NOTE: This Service Bulletin may only be accomplished on airplanes equipped with the standby alternator system.

Transcription

1 Caravan Service Bulletin October 19, 2009 CAB09-9 TITLE TKS ICE PROTECTION SYSTEM INSTALLATION EFFECTIVITY For the airplanes that follow that are equipped with a cargo pod but are not equipped with the Garmin G1000 avionics system: Model Serial Numbers 208B 208B0001 thru 208B1189, 208B1191 thru 208B1215, 208B1217 thru 208B1313, 208B1315 thru 208B1999 NOTE: This Service Bulletin may only be accomplished on airplanes factory equipped with the 675 SHP PT6A-114A Engine or airplanes on which the engine has been converted in accordance with SK SHP PT6A-114A Engine Installation (or latest revision). NOTE: This Service Bulletin must not be accomplished on airplanes that have an engine installed that was converted in accordance with SK SHP PT6A-114 Engine Installation (or latest revision). NOTE: This Service Bulletin may only be accomplished on airplanes with an existing McCauley part number P , P , or P propeller installed. As an alternative, a new TKS equipped propeller may be installed as specified in this Service Bulletin. NOTE: This Service Bulletin may only be accomplished on airplanes equipped with the standby alternator system. PURPOSE To announce the availability of a TKS Ice Protection System Service Kit for installation on the affected airplanes. COMPLIANCE Optional: may be accomplished if desired. NOTE: If not previously accomplished, Service Bulletin CAB08-7 Revision 1 Low Airspeed Awareness System Installation must be accomplished along with this Service Bulletin (CAB09-9). APPROVAL FAA approval has been obtained on technical data in this publication that affects airplane type design. Page1of9 To obtain satisfactory results, procedures specified in this publication must be accomplished in accordance with accepted methods and prevailing government regulations. Cessna Aircraft Company cannot be responsible for the quality of work performed in accomplishing the requirements of this publication. Cessna Aircraft Company, Customer Service, P.O. Box 7706, Wichita, Kansas 67277, U.S.A. (316) , Facsimile (316) COPYRIGHT 2009

2 MAN-HOURS Approximately 409 man-hours to install on an airplane with an existing factory installed de-ice system. Approximately 279 man-hours to install on an airplane without an existing de-ice system. MATERIAL The parts below are available from Cessna Parts Distribution through an appropriate Cessna Service Station. Part Number Description Qty/Airplane TKS Ice Protection System Installation Kit 1 U Adhesive (2.8 oz kit) 1 U Alodine 1132 Marker 1 U B4 Sealant (Semkit, 6 oz) 1 P Tape Approx 6 rolls K Corrosion Resistant Primer 1 U EA9309.3NA Adhesive (25 gram kit) Fiberglass Cloth Approx 2 square feet U Epoxy Adhesive Paste (25 gram kit) 1 U544053S Sealant (6 oz cartridge) 2 U Sealant (3.5 oz cartridge) 1 U Sealant (Semkit, 3.5 oz) 2 U544042S Sealant (Semkit, 6 oz) Approx 29 U Adhesive (16 oz) 1 U064092S or equivalent Adhesive, Epoxy (1 gallon) Approx 2 oz U000787S Adhesive, 1300L (16 oz) 1 IF-406B-KF-2.5M IF-406B-KF-5M IF-406B-KF-30M IF-406B-KF-55M IF-406B-KF-250M TKS Anti-ice Fluid (2.5 gallon) TKS Anti-ice Fluid (5 gallon) TKS Anti-ice Fluid (30 gallon) TKS Anti-ice Fluid (55 gallon) TKS Anti-ice Fluid (250 gallon) Approx 45 gallons CAB09-9 Page 2 October 19, 2009

3 The parts below will be necessary for airplanes with the standard paint scheme that replace the propeller during the forward-of-firewall installation. Part Number Description Qty/Airplane P TKS Propeller 1 E-7856 Bulkhead Assembly, TKS 1 The parts below will be necessary for airplanes with the FedEx paint scheme that replace the propeller during the forward-of-fuselage installation. Part Number Description Qty/Airplane P TKS Propeller 1 E-7856 Bulkhead Assembly, TKS 1 The parts below will be necessary for airplanes that modify the existing McCauley propeller during the forward-of-fuselage installation. Part Number Description Qty/Airplane D-7858 ModKit-C703TKS 1 The parts below will be necessary for airplanes equipped with Bendix/King Weather Radar. Part Number Description Qty/Airplane Porous Panel, Right Mid-Wing, Radar 1 The parts below will be necessary for airplanes not equipped with Bendix/King Weather Radar. Part Number Description Qty/Airplane Porous Panel, Right Mid-Wing without 1 Radar The parts below may be necessary to install the Lift Transducer. Part Number Description Qty/Airplane NAS1149FN816P Washer As required NAS1149FN832P Washer As required The part below will be necessary for airplanes with the Configuration Module for the Bendix/King Weather Radar installed on the wing rib at WS Part Number Description Qty/Airplane MS21044N06 Nut 2 CAB09-9 October 19, 2009 Page 3

4 The parts below will be necessary for airplanes that do not have access plates installed in the horizontal stabilizer. Part Number Description Qty/Airplane MS20426AD3-3A Rivet 12 S1021Z8-6 Screw 6 S1446-1S Doubler Assembly 2 S1447-1S Plate 2 The parts below will be necessary for airplanes that have existing holes in the cargo pod and the MLG fairing that were used for the optional anti-ice system. Part Number Description Qty/Airplane CM3827AD3-3 Rivet MLG Fairing Plate MLG Fairing Plug 2 The parts below will be necessary for airplanes that are equipped with the existing optional boot anti-ice system installed. Part Number Description Qty/Airplane AN3-5A Bolt 2 AN Cap 1 AN929-8 Cap 2 CM J1S Plug Button 1 CM3827AD3-3 Rivet 125 MS20470AD4-4A Rivet 2 MS Packing 1 MS Screw 2 S Rivet Filter, Blank Wing Plug Stabilizer Plate Stabilizer Plug Vertical Stabilizer Plate Vertical Stabilizer Plug Wing Plate 4 The parts below will be necessary for airplanes that are equipped with the existing optional windshield anti-ice panel installed. Part Number Description Qty/Airplane MS21044N3 Nut 2 CAB09-9 Page 4 October 19, 2009

