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ALBALQA' APPLIED UNIVERSITY
FACULTY OF ENGINEERING TECHNOLOGY
MECHANICAL ENGINEERING DEPARTMENT
Training report
Supervised by:
Dr. Zaid Abu Alghanam
Prepared by:
"MOHAMMAD NOUR" KHALIL SAMMOUR
30615022033
Second semester 2009/2010

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- Training company:
Jordan Aeronautical Systems Company (JAC).
fig 1: JAC logo
- Training location:
JAC is located in the heart of Amman, the capital of the Hashemite
Kingdom of Jordan; it is situated within the Royal Jordanian Air
Force (RJAF) Base.
This unique location adds additional security to JAC premises and
the Aircrafts within its facilities.
Accessing JAC is through the RJAF Base entrance.
- Training period:
Second semester 2009/2010
21st
Feb- 27th
May 2010
- About JAC:
At the heart of Amman, the Capital of the Hashemite Kingdome of
Jordan, Jordan Aeronautical-systems Company (JAC) stands as a
leading & specialized company in Aircraft Maintenance, Repair
and Overhaul for the C130, L100 and Boeing 727 & 737 Aircraft.
JAC was established in 2003, as a Private Company operating on
commercial basis completely owned by the Royal Jordanian Air
Force.

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Fig 2: RJAF C-130 Aircraft
Fig 3: Iraqi Air force C-130 Aircraft.
Fig 4: Jordan aviation B737-300 Aircraft.

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JAC roots trace to the year 2000 when it was known as Marshall
Jordan Ltd. This was established as a joint venture between
Marshall Aerospace of Cambridge (UK) and Royal Jordanian Air
Force to support Royal Jordanian Air Force C130 A/C and to
capture Foreign Markets. In 2006, JAC became qualified on the
Boeing 737-200 Aircraft Maintenance to serve potential B737-200
operators in the region. JAC is now capable of maintaining the
Boeing 727-100/200 and the Boeing 737-300, 400 & 500.
- JAC production departments:
1- GSE (Ground Support Equipments).
2- Engine.
3- Airframe.
4- Sheet metal.
5- Paint shop.
- Training departments:
1- GSE (Ground Support Equipments).
2- Engine.
3- Airframe.
FIRST: GSE Department:
My OJT program included the above three departments, at the first day
in JAC I had a company orientation tour by Mr Yousef Malkawi, and
then a welcome tour to identify the company main hangar and its
departments by Mr. Mohammad Amayreh the chief of safety
department and after the welcome tour we had a safety lecture,
included the main hangar fire fighting systems, main emergency exits
and the safety tools used while working on the Aircrafts.
After the welcome tour I moved into GSE department where Mr Ali
Rahahleh is the department chief. GSE is specialized in the aircraft
ground support equipment like:
1- APU:
2- GPU:
3- B737 Jacks:
4- C130 Jacks:
5- Water lavatory:
6- Service lavatory:
7- Aircrafts washing area pumps.
8- Main hangar Air Compressors.
Many tasks have been carried out by GSE employees and my assistant
as the following:

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• Make the daily breathing for the main hangar two compressors to
insure the usage of dry compressed air in the company devices and
on aircraft tools and all the shops have compressed air pipe lines to
insure the proper use of the tools.
• Make the three months schedule maintenance for GSE tow tractors
this maintenance include:
a- Change the oil filter for the 8 cylinder diesel engine.
b- Change the oil for the 8 cylinder diesel engine.
c- Change the spark ignition plugs.
d- Change the spark ignition plugs wires.
• The main hangar crane trapped moving in and out ward. So we
make reset for 10 minutes according to the manual using the reset
push button.
• Make the six month schedule maintenance for the forklift this
maintenance included oil and oil filter change.
• Disassembly the scizer (a hydraulic machine consist of two
hydraulic actuators to lift up a basket, the basket takes two men
with their tools for the aircrafts maintenance) and remove the left
actuator with the removal of the hydraulic oil from it, after that we
separate the inner cylinder from the one above to be sent to the
metal shop to get it fixed because there was a leakage from the top
of the cylinder because of the unpolished cylinder surface.
• During the training period GSE was responsible for the air hoses
and water pipes, so we cut out a 100m×1.5 cm hoses into 10 pieces
and arrange the hose sides with male and female pneumatic valves
to be connected to the compressed air lines in the hangar and sheet
metal and paint shops.
• The fire fighting system pump had been removed and sent to the
manufacturer due to some manufacturing problems and after we
received it we connect it to the fire fighting system and test it but
the pump was turning in counter clock wise after starting it so we
replace the electrical wires connected to it to change the motor
revolution after that we started the motor and after almost one
minute it get smoking from the coils and the pump was not self
starting it was need a bush to get started so we disconnect it from
the fire fighting system and resend it to the manufacturer work
shop, after that we find out that the wiring of the coils was not
correct.
• Main hangar door motor and gear system schedule maintenance:
a- Clean the gears and lubricate it using grease.
b- Check the motor coils and electrical connections.

