burned off by heat. The lead and pad should be heated enough for the solder to melt not the
connection point. The molten solder should "cling" to the pad and lead together by way of
surface tension. This is commonly referred to as wetting.
 If the solder does not melt onto the area, the most likely cause is insufficient heat has
been transferred to it, or the surface needs to be cleaned of grease or dirt.
4- Stop feeding the solder interface is filled. No more than a drop or two of solder should be
necessary for each joint, though it will vary slightly for different components. The correct
amount of solder is determined by:
 On plated-PCBs, you should stop feeding when a solid concave fillet can be seen
around the joint.
 On non-plated PCBs, you want to stop feeding when the solder forms a flat fillet.
 Too much solder will form a bulbous joint with a convex shape, while too little solder
will form a concave joint.
42
De soldering Procedures
Using a De soldering Pump
1- Locate the terminals for the component to be removed. A DE soldering pump, also
called a solder sucker, vacuums up melted solder to separate soldered components from a
circuit board. Thoroughly examine both sides of the board to isolate the specific spots holding
each component in place.
 The de soldering pump works best for through-hole connections. You can use it on
surface-mounted devices as well, but it is less effective. That said, it's one of the
cheapest options.
 You can easily ruin a circuit board by accidentally separating the board layers during
the de soldering process. Ensure that you only de solder the exact pins you need to
remove a faulty component.
2- Clean the terminals. Using isopropyl alcohol on a toothbrush, gently clean the terminals
of the component(s) to be removed. Ensure that you clean only the terminals on the soldered
side of the board and not anything on the component side.
3- Attach a heat sink. The heat from the soldering iron can damage sensitive components
such as integrated circuits or transistors. To dissipate some of the heat, clip a metal alligator
clip between the component and the terminal you plan to de solder.
4- Clean your soldering iron as it heats. Turn your soldering iron on and let it heat up for
about three minutes. Using a wet sponge make quick passes from base to tip over your
soldering iron to clean it.
 You may see a tiny bit of smoke as you pass the sponge, but it’s just from the moisture
in the sponge.
5- Push down on the de soldering pump. Press the end of the pump until it clicks into place.
This compresses a spring, and latches it in the depressed position.
43
6- Heat the old solder with your soldering iron. Using the tip of your soldering iron, heat
the old solder until it melts. You can push the terminal with the soldering iron tip at the same
time to help free the component as the old solder melts.
 Use an old soldering iron if you have one, since pushing with the iron can wear the
iron down.
7- Vacuum up the melted solder. Touch the tip of the DE soldering pump to the solder pad
and melted solder, without applying pressure. Release the spring (usually by pushing a button
on the side) and the piston will shoot back quickly. This creates a vacuum which pulls the
melted solder up into the pump.
 The tip of the pump may melt a little during use. Most pumps either have replaceable
tips or are cheap to begin with, but you can try to reduce the damage by pausing for a
moment after melting the solder.
 Melted solder can harden again quickly. Work with only one terminal at a time. For
the greatest efficiency, hold the soldering iron in one hand and keep the de soldering
pump ready in the other.
9- Empty the de soldering pump into the trash. After each use, push the pump down again
over a trash can to re-arm it and to clear out the solder. If you leave the old solder inside, it
can leak back out as you go to vacuum the next terminal.
44
Student Task Brief
INTRODUCTION:
Find faults in simple electrical circuits
TASK:
1- Troubleshooting
PROCESS:
GUIDANCE:
TOOLS REQUIRED:
1- DMM
2- Electrical Circuit Board
45
Task 14 Find faults in simple electrical circuits
CHECK THE CONTINUITY AND RESISTANCE ACCORDING TO