5 MS24694S3 Screw 2 MS24694S55 Screw 2 MS Screw 2 NAS1149F0363P Washer Blank Filter Cover Plate 1 The parts below will be necessary for airplanes 208B0001 thru 208B0213 that are not equipped with anti-ice equipment. Part Number Description Qty/Airplane A-7079B-24 Lamp 1 MS24693S27 Screw 3 MS Screw 2 NAS1149FN832P Washer 2 C15Green Switch Green Tip 1 MS20470A4-4N Rivet 8 MS20470AD4-4A Rivet 2 MS Nut 2 MS21919WDG2 Clamp 1 MS Switch 1 MS Grommet 1 S Circuit Breaker 1 S Socket 1 S Housing 1 S Housing Cap Cover Lens Bracket Housing Assembly Shim 2 (As required) LH1 Wire LH2 Wire LH3 Wire LH7 Wire LH8 Wire 1 CAB09-9 October 19, 2009 Page 5

6 The parts below will be necessary for airplanes that have not incorporated CAB04-9 / SK (or latest revision) Ice Protection Installation/Modification. Part Number Description Qty/Airplane SK A1 Detector, Windshield Ice 1 SK A2 Handle, Pilot Assist 1 The part below will be necessary for airplanes 208B0001 thru 208B1234 that have not incorporated CAB07-3 (or latest revision) Pilot's Operating Handbook Supplement S1 Revision and Operational Limitation Placard Installation. Part Number Description Qty/Airplane Placard, Icing Warning 1 The following materials are available locally or from the applicable manufacturer: Part Number Description Qty/Airplane Manufacturer CM Clear Polyurethane Paint As required Sherwin Williams Co. Phone: Polyurethane Enamel As required Commercially Available Paint TT-I-735 Isopropyl Alcohol As required Commercially Available EPON 815 or EPON 828 Resin 16 oz* Shell Chemical Company Plastics and Resin Division Houston, TX Cab-O-Sil, fumed silica As required** Cabot Corporation 157 Concord Road P.O. Box 7001 Billerica, MA Phone: Fax: MIL-PRF- Lubricant As required Commercially Available 83483C MS20995C25 Lockwire As required Commercially Available *EPON 815 or EPON 828 Resin may be used as an alternative to U Adhesive. **Cab-O-Sil may be used as a thickener for EPON 815 or EPON 828 Resin as necessary. CAB09-9 Page 6 October 19, 2009

7 The equipment below, or equivalent, will be required. Name Number Manufacturer TKS System Test Cart Clenching Tool, with Mandrel (3/16 Inch) Clenching Tool Body (3/16 Inch) Clenching Tool Mandrel (3/16 Inch) Clenching Tool Body (5/16 Inch) Clenching Tool Mandrel (5/16 Inch) Clenching Tool (5/16 Inch) T A T T T T T A Clenching Tool (1/2 Inch) T CAV Aerospace, Inc Arnold Court Salina, KS Phone: Fax: CAV Aerospace, Inc Arnold Court Salina, KS Phone: Fax: CAV Aerospace, Inc Arnold Court Salina, KS Phone: Fax: CAV Aerospace, Inc Arnold Court Salina, KS Phone: Fax: CAV Aerospace, Inc Arnold Court Salina, KS Phone: Fax: CAV Aerospace, Inc Arnold Court Salina, KS Phone: Fax: CAV Aerospace, Inc Arnold Court Salina, KS Phone: Fax: CAV Aerospace, Inc Arnold Court Salina, KS Phone: Fax: CAB09-9 October 19, 2009 Page 7

8 Name Number Manufacturer Clenching Tool (3/8 Inch) T Blank Olive with MN4856 Nut (3/16- Inch Tube) Nylon Ball with MN4855 Nut (5/16- Inch Tube) NylonBallwithMN6201Nut (1/2-Inch Tube) Plastic Sheeting Plastic Guttering Aluminum Tape Plastic Tubes Shutoff Valve P CAV Aerospace, Inc Arnold Court Salina, KS Phone: Fax: CAV Aerospace, Inc Arnold Court Salina, KS Phone: Fax: CAV Aerospace, Inc Arnold Court Salina, KS Phone: Fax: CAV Aerospace, Inc Arnold Court Salina, KS Phone: Fax: Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available PSI Fluid Gage Commercially Available Ratcheting Straps Eddy Current Instrument Commercially Available Commercially Available ACCOMPLISHMENT INSTRUCTIONS Service Kit : TKS Ice Protection System Installation instructions will be included in the Service Kit when shipped from Cessna Parts Distribution. NOTE: This information shall be considered an amendment to the Cessna Manufacturer's Service/Maintenance Manual. CREDIT Not applicable CAB09-9 Page 8 October 19, 2009