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c- Reconnect the motor to the casing in the door and connect the
gear box on the motor shaft using a coupling to insure the
connection between them.
d- Connect the belt used to transmit the motion to the door wheels
with the gear box gears and insure the meshing between them.
• The schedule maintenance for the gine boom which is a lifting
machine used to carry two labors with their tools for high spaces
and aircraft top and tail, this maintenance include:
a- Visual check of the structure include (rust, tires, oil leak, pins)
b- Adjustments:
i- Turrent rotation clearance adjustment.
ii- Telescopic boom sliding blocks clearance adjustment.
iii- Platform rotation clearance adjustment.
iv- Greasing for the connections.
v- Inclinometer adjustment.
c- Deformation of tubes and cable.
d- Battery check.
e- Hydraulic oil tank level check.
f- Every two years oil replacement.
g- Every two years oil filter replacement.
• Steam cleaner is a machine consisting of a water inlet and outlet
pipes, boiler, heater, piston pump and regulator. The main purpose
of it is to heat water and spray it using a water gun for cleaning the
aircraft. We had made a major maintenance for it because it has
been out of service for over two years, this maintenance included:
a- Boiler: kerosene driven boilers with two spark ignition plugs,
the boiler needed to be welded because there was a fuel leakage.
b- Motor and piston pump: a three piston pump used to get high
pressure; we checked the oil and plunger for the pump.
c- Piping system check for the suction and delivery lines of the
pump.
d- Pressure relief valve with solenoid.
e- Electrical and control board.
f- The water heater coil: made of copper to insure the water quick
heating.
• Sand blast machine: in JAC they changed the blast material from
sand into plastic, so we make the proper change on the machine to
get the new material and then we test it (using compressed air) on a
wing panel and it takes around 3.45 min to remove the paint from a
10×10 cm2
surface.

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SECOND: Engine Department:
Engine department consist of two team headed by Mr. Nawaf Donibat
the department chief and two supervisors Mr. Mustafa Majdouba and
Mr. Yousef Ababneh and four technicians Mr Nart, Mr Majd, Mr
Khalid and Mr Odeh.
The engine department are specialized with two types of engines:
1- B737-200 Pratt and Whitney JT8D Engine.
Fig 5: B737-200 Pratt and Whitney JT8D Engine
2- Propeller TO 1C-130H-2-61JG-10-1.
Fig 6: C-130 prop engine
There was two C-130 aircrafts in the company during my training
period so I have the major training on Propeller TO 1C-130H-2-61JG-
10-1 engine as the following tasks:
• Removal and installation of the Propeller TO 1C-130H-2-61JG-10-
1 engine as the following steps:
a- Removal inspection and installation of after body mounting
bracket.
b- Disconnect electrical plugs and control linkage.
c- Remove front spinner.
d- Remove dome assembly.
e- Remove pitchlock regulator assembly.
f- Remove pitchlock regulator assembly attaching parts.

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g- Remove propeller assembly.
h- Install propeller assembly.
i- Install pitchlock regulator assembly.
j- Install dome assembly.
k- Make adjustments and connect electrical plugs.
• Removal and installation of B737-200 Pratt and Whitney JT8D
Engine:
This task have been done on two B737-200 Jordan Aviation
Aircrafts by changing the engines of each one on another, the
removal procedure was carried out using special tools and first step
was to disconnect all electrical plugs and fuel pipes, the engine had
to be carried out from its connection with the wing using weighting
balances two on the front and one on the end to insure that its
weight while removing it is balanced from all directions then we
connect it to a moving cart called (Dolly) wish is a special tool
designed for carrying engines and we continued the removal using
the proper special tools, after removal of engine No 1 we install it
instead of engine No 1 on the other aircraft by reversing the
removal steps.
Fig 7: removal of B737-300 engine.
• Compressor wash of Propeller TO 1C-130H-2-61JG-10-1 engine:
Compressor wash is a job done on the engine compressor using
special tool which is a water tank with compressed air line to get
compressed water with air bubbles and its mixed with a special
cleaning material called NPN3100 chemical material, after
connecting the water pipes from the special tool to the compressor

