Doc. No.

: 02CAS096-D82 Cockpit Security Door Installation

Cascade Aviation AMM Supplement for
Fairchild/Dornier 328-100 and 328-300

FAA APPROVED

AIRPLANE MAINTENANCE MANUAL SUPPLEMENT

CASCADE AVIATION SERVICES BALLISTIC COCKPIT DOOR

AIRPLANE MAKE: Fairchild/Dornier

AIRPLANE MODEL: 328-100 & 328-300

TO BE ADDED TO AMM CHAPTER 52-51-00

This document describes the maintenance procedures for the Cascade Aviation Services
Ballistic Cockpit Door when it has been installed in accordance with Supplemental Type
Certificate __ST01181SE___.

The information contained herein supplements or supersedes the basic Airplane

Maintenance Manual only in those areas listed herein. For limitations, procedures, and
performance information not contained in this document, consult the basic Airplane
Maintenance Manual.

Page 1 of 12
Doc. No.: 02CAS096-D82 Cockpit Security Door Installation
Cascade Aviation AMM Supplement for
Fairchild/Dornier 328-100 and 328-300

LOG OF REVISIONS

REVISED
REV. NO. DESCRIPTION PAGES APPROVED BY DATE

New Initial Release All P.KINGSWELL 2/10/03

Page 2 of 12
Doc. No.: 02CAS096-D82 Cockpit Security Door Installation
Cascade Aviation AMM Supplement for
Fairchild/Dornier 328-100 and 328-300

Table of Contents

Section Page

1 General............................................................................ 4

2 Description & Operation ................................................. 4

3 Routine Maintenance...................................................... 4

4 Shear Pin Part Numbers................................................. 4

5 Shear Pin Replacement.................................................. 5

6 Verify Shear Pins ........................................................... 5

7 Reset Blow Out Panel Latches....................................... 6

8 General Repair Procedures............................................ 6

9 Deadbolt Assembly......................................................... 7

10 Header Assy.................................................................... 7

Fig 1: Security Door ........................................................ 8

Fig 2: Emergency Egress/Blow out Panel...................... 9

Fig 3: Nylon Latch Detail .............................................. 10

Fig 4: Latch Section ...................................................... 11

Fig 5: Latch Section ...................................................... 12

Page 3 of 12
Doc. No.: 02CAS096-D82 Cockpit Security Door Installation
Cascade Aviation AMM Supplement for
Fairchild/Dornier 328-100 and 328-300

1.0 GENERAL

1.1 The following document outlines the procedures for performing common
maintenance tasks on the Cascade Aviation Services (CAS) Do Security Cockpit
Door. For removal and installation procedures see CAS Engineering Order
02CAS096101

2.0 DESCRIPTION & OPERATION (SEE FIG 1)

2.1 The CAS Security Cockpit door is designed to be a direct replacement for the OEM
door. The CAS door mounts on the two existing roller tracks in the RH forward
partition and on the CAS supplied Header Assembly. The new door slides into the
R/H partition in the same manner as the OEM door, but there is no method for
latching the door from the passenger cabin. The Security door can only be locked
from the cockpit via the CAS supplied deadbolt.

2.2 The CAS door has a removable panel to facilitate emergency egress in case the
Security Door becomes jammed. This panel is opened by pulling up on the two
release latches and pushing the panel outward into the passenger cabin.

2.3 The emergency egress panel also incorporates a blow out panel, to compensate for
a decompression event between the flight deck and passenger cabin. The blow out
panel is held secure by two aluminum shear pins. Should a decompression event
occur the blow out door will open into the cockpit, shearing the two pins.

2.4 In the event that the blow out panel shear pins are broken, two spring loaded
latches engage the blow out panel and prevent any further cockpit intrusion.

3.0 ROUTINE MAINTENANCE

3.1 The Security Door, Dead Bolt Assy and Header Assy should be checked
periodically for smooth and correct operation. Visually check all parts for obvious
damage or wear. The roller tracks should be maintained in accordance with the
original Dornier AMM.

4.0 SHEAR PIN PART NUMBERS

4.1 The required shear pins are manufactured from either a MS20470A3XX or a
MS20426A3XX rivet. In both cases remove the head and trim to long. The
length can be adjusted +/- 1/8 if required

Page 4 of 12
Doc. No.: 02CAS096-D82 Cockpit Security Door Installation
Cascade Aviation AMM Supplement for
Fairchild/Dornier 328-100 and 328-300

5.0 SHEAR PIN REPLACEMENT (SEE FIG 2)

5.1 Remove the Emergency Egress/Blow Out Panel Assy from the Security Door by
pulling up on the two Emergency Release Latches and pushing the Assy out of the
Door.

5.2 Open the Blow out Panel by depressing the two nylon latches to the green
position and pushing Panel from the grill side. Temporarily block the door to stop
it swinging shut and engaging the latches. OPTIONAL: Remove the Blow Out
Panel by removing the nine 10-32 screws common to the Panel Hinge. This
makes removing the shear pins easier.

5.3 Remove the remaining piece of Shear Pin from the Blow Out Panel by either:

5.3.1 Pulling it out of the panel. A small sharp implement such as an awl,
marking scribe or knife blade will assist in pulling out the pin.