9 OWNER NOTIFICATION On November 2, 2009 the following Owner Advisory message will be sent to applicable owners of record in CAB09-9A. Dear Caravan Owner: This Owner Advisory is to inform you that Caravan Service Bulletin CAB09-9 has been issued to announce the availability of a TKS Ice Protection System. Airplanes affected by CAB09-9 are: The following airplanes equipped with a cargo pod but not equipped with the Garmin G1000 avionics system: Model 208B Serial Numbers 208B 208B0001 thru 208B1189, 208B1191 thru 208B1215, 208B1217 thru 208B1313, and 208B1315 thru 208B1999 Additional requirements are: CAB09-9 may only be accomplished on airplanes factory equipped with the 675 SHP PT6A-114A Engine or airplanes on which the engine has been converted in accordance with SK SHP PT6A-114A Engine Installation (or latest revision). CAB09-9 must not be accomplished on airplanes that have an engine installed that was converted in accordance with SK SHP PT6A-114 Engine Installation (or latest revision). CAB09-9 may only be accomplished on airplanes with an existing McCauley part number P , P , or P propeller installed. As an alternative, a new TKS equipped propeller maybeinstalledasspecified in CAB09-9. CAB09-9 may only be accomplished on airplanes equipped with the standby alternator system. Compliance is Optional: may be accomplished if desired. NOTE: If not previously accomplished, Service Bulletin CAB08-7 Revision 1 Low Airspeed Awareness System Installation must be accomplished along with this Service Bulletin (CAB09-9). NOTE: The information contained in the referenced Cessna Service Bulletin shall be considered an amendment to the Cessna Manufacturer s Service/Maintenance Manual. Please contact a Cessna Caravan or Propjet Service Station for detailed information and if desired, arrange to have Service Bulletin CAB09-9 accomplished on your airplane. * * * * * * * CAB09-9 October 19, 2009 Page 9

10

11 Caravan TITLE TKS ICE PROTECTION SYSTEM INSTALLATION EFFECTIVITY For the airplanes that follow that are equipped with a cargo pod but are not equipped with the Garmin G1000 avionics system: Model Serial Numbers 208B 208B0001 thru 208B1189, 208B1191 thru 208B1215, 208B1217 thru 208B1313, 208B1315 thru 208B1999 NOTE: This Service Kit may only be accomplished on airplanes factory equipped with the 675 SHP PT6A-114A Engine or airplanes on which the engine has been converted in accordance with SK SHP PT6A-114A Engine Installation (or latest revision). NOTE: This Service Kit must not be accomplished on airplanes that have an engine installed that was converted in accordance with SK SHP PT6A-114 Engine Installation (or latest revision). NOTE: This Service Kit may only be accomplished on airplanes with an existing McCauley part number P , P , or P propeller installed. As an alternative, a new TKS equipped propeller may be installed as specified in this Service Kit. NOTE: This Service Kit may only be accomplished on airplanes equipped with the standby alternator system. DESCRIPTION To provide the parts and instructions to install the TKS Ice Protection System. APPROVAL FAA approval has been obtained on technical data in this publication that affects airplane type design. CHANGE IN WEIGHT AND BALANCE The figures that follow show an estimated change only. For accurate weight and balance figures, you should weigh the airplane after this Service Kit has been accomplished. MODEL B equipped with radar 208B not equipped with radar WEIGHTINCREASE pounds pounds ARM inches inches October 19, 2009 Page 1 of 282 To obtain satisfactory results, procedures specified in this publication must be accomplished in accordance with accepted methods and prevailing government regulations. Cessna Aircraft Company cannot be responsible for the quality of work performed in accomplishing the requirements of this publication. Cessna Aircraft Company, Customer Service, P.O. Box 7706, Wichita, Kansas 67277, U.S.A. (316) , Facsimile (316) COPYRIGHT 2009

12 RESULTANTMOMENT inch-pounds inch-pounds MOMENT/ inch-pounds inch-pounds MATERIAL INFORMATION The parts below cover installation for one airplane. NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION 1 Kit, consisting of the following parts: AN3-3A 8 Bolt None None AN4-5A 32 Bolt None None AN525-10R20 4 Screw AN525-10R18 Discard AN525-10R6 4 Screw None None AN525-10R8 4 Screw None None AN840-6D 2 Adapter None None AN912-2D 2 Bushing None None C15Green 3 Switch Green Tip None None CCR244SS Rivet None None CM J1S 3 Plug Button None None CM J1S 1 Plug Button None None CM3827AD3-3 6 Rivet None None CM3827AD Rivet MS20470AD4-4-5 Discard CR Rivet Various Discard CR Rivet Various Discard CR Rivet Various Discard D1329-S Pilot's Operating Handbook Supplement S61 D1329S1 Discard F ft Duct None None F ft Velcro Loop Strip None None H ft Nylon Tubing None None H ft Nylon Tubing None None H ft Nylon Tubing None None H ft Grommet None None H ft Grommet None None HL20PB Pin None None Page 2

13 HL20PB Pin None None HL20PB Pin None None HL20PB Pin None None HL20PB Pin None None HL20PB6-5 2 Pin None None HL Collar None None HL Collar None None M85528/2-12-A 1 Mounting Flange None None M85528/2-16-B 1 Mounting Flange None None MN Sleeve None None MN Sleeve None None MN Sleeve None None MN Nut None None MN Nut None None MN Back Nut None None MN Back Nut None None MN Nut None None MN Tee, Bulkhead Equal None None MN Back Nut None None MN Tee, Bulkhead Unequal None None MN Connector, Bulkhead None None Short MN Reducing Bulkhead None None MN Blanking Cap Assembly, None None 5/16 MN Elbow, Bulkhead 1/2 None None MN Elbow Assembly None None MS20426AD3-4A 4 Rivet None None MS20470A4-7N 17 Rivet None None MS20470AD3-3A5 12 Rivet None None MS20470AD4-3A5 70 Rivet None None MS20470AD5-6A 4 Rivet None None MS Nut None None MS21044N06 4 Nut None None MS21044N08 4 Nut Same Discard MS21044N3 8 Nut None None MS21047L08 6 Nutplate None None Page 3

14 MS21069L08K 2 Nutplate None None MS21075L08N 4 Nutplate None None MS21083C3 8 Nut None None MS21919WDG12 6 Clamp None None MS21919WDG13 2 Clamp None None MS21919WDG14 2 Clamp None None MS21919WDG17 2 Clamp None None MS Switch None None MS Switch None None MS24694-C53 8 Screw None None MS24694-S5 2 Screw MS24693-S49 Discard MS24694-S6 2 Screw MS24693-S50 Discard MS Screw None None MS Screw None None MS Switch None None MS Screw None None MS Screw None None MS Screw None None MS Screw None None MS Screw None None MS Screw MS Discard MS Lock Washer, Flat Same Discard NAS1149C0363R 8 Washer None None NAS1149F0332P 16 Washer None None NAS1149F0432P 24 Washer None None NAS1149F0463P 8 Washer None None NAS1149F0563P 1 Washer None None NAS1149FN632P 4 Washer None None NAS1149FN832P 4 Washer None None NAS1515H08L 6 Washer None None NAS1835A3M 4 Insert None None NAS43DD3-31FC 4 Spacer None None NAS514P Screws None None PU320AC160 1 Proportioning Unit None None P041LH Switch, Pressure None P ft Protective Conduit None None Page 4