TABLE 1 &2
Circuit Diagram -1
Skt. 2 Coax.
1
2
3
4
Skt. 1 TB 1
5
6
Serviceable
Insulation
Continuity or
Check Resistance Signature
Resistance unserviceabl
to earth
e
A to 1
E to 2
e to 3
L to 4
W to 5
f to 6
A to coax
inner
Coax
screen to
earth
e to L
W to f
Table 1
46
Circuit Diagram -2
General Layout
Serviceable
Insulation
Continuity or
Check Resistance Signature
Resistance unserviceabl
to earth
e
A to A1
D to D1
E to E1
G to G1
J to J1
K to K1
L to L1
K to L
M to L
M1 to N1
N1 to P1
Table 2
48
Student Task Brief
INTRODUCTION:
Complete a wiring assessment that involves a variety of connector types,

crimping, soldering bulkhead feed through, loom splits and terminal blocks.
Including inspection and test
TASK:
1- Inspection
2- Testing
PROCESS:
GUIDANCE:
TOOLS REQUIRED:
1- DMM
49
Task 15 Cable Husbandry & Inspections
Cable husbandry involves the protection of wiring integrity, this can and is
carried out in many different ways depending on the environment a cable is expected
to operate in.
Cable which is seldom moved may be

loomed with a waxed or PVC covered cord (as
in Task 10) or tie wraps. Cable which is often
disturbed, such as interconnect cable, may
have a tough protective coating allowing a
certain degree of protection; an example is
flexible conduit.
Cables
and looms will be supported at regular intervals as
they travel through the aircraft. This may be by p-
clips or tie wraps; both though can cause problems
if incorrectly fitted by engineers. They can be too
tight or loose, both extremes will cause damage to
cables. There are a variety of ways to overcome this, such as special tooling or
experience in coming to a decision as to correct tension.
When cabling is installed there should

be no strain on the connections, this may cause
a mechanical failure of a joint. The run of travel
of the cable should be a smooth as
possible with no sharp bends or kinks. Cables
in looms should run parallel with each other and
not cross over; cables which cross over can
rub against one another and cause
insulation damage.
Cables and their looms may have extra protection such as spiral wrap, tape or
heat shrink applied to add further protection, whilst they could be considered to be
sacrificial. If these protections are damaged then the whole integrity of an assembly
will need looking into.
Visual cable inspections are a task that can help to maintain system
serviceability. The engineer may spot potential problems before they become
apparent; such as spotting incorrect routing of looms or cables. In the vast majority
of cases cables are rarely physically checked unless their serviceability is suspected.
50
 Chaffing
Cable Inspections  Bends
 Arcing
 Insulation damage
 Heat shrink damage
 Crimp condition
 Corrosion
 Routing
 Cable aging
 Heat damage
 Fluid contamination
 Tie wraps
 P-clips
 Lacing
 Connectors secure
 Connectors locked Touch & Feel
 Insulation damage
 Security of cables
 Movement of cables
 Heat
Student Task Brief
INTRODUCTION:
Perform disassembly/assembly of electrical boards and sub units in

aircraft electrical units.
TASK:
1- Disassembly
2- Assembly
PROCESS:
Refer to (Sabreliner) Aircraft maintenance manual:

ATA / CH. 24-30A-2
GUIDANCE:
1- Follow the A/C hangar safety precautions, warnings, cautions and

notes related to the proper manual.
TOOLS REQUIRED:
1- AIRCRAFT GENERAL TOOL BOX.

52
Student Task Brief
INTRODUCTION:
Perform removal and installation of components in aircraft (PCB) printed

electrical boards.
TASK:
1- Removal / Installation
PROCESS:
GUIDANCE:
TOOLS REQUIRED:
1- PCB
2- Soldering Iron
3- Sucker
4- Solder
53
Task 17
Perform removal and installation of components in aircraft (PCB) printed
electrical boards.
How to Remove Electronic Components from a Circuit Board"
Introduction
Circuit boards consist of various electronic components that are soldered in order to
form a complete circuit. However, sometimes one or more of these components may
get damaged or start malfunctioning because of any technical issue. In such cases,
damaged components can render the entire flex PCB of no use. To rectify this issue,
you will need to DE solder the malfunctioning component from the circuit board and
replace it with a new one. DE soldering is not as easy process as soldering, because if
you are not careful enough, you might end up causing damage to the neighboring
components as well. Here we will learn about the safe techniques involved in
removal of the electronic components from flexible circuit boards.
Steps Step-by-step instructions that clearly explain how to do the task
1- Preheat the soldering iron. In order to melt the solder, preheat a soldering iron not
more than five to ten minutes.
2- Clean the tip of your soldering iron. While the iron is heating, clean its tip with the
help of a wet sponge. Wipe the sponge two or three times in order to thoroughly clean
the tip.
3- ocate the terminals of the components to be removed. In this step, you will need to
locate or roughly mark the components that you need to take off the flex PCB and
identify their terminals.
4- Place the DE soldering braid on flexible circuit board. From a spool of DE

