Page 2 of 20 SB-328J-52-213R1 Manpower

Access/Prep.: 4.0 Mhrs.

Modification: 25.0 Mhrs. Close-up: 4.0 Mhrs.

Functional checks: 4.0 Mhrs.

Total: 37.0 Mhrs.

Material

According to Material Parts List

Special Tools

Dynamometer GSE GM.4.07

Manometer GSE GE.4.14 Mounting Tool GSE 52.5.04

Multimeter GSE GE.4.01 Pax Door trolley GSE 52.5.05 (or suitable alternative work platform) Rigging Pin GSE 52.5.02 Drilling Jig C2221001A521R0501000 (tool item 1) Locator C2221001A521R0501000 (tool items 2 & 3) Bush C2221001A521R0501000 (tool items 4 & 5)

Weight and Balance

The weight and balance data must be incorpor ated into the Basic Weight and Balance

Record.

Change of weight: 1.5 kg (3.3 lb.) Change of moment: 8.4 kgm (moment/1000: 0.7 lb in)

Electrical Load Data

Not affected.

References

Not affected.

Other Publications Affected

AIPC X

AMM X

Reporting

Compliance of this Service Bulletin must be reported to 328 Support Services GmbH Customer Services Department using the Co mpliance Report for Configuration Control.

# SB

Dornier 328J
Service Bulletin

Model Dornier 328J Rev. No. 1 No. SB-328J-52-213

Rev. Date. Aug 17, 2011 Date of Issue Feb 04, 2005

Page 3 of 20 Customer Services

· Global Support Center

P. O. Box 1252 D-82231 Wessling Germany Phone +49 (0) 8153 – 88111 6666 Telefax +49 (0) 8153 – 88111 6565 e-mail gsc.op@328support.de



### 2. ACCOMPLISHMENT INSTRUCTIONS

A Preparation

CAUTION: Obey the Safety Precautions a nd the General Maintenance Practices according to the AMM JIC Chapter 00.

Note: Obey the following SRM Chapters.

51-00-00. Standard Practices Structures General 51-21-00. Cleaning Processes 51-22-00. Sealing

51-40-10. Drill & Hole Data 51-40-20. Countersinking

51-41-20. Rivet installation and removal-Metal Structure

51-41-30. Rivet installation and removal-Non-Metal Structure 51-43-20. Bolts, Screws and Nuts Installation and Removal 51-70-00. Repairs

51-74-20. Corrosion Preventative Treatment

51-90-00. Surface Protection

(1) Make the aircraft safe for main tenance according to AMM JIC 00-30-01.

(2) Do a measurement check of the pax door according to AMM JIC 52-10-00-820- 801. Record the gaps around the door at the stop positions.

(3) Remove the LH partition wall at Fr . 14 (if installed), retain fixings.

(4) Remove the lining around the pax door according to AMM JIC 25-22-00-020-

801.

(5) Remove the passenger entrance stairs (c/w with pax door) according to AMM

JIC 52-12-00-020-801. Place the stairs onto a suitable work platform.

(6) Remove and retain the front and rear handrails, struts and associated

attachments from the stairs a ccording to AMM JIC 52-12-20-020-801.Page 4 of 20 SB-328J-52-213R1 B Modification

1. Door Sill

(1) At the bottom sill of the door entranc e, remove and discard the guide brackets P/N 001A532B4030 (fwd and rear Stn X5208. 0 - X5728), refer to Fig. 10.

(2) Clean off all the sealant from the bracke t attachment area on the floor surface. Fill the redundant holes with sealant PR1436 (item 40), refer to Fig. 10.

2. Front Hinge Support (item 2) Figs.2 & 5:

(1) Loosen the qty. 14 attachment bolts and remove the front hinge support P/N 001A521B0501-004 from the passenger stairs . Retain the lower grounding strap
and attachments, discard all the other attach ment bolts (qty. 13), (refer to Fig. 2).

(2) Remove and retain the stop assy P/N 001A521B0503-206 from the front hinge support (refer to Fig. 2).

Note: Do not remove 'guide' P/N 001A521B0527-204 from the hinge support, as this hole is not to be transferred into the new hinge support (see Fig. 2).

(3) Clean off all the sealant from the back surface of the removed front hinge support, around the holes edges and from the mating surface on the stairs.

(4) Put the front hinge support onto the blank drilling jig (tooling item 1), align using the two locators (tooling items 2 and 3) at each of the ends. Make sure that the hinge support is sitting flat onto the template, clamp together.

(5) Mark the contour of the front hinge s upport with indelible marker pen or similar.