15 P ft Plastic None None P ft ProtectiveConduit None None P ft Protective Conduit None None R ft Hose None None S1021Z8-6 3 Screw None None S Grommet None None S Circuit Breaker None None S Circuit Breaker None None S1446-1S 1 Doubler Assembly None None S1447-1S 1 Plate None None S Anchor None None S Connector None None S Clamp, Worm Drive None None S Mount None None S Tie, Strap None None S Mount None None S Fluid Tank & Equipment None None Pack S Filler Door Assembly None None S Sealing Ring None None S Sealing Ring None None S Rivet None None S Rivet None None S Rivet None None S Bracket None None S Ferrule None None S Rivet Various Discard S Rivet Various Discard S Clamp None None S3899A4-8N 1 Rivet None None S3899A5-5N 8 Rivet None None ZN Olive for 3/16 Nylon None None ZN Sleeve None None ZN Nut None None ZN Nut None None ZN Nut None None ZN Fitting None None Page 5

16 ZN Back Nut None None ZN Fitting None None D8EP 1 Clamp None None Seal None None Porous Panel, Left None None Outboard Wing Porous Panel, Right None None Outboard Wing Porous Panel, Left None None Mid-Wing Porous Panel, Left None None Inboard Wing Porous Panel, Right None None Inboard Wing Porous Panel, Left Wing None None Strut Porous Panel, Right Wing None None Strut Porous Panel, Left None None Horizontal Stabilizer Porous Panel, Right None None Horizontal Stabilizer Porous Panel, Vertical None None Stabilizer Bolt Filler Gasket None None Filler Cap Flange None None Filler Cap None None Spray Bar Assembly None None Deflector None None Bracket None None Propeller Nozzle None None Fluid Quantity Gage None None Bracket None None Bracket Assembly None None Proportioning Unit, Left None None Proportioning Unit, Right None None P-Clip None None Low Pressure Switch None None Wire Harness Anchor Plate None None Page 6

17 Placard, Operational Discard Limitations Bulkhead Assembly Discard Cable Cover Assembly Discard Cable Cover Discard Forward Shear Plate None None Assembly Aft Shear Plate Assembly None None Rear Shear Plate None None Assembly, Left Rear Shear Plate None None Assembly, Right Drip Pan None None Internal Attach Clip, Right None None Attach Clip, Rear None None Attach Clip, Front None None Internal Attach Clip, Left None None Doubler, Left Fuselage None None Doubler, Right Fuselage None None Doubler, Tail Prop Unit None None Cargo Net Assembly None None Cargo Net Fitting None None Placard, Icing Conditions Discard Placard, TKS Operational None None Limit Placard, TKS Operational None None Limit Placard, Circuit Breaker Discard Panel Placard, Circuit Breaker Discard Panel Bus Bar Discard Post Light Assembly None None TKS Cable Assembly None None Cockpit Annunciator None None 3D Vortex Generator None None Hose Assembly None None Hose Assembly None None Placard, Solvent Cleaning None None Page 7

18 Placard, Windshield None None Anti-Ice Placard, Filler Cap None None 1 Instructions The parts below will be necessary for airplanes equipped with Bendix/King Weather Radar: NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION Porous Panel, Right None None Mid-Wing, Radar The parts below will be necessary for airplanes not equipped with Bendix/King Weather Radar: NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION Porous Panel, Right None None Mid-Wing without Radar The parts below may be necessary to install the Lift Transducer: NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION NAS1149FN816P As required Washer None None NAS1149FN832P As required Washer None None The part below will be necessary for airplanes with the Configuration Module for the Bendix/King Weather Radar installed on the wing rib at WS NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION MS21044N06 2 Nut Discard The parts below will be necessary for airplanes with the standard paint scheme that replace the propeller during the forward-of-firewall installation. Refer to Figure 22. NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION P TKS Propeller Various Return to Cessna E Bulkhead Assembly, TKS E-6391 Discard The parts below will be necessary for airplanes with the Fedex paint scheme that replace the propeller during the forward-of-fuselage installation. Refer to Figure 22. NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION P TKS Propeller Various Return to Cessna E Bulkhead Assembly, TKS E-6391 Discard Page 8

19 The parts below will be necessary for airplanes that modify the existing propeller during the forward-of-fuselage installation. Refer to Figure 22. NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION D Mod Kit - C703 TKS Various Discard The parts below will be necessary for airplanes that do not have access plates installed in the horizontal stabilizers. Refer to Figure 7. NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION MS20426AD3-3A 12 Rivet None None S1021Z8-6 6 Screw None None S1446-1S 2 Doubler Assembly None None S1447-1S 2 Plate None None The parts below will be necessary for airplanes that have holes installed in the cargo pod and the MLG fairingfortheoptionalanti-icesystem. RefertoFigure32andFigure17. NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION CM3827AD Rivet None None MLG Fairing Plate None None MLG Fairing Plug None None The parts below will be necessary for airplanes that have the optional boot anti-ice system installed. RefertoFigure10andFigure15. NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION AN3-5A 2 Bolt AN3-15A Discard AN Cap None None AN Cap None None CM J1S 1 Plug Button None None CM3827AD Rivet None None MS20470AD4-4A 2 Rivet Same Discard MS Packing None None MS Screw None None S Rivet None None Filter, Blank Discard Wing Plug None None Stabilizer Plate None None Stabilizer Plug None None Page 9