soldering braid, unroll approximately 1 inch (2.5 cm) and place it on the board in such
a way that its tip is pressed over the solder and one leg of the electronic component on
the PCB.
5- Melt the solder using heated iron. Place the tip of the heated solder iron on top of
the DE soldering braid in such a way that it will cause melting of the solder around
the electronic component that is to be removed. The melted solder will get wicked
into the braid and the leg of component will come off of the circuit board.
6- Remove the solder iron and DE solder braid. As soon as the solder gets absorbed in
the DE soldering braid, you need to take the iron and braid away from the flexible
circuit board to avoid undesired melting of solder surrounding other components.
7- Take off other legs of the electronic component. In order to remove the component
completely, repeat steps 5 and 6 and take off other legs of the component. Once the
component is completely free, let it cool for some time and then lift it off the board. If
the electronic component is very small in size, then you can use a fork or tweezers
(forceps) to pick it off the board.
56
Student Task Brief
INTRODUCTION:
Perform removal (extraction) and installation (insertion) of plugs and

sockets of actual a/c receptacles.
TASK:
1- Disassembly/ Assembly
PROCESS:
Refer to (Sabreliner) Aircraft maintenance manual:

ATA / CH. 24-30A-2
GUIDANCE:
1- Follow the A/C hangar safety precautions, warnings, cautions and

notes related to the proper manual.
TOOLS REQUIRED:
1- AIRCRAFT GENERAL TOOL BOX.
57
Student Task Brief
INTRODUCTION:
Perform disassembly/assembly of analogue and digital multimeter,

inspection and recognize parts.
TASK:
Disassembly/ Assembly
PROCESS:
GUIDANCE:

TOOLS REQUIRED:
2- Analogue Multimeter
3- Tool Box
58
Task 19 Perform disassembly/assembly of analogue and digital multimeter,
inspection and recognize parts.
Recently there was a customer sent in a laser printer for repair and the complaint was
no power. I found that that main fuse was good so I disassembled the circuit board
from the casing. I checked on the big filter capacitor and made sure there was no
voltage so that I can begin to work on the board. The voltage reading of the capacitor
was zero volts and this means I can start to check on the component. The moment I
placed my test probes (set to x 1 Ohm) on the power FET pins (to check if FET is
shorted or not) I could hear a loud sound “Poof” from my new analogue meter.
I experienced this before in the old meter model. I knew that the internal resistor of
the meter could have blown and the cause of the problem usually was due to the un-
discharged voltage in the main big filter capacitor. But I had checked earlier that there
were zero volts across the main filter capacitor. Later I realized that one of my meter
probes actually had an intermittent loose connection. It did not insert properly into the
connector. This is my mistake and I should have checked the test probes first before
performing any repair work.
This is the reason why I got zero volt when measuring the voltage across the main
filter capacitor. After connecting back the probe and rechecked the main filter
capacitor (set to 1000VDC) it was showing about 300VDC wow! This also proven
that the laser printer itself already have problem. Due to the intermittent loose
connection in one of the test probes, my new meter was blown.
Well, as a repairer I have to open up the meter and start to repair it.
59
Upon close inspection in the X1 Ohm range area I saw 2 SMD resistors with the value
of 36R5, one of them already had a burnt mark. Both resistors tested open circuit.
There were another one SMD resistor with a coding of 2000 (200 Ohms) also had an
open circuit. It was replaced with a 220 Ohm SMD resistor.
I don’t have info for this SMD resistor code 36R5. The question now is how to read
this SMD code? Here is the tip, when I checked on other good SMD resistors in the
meter circuit board I found that 10R0 was 10 Ohm, 7R87 was 7.8 Ohm so this 36R5
should be 36 Ohm. I don’t have the info for “5” (36R5) or even “7” (7R87) at the end
of the resistor.
Since these two identical SMD resistors was connected parallel in the circuit this
means the total value is 18 ohm based on the resistor parallel formula.
60
If you owned the older model of 360 analogue multimeter I believe you have replaced
the X1 Ohm resistor before and the value was also 18 Ohm. Why X1 Ohm resistor
value? Because this is the most frequent range that we use to perform checking and
troubleshooting. This is why the failure rate is high on the X 1 Ohm range.
Since I don’t have the parts for the SMD resistor so I used carbon film ½ watt 18 Ohm
as replacement. If I have 1/8 watt or 1/4 watt I will definitely use it. After I have
soldered the resistor, I performed the value test to see if it still produces accurate
reading or not. Check out the photo below:
61
Conclusion-
If you own this type of meter and if the X1 Ohm internal resistor have problem you
can always use 18 Ohm carbon film resistor as replacement. In the future if you came
across SMD resistors coding that you don’t understand, always refer to the
surrounding SMD resistors coding for answer. One more thing, always make sure the
test probes are connected properly to avoid any future problem to the meter. My
mistake can be your gain.
62
Unfortunately this meter has un-fused shunts, so if you were to overload it, then
chances are that the PCB traces will burn. If you have damaged you meter in this way,
then you will need to look for burnt traces.
Also, look for burnt SMD resistors, and components. If you are able to find any then
consider yourself lucky as you will have to replace them.
63