(6) Using drill bushes (tooling items 4 & 5) at pilot size 2.46mm/0.097 in. dia., transfer drill the qty. 14 attachment holes from t he front hinge support into the drilling jig; refer to Figs. 2 & 4.

Note: Use the conical bush (tooling item 4, Fig. 4) to transfer the hole close to the flange, for all other holes use the flat bush (tooling item 5).

(7) Transfer drill the one 6.5mm/0.255 in. dia hole into the drilling jig, refer to Fig. 2.

(8) Remove the old front hinge support fr om the drilling jig (tooling item 1).

(9) De-burr holes in the jig. Identify this part of the drilling jig (tooling item 1) as ‘Front’; refer to Fig. 4).

CAUTION: The drilling jig will be double sided, to be used for front and rear hinge support attachment holes. Take extra care to identify the hole drilled in the jig at the 'Centre Crossing' as 'Front' (see Fig. 4). (10) Put the new front hinge support (item 2) onto the 'Front' side of the drilling jig (tooling item 1), align using the locators (tooling items 2 & 3) at each of the ends. Make sure that the hinge support is sitti ng flat onto the jig and clamp together.

# SB

Dornier 328J
Service Bulletin

Model Dornier 328J Rev. No. 1 No. SB-328J-52-213

Rev. Date. Aug 17, 2011 Date of Issue Feb 04, 2005

Page 5 of 20 Customer Services

· Global Support Center

P. O. Box 1252 D-82231 Wessling Germany Phone +49 (0) 8153 – 88111 6666 Telefax +49 (0) 8153 – 88111 6565 e-mail gsc.op@328support.de

Note: Do not damage the surface, use protection on clamps.

(11) Secure the locators (tooling items 2 & 3) to the jig (tooling item 1) using tape to avoid falling out of position once the jig is overturned to transfer drill the holes.

(12) Transfer drill the qty. 14 attachment hol es from the backside of the drilling jig to the new front hinge support, using a pilo ted drill bit and a bench drilling machine i.e. not by hand. Open up the qty. 14 attach ment holes from 2.46 to 3,26mm dia. (0.097 to 0.128 in.), from the backside of the drilling jig (tooling item 1).

Note: When drilling, use a suitable packing under the tapered end of the hinge support, to ensure the hinge support remains flat and level.

(13) Transfer drill the one 6.5mm/0.255 in. dia hole into the new front hinge support, refer to Fig. 2.

(14) Remove the new front hinge support fr om the drilling jig (tooling item 1). Tape

over the drilled holes on the backside of t he jig in order to avoid confusion when drilling the new rear hinge support

(15) Using a piloted drill bit and a bench drilling machine i.e. not by hand, open up the qty. 14 attachment holes in the new front hinge support, from 3.26 to 4,75mm dia. (0.128 to 0.187 in.).

(16) Using a bench drilling machine i.e. not by hand, ream the qty. 14 attachment holes in the front hinge support to fi nal size 4,83mm H7/0.190 in dia.

(17) De-burr all holes.

(18) Perform a temporary trial fit of t he new front hinge support onto the stairs.

Note: If necessary, it is permitted to drill any two of the holes to a final size of

4.90mm H7/0.193 in. 3. Rear Hinge Support (item 1) Fig. 7:

(1) Loosen the attaching fasteners securing t he conduit (with plug 14VP) to the rear hinge support. Retain the fasteners, conduit remains attached with the stairs.Page 6 of 20 SB-328J-52-213R1 (2) Loosen the qty. 14 attachment bolts and remove the rear hinge support P/N 001A521B0503-208 from the passenger stairs. Retain the lower grounding strap
and attachments, discard all the other atta chment bolts (qty. 13), (refer to Fig. 7).

(3) Remove the stop bracket P/N 001A521B 0503-204 from the rear hinge support.

Note: Do not remove 'guide' P/N 001A521B0527-204 from the hinge support, as this hole is not to be transferred into the new hinge support (see Fig. 2).

(4) Clean off all the sealant from the back surface of the removed rear hinge support, around the hole edges and from t he mating surface on the stairs.

(5) Repeat the drilling operations para. 2.4) to 2.17) (item 2) for the Rear hinge support (item 1).

CAUTION: The drilling jig is double sided to be used for the transfer of both front and rear support attachment holes. Take extra care to make

sure that the correct hole is identified for each side at the 'Centre Crossing' as only ONE hole relates to each of the front and rear side of the template, (see Fig. 4).

(6) Perform a temporary trial fit of t he new rear hinge support onto the stairs.