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first stage inlet and final stage outlet, and after closing all the
hydraulic electrical and pneumatic valves and plugs we started the
washing process. This process is done while the engine is working
and also the propeller to insure the movement of the compressor 14
stages so the engine started pneumatically without any fuel burning
after the first wash ended with the special material the compressor
the chemicals are removed the water wash should be carried twice,
the compressor wash process is done to increase the compressor
efficiency.
• Changing the breathing valves for four Propeller TO 1C-130H-2-
61JG-10-1 engine according to schedule maintenance and also
cleaning the air filter for the compressor and wiring both very well.
• Installing the valve housing on the Propeller TO 1C-130H-2-61JG-
10-1 engine, the valve housing could be named the brain of the
aircraft because it controls the working of the propeller and also the
gear box meshing, it must be calibrated on right angles so that the
propeller blades are in the correct position to insure the movement
of the aircraft and the working of the propeller. And also we add to
the valve housing to insure the smooth movement of the gears and
valves.
• Make a test starting of a C-130 aircraft every engine on turn
starting from engine No. 1 then 2, 3, 4. This test is run to insure
that there is no leakage from the pipes and tanks of engine which
appear on the outer casing of the engine if any leak appear the
engines must be turned off to insure no accidents occur.
• A visual check for the propeller motion to insure that its meshed
with the gear box so no vibration or unbalancing appear with the
visual check.
• During the installation of any engine the bolts and nuts should be
tightened with a appropriate torque using a special tool called
torque rench this device could be set on the torque value required
according to standards and DCMA regulations.
THIRD: Airframe department:
Airframe department is one of the must important departments in JAC
where its responsible for the must important parts of the aircraft, the
main jobs that carried by airframe is:
1- Fuel system on aircraft.
2- Hydraulic system on aircraft.
3- Utility system on aircraft including:
a) Bleed air system.
b) Air condition system.
c) Anti icing system.

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d) Pressurization system.
e) Oxygen system.
4- Flight controls and doors, hatches.
Not so many jobs have been carried by airframe during my training
period; my training supervisor was Mr bassam Alabed who is the head
of the department, and this department is almost 30 labor including
engineers technicians and supervisors.
Bellow is the main jobs I had done with the technicians:
• Installation of fuel tanks and make the system operation check and
leakage check to insure no leakage in the pipes found, so we used a
soap with water to check the leakage by using compressed air at
the inlet of fuel line.
• Installation of sealants and anti sealing elements to insure no
leakage out of the fuel tanks.
• Aircraft weighting using a special device for the weighting
including four gauges connected on the top of the hydraulic jacks
one on the back and nose and lift an right sides of the aircraft, after
the device is started the readings of the four gauges is taken and put
into an equation to get the result as the weight of the aircraft.
• The nose landing gear have trapped on the down signal, after the
removal of the gear and the check of the actuators and sensor, it
was found that the calibration of the rear sensor which its
responsible for signal sent to the cockpit to check the landing gear
statues if its up or down, the problem was the incorrect calibration
of the sensor so we decreased its calibration and after the
operational check had been done everything is correct.
• The cargo door hand pump had been removed and changed with a
new one because there was a leakage from the top of the pump, this
hand pump is connected to a hydraulic oil tank when removing the
pump suction and delivery line an oil leakage occurred due to no
valve connected to the tank to close the lines.
• Wiring the left and right landing gears connecting shaft to insure
the hand tight of the bolts and nuts for safety reasons where the
crew could make a hand landing for the gears in case of automatic
landing failure.
• Installing the internal panels of the left and right landing gears
where they should be hand installed to insure the easily removal of
it for hand landing.
• Calibration of the left and right wing levers which is responsible
for the height of the aircraft, its calibration is due to the first visual
test and check where it was going on full close and full open so it
must be calibrated to insure the operational check, so we make it

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go full up using hand rotation where we rotate the shaft until we
get it full up after that we calibrate the torque shafts on the proper
adjustment using hand adjustment, after we make the proper
adjustments we start the operational check another time and ever
thing was ok.
• Conclusions:
After finishing the training period in JAC I could say that I had
have the following information and results:
I- Knowing the proper tools used in the mechanical engineering
hand work and knowing the importance of tool control and
knowing the following tools:
a- O ring size and use.
b- L-in and L-on keys use.
c- Torque rench use and calibration.
d- Flat and cross screw driver.
e- Safety wires 25 and 32.
f- Twister.
g- Cutter.
II- Knowing the construction of the two types of aircrafts B737-
200 and C-130.
III- Knowing the main construction of the propeller engine
including: compressor, turbine, combustion chamber, air inlet
and exhaust system.
IV- Knowing the main principles for the hydraulic pumps in the
aircraft.
V- Knowing the working principle of the turbo prop and turbo fan
engine.
VI- Knowing that all engineering jobs should be carried out using
standards and catalogs and manuals.
VII- Knowing that there are three types of fuel tanks in aircraft
which are main, auxiliary and separate fuel tanks.
VIII- Knowing the usage of the special tools used for the engine
removal and installation.
IX- Knowing the main ground service equipments used in the
airport.
After that I found that the training period is a very important time
in our study because in this period you learn how the real life and
work is, and over all of this you learn how to deal with people who
you are working with.