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B07EP

5. Move around slowly to avoid knocking things over.

8. Voltages above 50 V rms ac and 50 V dc are always dangerous. Extra

9. Always be careful when electricity is applied to the experiment circuit. Some

STANDARD FORMAT-Practical Skills Instruction sheet

PRACTICAL ASSESSMENT TASK

B07EP - Electrical Practices (EPE) - 1

Student Task Brief

Refer to B07EP - Electrical Practices TASK 1

1. Prepare the required tools for the job.

2. Perform housekeeping upon completing your task.

Following the demonstration on tinning a stripped wire prepare a variety of

STANDARD FORMAT-Practical Skills Instruction sheet

B07 EP - Electrical Practices (EPE) 2

Student Task Brief

Refer to B07EP - Electrical Practices TASK 2

1- Prepare the required tools for the job.

2- Perform housekeeping upon completing your task.

Joints should have an even flow

STANDARD FORMAT-Practical Skills Instruction sheet

PRACTICAL ASSESSMENT TASK

B07EP - Electrical Practices (EPE) - 3

Student Task Brief

Complete a simple soldering assessment

1- Joining Wires Together with Solder

Refer to B07EP - Electrical Practices TASK 3

1- Prepare the required tools for the job.

2- Perform housekeeping upon completing your task.

60mm All corner

STANDARD FORMAT-Practical Skills Instruction sheet

PRACTICAL ASSESSMENT TASK

B07EP - Electrical Practices (EPE) - 4

Student Task Brief

Carry out pre-use checks of digital multi-meter

Refer to B07EP - Electrical Practices TASK 4

1. Prepare the required tools for the job.

2. Perform housekeeping upon completing your task.

For any test leads to be used inspect the following:

 Completeness and no damage of the insulation

 Casing for any damage including the screen

Set multimeter to Ohms ( Ω )

 Check reading is infinite/open circuit

Set multimeter to diode ( ) check position

Pre-use test completed

STANDARD FORMAT-Practical Skills Instruction sheet

PRACTICAL ASSESSMENT TASK

B07EP - Electrical Practices (EPE) - 5

Student Task Brief

Safe measurement of voltages & current in a simple circuit using a

1- Safe Measurement of Voltage and Current

Refer to B07EP - Electrical Practices TASK 5

1- Prepare the required tools for the job.

2- Perform housekeeping upon completing your task.

1- LOCKTRONICS ELECTRICAL EXPERIMENT KIT.

Calculate the voltage at points A through to D if measured with respect to

Calculate the circuit current at points A through to D and record in table 2

Voltages should always be measured in relationship to a reference, in the

Pre use check of the DMM

 Connect the positive lead to the point to be measured

Turn off the power supply and DMM

In order to measure currents a circuit needs to be physically broken and the

Pre use check of the DMM

 Turn the circuit on