20 Vertical None None Stabilizer Plate Vertical None None Stabilizer Plug Wing Plate None None The parts below will be necessary for airplanes that have the optional windshield anti-ice panel installed. RefertoFigure18orFigure31. NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION MS21044N3 2 Nut MS24694S3 2 Screw MS24694S55 2 Screw MS Screw NAS1149F0363P 2 Washer Blank Filter Discard Cover Plate None None The parts below will be necessary for airplanes 208B0001 thru 208B0213 that are not equipped with anti-ice equipment. Refer to Figure 29. NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION A-7079B-24 1 Lamp None None MS24693S27 3 Screw None None MS Screw None None NAS1149FN832P 2 Washer None None C15Green 1 Switch Green Tip None None MS20470A4-4N 8 Rivet None None MS20470AD4-4A 2 Rivet None None MS Nut None None MS21919WDG2 1 Clamp None None MS Switch None None MS Grommet None None S Circuit Breaker None None S Socket None None S Housing None None S Housing Cap None None Cover None None Lens None None Bracket None None Page 10

21 Housing Assembly None None (As required) Shim None None LH1 1 Wire None None LH2 1 Wire None None LH3 1 Wire None None LH7 1 Wire None None LH8 1 Wire None None The parts below will be necessary for airplanes that have not incorporated CAB04-9 / SK (or latest revision) Ice Protection Installation/Modification. NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION SK A1 1 Detector, Windshield Ice None None SK A2 1 Handle, Pilot Assist None None The part below will be necessary for airplanes 208B0001 thru 208B1234 that have not incorporated CAB07-3 (or latest revision) Pilot's Operating Handbook Supplement S1 Revision and Operational Limitation Placard Installation. Refer to Figure 20. NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION Placard, Icing Warning None None The following materials, or equivalent, are necessary. NAME NUMBER MANUFACTURER USE Adhesive U Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box 1521 Wichita, KS Alodine U Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box 1521 Wichita, KS B4 Sealant (Semkit, 6 oz) U Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box 1521 Wichita, KS To fill fiber around holes in bottom of cargo pod To apply to bare metal To fillet seal around drain tubes at bottom of cargo pod and around anti-ice panel windshield installation holes after windshield panel is removed Page 11

22 NAME NUMBER MANUFACTURER USE Tape P Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box 1521 Wichita, KS Clear Polyurethane Paint Polyurethane Enamel Paint Corrosion Resistant Primer EA9309.3NA Adhesive (25 gram kit) CM K U Sherwin Williams Co. Phone: Available Locally Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box 1521 Wichita, KS Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box 1521 Wichita, KS Fiberglass Cloth 7781 Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box 1521 Wichita, KS Epoxy Adhesive Paste U Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box 1521 Wichita, KS To apply to panels and skin for protection during cleaning and installation procedures To edge seal placards To paint the areas around the TKS modification to match the airplane For corrosion protection To install inserts To repair hole in cargo pod To install a grommet Isopropyl Alcohol TT-I-735 Available locally To clean wing surface before VG installation Sealant U544053S Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box 1521 Wichita, KS Sealant (3.5 oz cartridge) Sealant (Semkit, 3.5 oz) U U Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box 1521 Wichita, KS Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box 1521 Wichita, KS To seal access panels on wing To fillet seal edges of spray bar installation and to install porous panels To install ice detector light and to fay seal around repair plugs in wing, wing root rib, empennage, and fuselage Page 12

23 NAME NUMBER MANUFACTURER USE Sealant (Semkit, 6 oz) U544042S Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box 1521 Wichita, KS Adhesive U Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box 1521 Wichita, KS EPON 815 or EPON 828 Cab-O-Sil, fumed silica Shell Chemical Company Plastics and Resin Division Houston, TX Cabot Corporation 157 Concord Road P.O. Box 7001 Billerica, MA Phone: Fax: To install porous panels To fill core plug and repair hole in cargo pod (Alternative to U000941) to repair hole in cargo pod Optional, to apply filler material to EPON 815 or 828 resin Lubricant MIL-PRF-83483C Available locally To lubricate parts in propeller installation Adhesive, Epoxy U064092S or equivalent Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box 1521 Wichita, KS To install grommets Lockwire MS20995C25 Available locally To safety fasteners on the propeller Adhesive, 1300L U000787S Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box 1521 Wichita, KS TKS Anti-ice Fluid IF-406B-KF-2.5M (2.5 gallon) IF-406B-KF-5M (5 gallon) IF-406B-KF-30M (30 gallon) IF-406B-KF-55M (55 gallon) IF-406B-KF- 250M (250 gallon) Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box 1521 Wichita, KS To install vortex generators and velcro TKS Anti-ice fluid for TKS system Page 13

24 The equipment below, or equivalent, will also be necessary: Name Number Manufacturer Use TKS System Test Cart To do the TKS porous CAV Aerospace, Inc. panel purge and test 2734 Arnold Court procedures Salina, KS Phone: Fax: Plastic Guttering Commercially Available To catch anti-ice fluid from the TKS panel purge procedure Clenching Tool, with Mandrel (3/16 Inch) Clenching Tool Body (3/16 Inch) Clenching Tool Mandrel (3/16 Inch) Clenching Tool Body (5/16 Inch) Clenching Tool Mandrel (5/16 Inch) Clenching Tool (5/16 Inch) T A CAV Aerospace Inc. To fabricate TKS tubing T CAV Aerospace Inc. To fabricate TKS tubing T CAV Aerospace Inc. To fabricate TKS tubing T CAV Aerospace Inc.. To fabricate TKS tubing T CAV Aerospace Inc. To fabricate TKS tubing T A CAV Aerospace Inc. To fabricate TKS tubing Clenching Tool (1/2 Inch) T CAV Aerospace Inc. To fabricate TKS tubing Clenching Tool (3/8 Inch) T CAV Aerospace Inc.. To fabricate TKS tubing Blank Olive with MN4856 Nut (3/16- Inch Tube) Nylon Ball with MN4855 Nut (5/16- Inch Tube) Nylon Ball with MN6201 Nut (1/2-Inch Tube) P075 CAV Aerospace Inc. To cap the TKS tubing during tests CAV Aerospace Inc. To cap the TKS tubing during tests CAV Aerospace Inc. To cap the TKS tubing during tests Plastic Sheeting Commercially Available To catch anti-ice fluid from the TKS panel purge procedure Aluminum Tape Commercially Available To attach guttering and tubes to catch anti-ice fluid from the TKS panel purge procedure Plastic Tubes Commercially Available To catch anti-ice fluid from the TKS panel purge procedure Shutoff Valve Commercially Available To modulate system pressure during functional test Page 14