Note: If necessary, it is permitted to drill any two of the holes to a final size of

4.90mm H7/0.193 in.

4. Hinge Support Assemblies:

(1) Position the retained Stop Assy P/N 001A521B0503-206 onto the front hinge support (item 2). Clamp to the dimensions given; refer to Fig. 6 A2 – A2.

(2) Transfer drill holes into the front hi nge support from the stop assy, using drill bushes (tooling items 4 & 5 or other su itable bush as available) and in 3 progressive stages: 1 – 2.46 to 3,26mm dia. 2 – 3.26 to 4.75mm dia. 3 – ream to

final size 4.83 H7. Remove and de-burr holes.

Note: A 90° drilling tool with a short length drill is required for the above operation.

(3) Install the stop assy onto the front hi nge support (item 2) using sealant (item 40), attach with fasteners (items 9, 10, 13 & 24), and refer to Fig. 6 A2 - A2.

(4) Position the new stop bracket (item 5) onto the new rear hinge support. Clamp to the dimensions given, refer to Fig. 8. (5) Transfer drill holes into the rear hinge support from the stop bracket in 3 progressive stages: 1 – 2.46 to 3.26mm dia. 2 – 3.26 to 4,75mm dia. 3 – ream to

final size 4.83 H7. Remove and de-burr holes.

# SB

Dornier 328J
Service Bulletin

Model Dornier 328J Rev. No. 1 No. SB-328J-52-213

Rev. Date. Aug 17, 2011 Date of Issue Feb 04, 2005

Page 7 of 20 Customer Services

· Global Support Center

P. O. Box 1252 D-82231 Wessling Germany Phone +49 (0) 8153 – 88111 6666 Telefax +49 (0) 8153 – 88111 6565 e-mail gsc.op@328support.de

Note: A 90° drilling tool with a short length drill is required for the above operation.

(6) Install the stop bracket (item 5) onto the new rear hinge support (item 1) using sealant (item 40), attach with fasteners (ite ms 9, 10 & 13), and refer to Fig. 8 C1

- C1.

Note: Install all fasteners using Mastinox item 42.

(7) Install fasteners (items 17 & 13, 32 & 24) onto stop bracket (item 5) with (item 42); refer to Fig. 8 C1 - C1.

(8) Install the new front hinge support (item 2) onto the stairs using sealant (item 40), attach with new fasteners (items 23 & 24, 3 plcs, Items 23a & 24, 10 plcs) using (item 42).

(9) Attach the lower grounding strap usi ng retained fastenings, refer to Fig. 2.

(10) Install the new rear hinge support (ite m 1) onto the stairs using sealant (item 40), attach with new fasteners (items 23 & 24, 3 plcs, Items 23a & 24, 10 plcs) using (item 42), refer to Fig. 7.

(11) Attach the lower grounding strap usi ng retained fasteners, refer to Fig. 7.

(12) Position strap (item 7) with the two pre-drilled holes. Drill the two outstanding holes from the opposite side hinge assy, progr essively to final sizes 5,0mm dia. CSK the two new holes in the plate, refe r to Fig. 6 View on Arrow A2 Detail A3.

(13) Install strap (item 7) and shims (ite m 8 and/or items 19 to 22) using sealant (item 40), attach at both ends to the hinge supports with fasteners (items 13 & 15 using item 42) refer to Fig. 6 Detail X.

(14) Attach electrical conduit at the one or iginal position using fasteners as per Fig.

8.

(15) Attach electrical conduit at the 3 new positions using fasteners as per Fig. 8.

5. Front and Rear Handrails/Struts:

(1) Disassemble the front handrail a ssy. Refer to AMM JIC 52-12-20-020-801.Page 8 of 20 SB-328J-52-213R1 (2) Carefully rework the edges from the bo ttom attachment point of the handrail P/N 001A521R0530 as per Fig. 6 sec. F2-F2. Ma ke the surface flat and smooth to fit the new milled part (item 6). Restore pr otective treatment and paint finish.

(3) Assemble the front handrail assy with new milled part (item 6) attached to new strut (item 4) using sealant (item 40) and fasteners items as per Fig. 6.

(4) Remove the stop plate from the ol d front strut P/N 001A521B0544-000, retain fasteners (2 off) and discard the old strut (refer to Fig. 6 Detail Y2).

(5) Install the stop plate onto the new front strut (item 4) using sealant (item 40) and retained fasteners (2 off), refer to Fig. 6 Detail Y2.