5.3.2 The pin will also drop out if the Panel is held vertically and tapped gently
on a non-metallic surface.

5.3.3 If pin is unable to be pulled out, the pin can be pushed through into the
Blow Out Panel using 1/16 dia drill.

5.3.4 DO NOT attempt to drill out the shear pin as this could damage the
panel to the point that it requires placement.

5.4 Remove the remaining piece of shear pin from the Security Grill.

5.5 If removed, reinstall the Blow out panel on the Security Door.

5.6 While holding the latches in the green position, close the Blow Out Panel until
the two tabs engage in the latch plate slots and retain the nylon latches.

5.7 Insert a new shear pin through the Security Grill into the blow out door. Ensure
the pin is flush with the edge of the Security Grill.

6.0 VERIFY SHEAR PINS:

6.1 To verify whether the shear pins are intact or not, first ensure that the latches
are in the green position. Use hand pressure (approx 20lbs) to try to push the
blow out panel open.

6.2 If the door does not open, shear pins are intact.

Page 5 of 12
Doc. No.: 02CAS096-D82 Cockpit Security Door Installation
Cascade Aviation AMM Supplement for
Fairchild/Dornier 328-100 and 328-300

7.0 RESET BLOW OUT PANEL LATCHES (FIGURES 3, 4 & 5)

7.1 If either of the latches is found to be in the red position perform the following to
reset them to the green position.

7.2 Pull both latches down as far as possible to disengage them from the Blow Out
Panel. Use hand pressure (approx 20lbs) to try to push the blow out panel open.

7.3 If the panel opens, then the shear pins need replacing. See Para 5.0 through
5.7 for Shear Pin replacement and resetting the latches.

7.4 If the panel does not open this indicates the Shear Pins are still intact. There
are two ways to reset the Latches in this situation:

7.4.1 Push the Blow Out Panel through the security grill so it deflects just
enough to allow the Blow Out Panel Tab to disengage and the latch can
be reset back to the green position

7.4.2 Deliberately break the shear pins to enable the Blow Out Panel to be
opened. Reset the latches and replace the shear pins per para 5.0
through 5.7. Use caution to avoid damage to the Blow Out Panel when
breaking the shear pins.

8.0 GENERAL REPAIR PROCEDURES:

8.1 For all the following repairs use applicable Dornier or OEM procedures.

8.2 Scuffs, Nick, Scratches etc in the decorative finish of the door may be touched
8.2.1 up using a matching protective finish.

8.3 For reference purposes the following decorative finishes are applied to the CAS
Door:

8.3.1 Cockpit Side of Door, Header & Dead Bolt: 2 Coats Polane L Type II 26176
Grey.

8.3.2 Cabin Side of Door & Header: Decorative Laminate, Skyline

70F35014022C.

8.4 Minor nicks & scratches to aluminum parts should polished/blended out as
required. Reworked area should be alodined and primed. Apply top coat to
match surrounding finish.

Page 6 of 12
Doc. No.: 02CAS096-D82 Cockpit Security Door Installation
Cascade Aviation AMM Supplement for
Fairchild/Dornier 328-100 and 328-300

8.5 Dents in the fwd or aft side of the door are acceptable providing that no
honeycomb (fwd side) or Kevlar (Aft Side) is exposed.
8.6 Punctures through the fwd skin of the door exposing honeycomb core should be
filled with potting compound. The repair should then be sanded flush and
touched up to match the surrounding finish.

8.7 Punctures through the aft skin, can be repaired as long as the Kevlar is
undamaged with no obvious cuts or nicks in the fiber. Fabricate a 2024-T3 .063
thk Aluminum plate to match the size of the damage. Ensure the plate overlaps
undamaged skin by .50 min. Alodine and Prime the plate and bond in place
using 2-part epoxy adhesive. Apply top coat to match surrounding finish.

8.8 If the Kevlar is damaged the door should be returned to manufacturer for repair.

9.0 DEADBOLT ASSEMBLY

9.1 If the Dead Bolt Assy is damaged to such an extent that it cannot be operated or
does not lock the Security Door, return to the manufacturer for repair or
replacement.

10.0 HEADER ASSY

10.1 If the Header Assy is damaged to such an extent that it impedes the proper
operation of the door, return to the manufacturer for repair or replacement.

Page 7 of 12
Doc. No.: 02CAS096-D82 Cockpit Security Door Installation
Cascade Aviation AMM Supplement for
Fairchild/Dornier 328-100 and 328-300

Page 8 of 12
Doc. No.: 02CAS096-D82 Cockpit Security Door Installation
Cascade Aviation AMM Supplement for
Fairchild/Dornier 328-100 and 328-300

Page 9 of 12
Doc. No.: 02CAS096-D82 Cockpit Security Door Installation
Cascade Aviation AMM Supplement for
Fairchild/Dornier 328-100 and 328-300

Page 10 of 12
Doc. No.: 02CAS096-D82 Cockpit Security Door Installation
Cascade Aviation AMM Supplement for
Fairchild/Dornier 328-100 and 328-300

Page 11 of 12
Doc. No.: 02CAS096-D82 Cockpit Security Door Installation
Cascade Aviation AMM Supplement for
Fairchild/Dornier 328-100 and 328-300

Page 12 of 12