25 Name Number Manufacturer Use PSI Fluid Gage Commercially Available To measure pressure in the system during functional test Ratcheting Straps Commercially Available To apply force to the inboard wing porous panels The equipment below, or equivalent, may be necessary: Name Number Manufacturer Use Eddy Current Instrument Commercially Available To inspect the wing leading edges Page 15

26 ACCOMPLISHMENT INSTRUCTIONS NOTE: You must accomplish Service Kit SK B, Low Airspeed Awareness System Installation for Airplanes with TKS, or latest revision in conjunction with this Service Kit. NOTE: Accomplish SK B after this Service Kit () is installed because a necessary connector - PI003/JI003 - is not installed until you install wiring for TKS. 1. (Refer to Figure 30, Detail A.) Find the TKS Porous Panels and install P Tape on the surface of each panel. The tape will give some protection to the panels during their installation, and will give an edge when you do an edge/fillet seal. 2. Prepare the airplane for maintenance as follows: A. (Airplanes with a anti-ice system installed) Put the airplane in a location where you can easily apply paint. B. Electrically ground the airplane. C. Make sure that all switches are in the OFF/NORM position. D. Disconnect electrical power from the airplane. (1) Disconnect the airplane battery. (2) Disconnect external electrical power. E. Attach maintenance warning tags to the battery and external power receptacle that have "DO NOT CONNECT ELECTRICAL POWER - MAINTENANCE IN PROGRESS" writtenonthem. F. Obey the general cautions, warnings, and instructions that follow when you install or work near the ice protection system: CAUTION: Be careful when you install the porous panels to make sure that you do no damage to the wing leading edge skin. WARNING: WARNING: WARNING: For heath and environmental data, review the Material Safety Data Sheet (MSDS) for TKS fluid. Refer to the MSDS that should be included with the shipment of TKS fluid. If you cannot locate the MSDS, contact your supplier of the TKS fluid to obtain the MSDS. Make sure that you use applicable eye protection when you work near the ice protection system. The system uses high pressure in the lines to operate correctly, and the fluid pressure stays in the system lines until it is released. If you do not use applicable eye protection, fluid under pressure can hit your eyes and cause damage when you do work on the system. Discard all unwanted TKS fluid and/or dirty cloths correctly. TKS fluid is a hazardous waste and must be discarded in accordance with procedures approved by the local jurisdiction. (1) Make sure that you wear applicable eye protection when you do work on or near the ice protection system. WARNING: Before you disconnect components of the TKS anti-ice system, slowly loosen the coupling that is connected to the component to be removed because it is possible that high pressure is still in the system. (2) Slowly loosen the connection at the necessary fitting to release high pressure in the system. Page 16

27 WARNING: Make sure that you remove ice protection fluid from the floor surfaces where passengers and personnel walk. The fluid can make surfaces slick. (3) Remove all ice protection fluid from areas where people walk. Since there is leakage of fluid from the panels for a while after the system is no longer in operation, make sure that you collect fluid that drips from the airplane or continue to remove fluid from the floor until there is no more leakage. CAUTION: Never use unapproved ice protection fluids in the ice protection system. Never use a thickened anti-ice fluid or one that is made for use on the runway, in automobiles, or on parked airplanes. If you use fluids that do not meet the DTD406B specification, you will do damage to the membranes in the porous panels and other system components. CAUTION: Use only clean, filtered fluid in the TKS system. Contamination will cause fluid blockage and/or damage to the porous panel. (4) Use only ice protection fluids that meet the DTD406B specification in the ice protection system. (5) You can mix fluids that meet the DTD406B specification in any proportions in the airplane tank. CAUTION: Donotdodamagetotheiceprotectionsystemwithsolventsorpaints. Most solvents and all paints can cause damage to the plastic membrane in the porous panels. Use only the materials from the list below when you work on or near the porous panels. Never use MEK, acetone, or lacquer thinner. Always use masking material when you use paint or solvents that are not on the list below when you work on or near the porous panels. (6) The materials that follow are approved to clean the porous panels. Use them with a brush or a lint-free cloth: Water with soaps or detergents Aviation gasoline Isopropyl alcohol Industrial methylated spirit Ice-protection fluids that are approved for use on the airplane Aviation turbine fuel Ethyl alcohol. (7) Always use P Tape or equivalent low-residue masking material to make sure that unapproved materials do not touch the porous panels. (8) (Refer to Figure 27.) Use these instructions when you do the assembly and the installation of the tubing and the lines: (a) (b) (c) (d) CAUTION: Donotdodamagetothenylontubingintheiceprotectionsystem.There must be no tension or strain on the nylon tubing, as these forces when applied to the nylon tubing can cause damage. Cut and install the nylon tubing in lengths that take into consideration the effects of tension and strain. When you cut the nylon tubing, add no less than 3% (1 inch for each 3 feet) to the necessary length for thermal shrinkage and airframe flexure. Do not use components of dissimilar metals unless the instructions specify components that have dissimilar metals. Use only the specified nylon tubing, coupling bodies, olives, rubber sealing rings, and nuts in accordance with these instructions to make compression fitting connections. Page 17