(6) Disassemble the rear handrail assy. Dr ill out the attaching handrail/strut blind

rivets. Refer to AMM JIC 52-12-20-020-801.

(7) Remove the stop plate from the old rear strut P/N 001A521B0544-002, retain fasteners (2 off) and discard the old strut (s imilar to front strut, refer to Fig. 6).

(8) Install the stop plate onto the new rear strut (item 3) using sealant (item 40) and retained fasteners (2 off).

(9) Assemble the rear handrail assy with new strut (item 3).

Note: Do not drill the (rotating) handrail/s trut attachment holes at this stage; this must be done later when the assy is installed onto the aircraft.

(10) Install the passenger entrance stairs onto the aircraft according to AMM JIC 52-

12-00-420.

(11) Drill the rear handrail/st rut attachment points; refer to Figs. 7 & 8 W1-3, X1-3.

(12) De-burr and restore protective treatment.

(13) Attach the rear handrail to the rear stru t using rivets (item 16 ), refer to Fig. 8.

(14) Attach grounding straps (item 25) to the front and rear hinge supports with fasteners (items 28 - 31). Ensure there is a gap as per note, refer to Fig. 6. G2- G2 (H2-H2). Attach the other end of the st raps to the structure as found, using existing fasteners.

(15) Overcoat grounding straps wit h sealant according to SRM.

(16) Record the modification details onto the new identification plate (item 33a) and attach adjacent to the existing pax door identification plate, using protection (item 33b or 43):

P/N 001A521R0010150, SB-328J-52-213, Date of Modification & Serial No C Close-up

(1) Complete the installation of the passenger entrance stairs by installing the floor panel 221CZF and covers according to AMM JIC 52-12-00-420.

# SB

Dornier 328J
Service Bulletin

Model Dornier 328J Rev. No. 1 No. SB-328J-52-213

Rev. Date. Aug 17, 2011 Date of Issue Feb 04, 2005

Page 9 of 20 Customer Services

· Global Support Center

P. O. Box 1252 D-82231 Wessling Germany Phone +49 (0) 8153 – 88111 6666 Telefax +49 (0) 8153 – 88111 6565 e-mail gsc.op@328support.de

(2) Do the adjustment, alignment and calibration of the passenger door according to AMM JIC 52-10-00-820. Observe notes at Fig. 9.

(3) Perform the proximity switch adjus tment according to AMM JIC 52-71-00-820.

(4) Do the Operational test of the door according to AMM JIC 52-71-00-710.

(5) Do a fuselage leak test according to AMM JIC 53-00-00-750.

(6) Install the lining around the pax door according to AMM JIC 25-22-00-420-801.

(7) Install the LH partition wall at Fr. 14 (if previously installed), use retained fixings.

(8) Perform a foreign object inspection in and around the modification area.

(9) Close all opened doors and panels according to AMM JIC 06-40-02.

(10) Return the aircraft to a serviceable condition.



### 3.MATERIAL INFORMATION

A Material Parts List

One SB Kit PN Number SB328J-52-213 is necessary to perform the SB on one

A/C.

SB Kit PN Number SB328J-52-213 contains:

Item No P/N Qty Nomenclature Remark 1 001A521R0501000 1 Hinge Support - Rear 2 001A521R0501002 1 Hinge Support - Front

3 001A521R0547000 1 Strut - Rear

4 001A521A0547008 1 Strut - Front 5 001A521B0503216 1 Stop Bracket

6 001A521B0525222 1 Milled Part 7 001A521B0517208 1 StrapPage 10 of 20 SB-328J-52-213R1 8 001A521B0517210 1 Shim/Liner

9 NAS6803A5 4 Screw

10 NAS6803A4 4 Screw

11 NAS6703-15 2 Screw

12 NAS1153E19 3 Screw

13 NAS1726C3D 22 Nut 14 001A521B0543204 3 Spacer

15 NAS1153E11 4 Screw

16 CR3522-5-3 6 Blind Rivets

17 001A524A1132200 1 Bolt

18 001A524A1133158 1 Shim

19 001A521B0517212 1 Shim/Liner

20 001A521B0517214 1 Shim/Liner

21 001A521B0517216 1 Shim/Liner

22 001A521B0517218 1 Shim/Liner

23 NAS6703U1 6 Bolt

23a NAS6703U2 20 Bolt

24 NAS1587A3C 35 Washer 25 LN9264-10X250 2 Grounding Strap

26 NAS1149C0332R 2 Washer

27 NAS6703U2 2 Bolt 28 DOLN229-64120 2 Spacer

29 NAS6704-10 2 Bolt

30 NAS1726C4D 2 Nut

31 AN960C416L 2 Washer

32 NAS1802-3-9 1 Screw

33a DON178A-1M 1 Identification Plate

33b DON178Z 1 Protective Foil

The following expendables to be provided by operator and/or ordered separately (not part of the Kit):

34 MS24665-153 A/R Split Pin 35 MS24665-300 A/R Split Pin 36 MS24665-302 A/R Split Pin

37 AN960XC616L A/R Washer

38 001A521B0102208 A/R Shim

39 LN9424-1.4546.9-0.5 A/R Lo cking Wire CML05-008

The following consumables to be provided by oper ator and/or ordered separately in commercial quantity (not part of the Kit):

40 PR1436/DOL259 A/R Sealant 41 Loctite 243 A/R Compound CML08-013

42 DOL 40 A/R Mastinox 6856H CML05-001

43 DON 26 A/R Clear Varnish Paint CML07-006

# SB

Dornier 328J
Service Bulletin

Model Dornier 328J Rev. No. 1 No. SB-328J-52-213

Rev. Date. Aug 17, 2011 Date of Issue Feb 04, 2005

Page 11 of 20 Customer Services

· Global Support Center

P. O. Box 1252 D-82231 Wessling Germany Phone +49 (0) 8153 – 88111 6666 Telefax +49 (0) 8153 – 88111 6565 e-mail gsc.op@328support.de



## Fig. 1Page 12 of 20 SB-328J-52-213R1 

## Drilling Jig - Before (Undrilled)



## Fig. 3 View on Arrow A 

## Fig. 2

# SB

Dornier 328J
Service Bulletin

Model Dornier 328J Rev. No. 1 No. SB-328J-52-213

Rev. Date. Aug 17, 2011 Date of Issue Feb 04, 2005

Page 13 of 20 Customer Services

· Global Support Center

P. O. Box 1252 D-82231 Wessling Germany Phone +49 (0) 8153 – 88111 6666 Telefax +49 (0) 8153 – 88111 6565 e-mail gsc.op@328support.de



## Drilling Jig - Before (Undrilled)



## Fig. 3Page 14 of 20 SB-328J-52-213R1 

## Drilling Jig - After (Drilled) (Shown with both Hinge Supports)



## Fig. 4

# SB

Dornier 328J
Service Bulletin

Model Dornier 328J Rev. No. 1 No. SB-328J-52-213

Rev. Date. Aug 17, 2011 Date of Issue Feb 04, 2005

Page 15 of 20 Customer Services

· Global Support Center

P. O. Box 1252 D-82231 Wessling Germany Phone +49 (0) 8153 – 88111 6666 Telefax +49 (0) 8153 – 88111 6565 e-mail gsc.op@328support.de



## View Looking Aft on Front Hinge Support (Handrails shown folded)



## Fig. 5Page 16 of 20 SB-328J-52-213R1 

## Fig. 6

# SB

Dornier 328J
Service Bulletin

Model Dornier 328J Rev. No. 1 No. SB-328J-52-213

Rev. Date. Aug 17, 2011 Date of Issue Feb 04, 2005

Page 17 of 20 Customer Services

· Global Support Center

P. O. Box 1252 D-82231 Wessling Germany Phone +49 (0) 8153 – 88111 6666 Telefax +49 (0) 8153 – 88111 6565 e-mail gsc.op@328support.de



## View Looking Fwd on Rear Hinge Support (Handrails shown folded)



## Fig. 7 Note: Quantities Given in Figure 7 refer to one side only; same quantities apply for opposite side! 23,24(3plcs) 23a,24 (10plcs)Page 18 of 20 SB-328J-52-213R1 

## Fig. 8

# SB

Dornier 328J
Service Bulletin

Model Dornier 328J Rev. No. 1 No. SB-328J-52-213

Rev. Date. Aug 17, 2011 Date of Issue Feb 04, 2005

Page 19 of 20 Customer Services

· Global Support Center

P. O. Box 1252 D-82231 Wessling Germany Phone +49 (0) 8153 – 88111 6666 Telefax +49 (0) 8153 – 88111 6565 e-mail gsc.op@328support.de



### Note: Adjustment of stops for door open position:

1. Shim the stop of the forward hingearm so that the hook to hold the airstair open can engage (see fig. above).

2. Shim the stop on the aft hingearm, so that both stops (the aft and the forward stop) have contact with the door struts when unloaded.



## Fig. 9Page 20 of 20 SB-328J-52-213R1 

## Bottom Sill of Door Entrance



## Fig. 10