28 (e) (f) (g) (h) In a warm water (temperature of the water is not to be more than 140 degrees) and detergent solution, clean all tubing and fittings completely and then dry them with clean air before you assemble the lines. Use only the specified clenching tools in accordance with these instructions to make compression fitting connections. When you assemble the line, put the correctly sized nut on the tubing in the correct position. (Refer to the Model 208 Maintenance Manual, Chapter 30, TKS Anti-Ice Fluid Distribution System - Maintenance Practices, Figure 204.) Put the olive on the tubing with the bevel end of the olive toward the end of the tubing. (Refer to the Model 208 Maintenance Manual, Chapter 30, TKS Anti-Ice Fluid Distribution System - Maintenance Practices, Figure 204.) CAUTION: Do not use the coupling nut to clench the olive to the fluid tubing. Use only specified clenching tools to do the clenching operation. Also, do not torque the couplings too much during the repair or replacement procedure. If the couplings leak, install new seals as necessary. (i) (j) (k) (l) (m) (n) (o) (p) (q) CAUTION: Clench the olive to the tubing without a sealing ring in position. If you clench the olive with a sealing ring in position, you will prevent a correct clenchandthesealingringwillbeunserviceable. Put the end of the nylon tubing into the correctly-sized clenching tool as far as it will go. Make sure that the outer end of the olive is in the correct position in the bore of the nut. Turn the nut onto the clenching tool until it is finger tight plus 315 (five and one quarter flats). 1 Make sure that the nylon tubing stays bottomed out in the clenching tool until the clenching operation is completed. 2 Make sure that the mandrel is fully engaged in the tool. NOTE: Clenching tools for 3/16-inch and 5/16-inch outside diameter tubing have mandrels to hold the inside of the tubing. 3 The tubing, olive, and mandrel can turn during the clenching operation, and that is permitted. Unscrew the nut and remove the olive and the tubing from the clenching tool. NOTE: It may be necessary to remove the mandrel from the clenching tool to remove the tubing. Do an inspection of the installed olive to see that it is correctly swaged. CAUTION: Do not use the seals again after you loosen or disconnect a tube coupling. Replace the 3/16-inch and 5/16-inch sealing ring and/or 1/2-inch O-ring, as applicable, when you assemble a tube coupling. Examine the seal for damage and make sure that it is in the correct position. This will help to prevent fluid leakage from the coupling. Put a sealing ring of the correct dimension over the end of the tubing. Put the tubing into the coupling body and move the sealing ring into the recess at the end of the coupling body. Push the tubing toward the coupling body to make the olive hold the sealing ring in position. Engage and finger tighten the nut. Page 18

29 (r) (s) Tighten the nut until the torque starts to increase quickly (to approximately 180 from finger tight). Use safety wire to safety nuts only where it is specified in the instructions. If not specified in the instructions, safety wire is not necessary on the TKS fittings. CAUTION: After you remove and before you install a porous panel, apply P Tape or equivalent low-residue masking material on the panel to give it protection. (9) (Refer to Figure 27.) When tubing repair or replacement is necessary, the olive must always be clenched (swaged) to the tubing as a separate operation. Use approved clenching tools before you assemble the coupling. (10) (Refer to Figure 27.) Assemble the nylon tubing and the couplings in accordance with approved maintenance practices. CAUTION: As you accomplish this Service Kit, make sure that you keep a minimum edge distance of no less than two times the diameter of the rivet. (11) Install all rivets with a minimum edge distance of no less than two times the diameter of the rivet. 3. Get access for the installation as follows: A. Do an initial weight and balance of the airplane before installation of the TKS Ice Protection System Installation and the SK B Low Airspeed Awareness System Installation. (Refer to the applicable Pilot's Operating Handbook and the Model 208 Maintenance Manual, Chapter 8, Leveling and Weighing.) B. Remove the spinner and the propeller. Keep the B4864 Spinner Support. Keep the B4940 Shims, if shims are installed. (Refer to the 208 Maintenance Manual, Chapter 61, Propeller - Maintenance Practices.) C. Remove all of the wing inspection panels and access panels from both wings. (Refer to the 208 Maintenance Manual, Chapter 6, Access Plates and Panels Identification - Description and Operation.) NOTE: Although some panels need not be removed for access, all of the access panels but the fuel bay panels must be removed to apply sealant. D. Remove the fuselage wing and wing strut fairings. (Refer to the 208 Maintenance Manual, Chapter 57 - Wings - Removal/Installation.) E. Remove the pilot's and the copilot's seats. (Refer to the 208 Maintenance Manual, Chapter 25, Flight Compartment - Maintenance Practices.) F. Remove the cabin upholstery and passenger seats as necessary to get access to do the installation and the routing of the tubing and the wiring. (Refer to the 208 Maintenance Manual, Chapter 25, Cabin Upholstery - Maintenance Practices.) G. Remove the floor inspection covers in the area between FS and FS and along the left and the right sides of the floor. (Refer to the 208 Maintenance Manual, Chapter 53, Floorboards and Access Plates - Maintenance Practices.) H. Remove the aft cabin bulkhead cover. I. Remove Panel 320A from the lower tailcone area. (Refer to the 208 Maintenance Manual, Chapter 6, Access Plates and Panels Identification - Description and Operation.) J. Remove all of the horizontal and vertical stabilizer inspection panels, if installed. (Refer to the 208 Maintenance Manual, Chapter 6, Access Plates and Panels Identification - Description and Operation.) K. Remove the engine cowlings and the upper center cowl assembly. (Refer to the 208 Maintenance Manual, Chapter 71, Engine Cowling and Nose Cap - Maintenance Practices.) Page 19

30 L. (Airplanes equipped with radar) Remove the radome and the radar and put them in a safe location. (Refer to the 208 Maintenance Manual, Chapter 34, Garmin GWX-68 Weather Radar - Maintenance Practices.) M. Remove the stall warning detector and let it hang from the airplane wing. Discard the gasket on the stall warning detector. (Refer to the Model 208 Maintenance Manual, Chapter 27 - Stall Warning System - Maintenance Practices.) NOTE: You will not use the gasket when you install the stall warning detector again. 4. Remove applicable anti-ice systems installed on the airplane as follows: NOTE: During the anti-ice system removal, try to completely remove the applicable wires from the system. But where this is not possible, put caps on the connectors and stow wiring that will no longer be used in accordance with standard shop practice. NOTE: RefertoFigure16duringwireremoval.Wireswithhatchmarksonthefigurearewiresthatwillno longer be used and can be removed from the airplane. A. (Refer to Figure 15.) Remove the parts shown in Figure 15 to remove the anti-ice system, if installed, from the airplane. NOTE: You can cut old pneumatic anti-ice lines as necessary for easier removal of the system. B. Clean the area of the wings, horizontal and vertical stabilizers, gear legs and front of cargo pod where you removed the anti-ice boots. (Refer to the 208 Maintenance Manual, Chapter 20, General Solvents/Cleaners - Maintenance Practices.) C. After removal of all wing, empennage, and gear leg anti-ice boots, do an inspection of the leading edge skins for evidence of corrosion. (Refer to Model 208 Structural Repair Manual, Chapter , Corrosion Repair.) (1) If there is corrosion and it is more than the acceptable damage limits listed in Chapter 51 of the Model 208 Structural Repair Manual, speak to Cessna Aircraft Customer Service at for more instructions. (2) If there is corrosion and you can repair it after a damage evaluation in accordance with Chapter 51 of the Model 208 Structural Repair Manual, repair in accordance with the applicable instructions. (3) If there is no corrosion, no repair is necessary. D. (Airplanes with anti-ice installation) (Refer to Figure 15, View A-A.) Install one AN Cap on the ejector supply line AN Elbow on the aft side of the firewall as shown. E. (Airplanes with anti-ice installation) (Refer to Figure 15.) Install two AN929-8 Caps on the anti-ice tube fittings that you left in the airplane ceiling. F. (Airplanes with anti-ice installation) (Refer to Figure 15, View B-B.) Install a Blank Filter to replace the Filter that you removed. G. (Airplanes with propeller heat installation) (Refer to Figure 28.) Remove the parts shown in Figure 28 to remove the propeller heat installation from the airplane. H. (Airplanes with optional double-wide windshield anti-ice panel) (Refer to Figure 18.) Remove the parts shown in Figure 18 to remove the optional windshield anti-ice panel system from the airplane. I. (Airplanes with optional windshield anti-ice panel.) (Refer to Figure 31.) Remove the optional windshield anti-ice panel system from the airplane. J. (Airplanes with optional single-wide windshield anti-ice panel.) (Refer to Figure 18, Detail A and Figure 31.) Install the two MS Screws, two MS24694S3 Screws, one Cover Plate, two MS24694S55 Screws, two NAS1149F0363P Washers, and two MS21044N3 Nuts to repair the area where you removed the windshield anti-ice panel. K. (Airplanes with optional windshield anti-ice panel) (Refer to Figure 18 and Figure 31.) Install a Blank Filter to replace the Filter that you removed. Page 20

31 L. (Airplanes with optional cargo pod and landing gear anti-ice installation.) Install hardware in open holes. (1) (Refer to Figure 15, View G-G.) On the engine firewall, install one AN3-5A Bolt in the heater shroud assembly. (2) Install two MS Screws where the mounting plate for the ejector flow control valve on the firewall was removed. (3) Stow the two wires from the ejector flow control valve that was removed. (4) (Refer to Figure 15, Detail E.) Install CM J1S Plug Button in the 0.62-inch diameter hole at front of cargo pod. (5) With U Sealant, fillet seal around the edges of the CM J1S Plug Button. (6) (Refer to Figure 15, View H-H.) On the airplane belly skin, install MS20470AD4-4 Rivets in holes on the cover where the bracket was removed. NOTE: Some airplanes did not have a bracket installed. (7) (Refer to Figure 15, View H-H.) If there were rivets installed in the mounts that you removed from the airplane belly skin, install five or six S Rivets as necessary in the open holes. (8) (Refer to Figure 15, View G-G.) Install one AS5169D10 Plug/Bleeder and one MS Packing in the tee that is mounted on the engine firewall. M. (Airplanes with optional cargo pod and landing gear anti-ice installation.) Repair the holes in the cargo pod and in the main landing gear fairings. (1) Repair the hole in the cargo pod as follows: (a) Read through the steps that follow before you begin the repair of the hole, and speak to Cessna Aircraft Customer Service at if the repair cannot be accomplished as described below. (b) Scarf back two layers of fiberglass on the inside and the outside of the Forward Cargo Pod Assembly with a 0.75-inch step exposure. (c) Remove the finish for 0.75 inch all around the last scarfed layer. (d) Install a 1.50-inch diameter circular core plug made from 0.50-inch thick Nomex honeycomb to fill the hole. (e) Fill the core plug with U Adhesive. 1 As necessary, add fumed silica (Cab-O-Sil) or microballoons, up to 5 percent by weight, to thicken the paste. 2 As an option, you can fill with EPON 815 or equivalent fiberglass resin in accordance with the Model 208 Structural Repair Manual, Chapter 51, Glass Fabric Repair. (f) (Refer to Figure 32, Detail B.) Overlay each side of the plug with three circular layers of 1.50-inch diameter woven fiberglass plies and three circular stepped layers of woven fiberglass plies. 1 You can use styles 120, 1581, or 7781 fiberglass cloth. 2 Orient each ply to align with the weave orientation of each removed ply. 3 Overlap the top splice layer over the edge of the outer removed layer by 0.75-inch all around the circumference. (g) Impregnate all layers with resin and put in position in accordance with the Model 208 Structural Repair Manual, Chapter 51, Glass Fabric Repair, or impregnate all layers with U Adhesive. (h) Cure with applied pressure for the manufacturer's specified cure time. Page 21

32 (i) Sand the area with 600-grit sandpaper to the correct surface finish. (j) Do a touch-up of the paint. (Refer to the Model 208 Maintenance Manual, Chapter 20, Interior and Exterior Finish - Cleaning/Painting.) (2) (Refer to Figure 17.) Repair the holes in the main landing gear fairings as follows: (a) Put the two MLG Fairing Plates in position on the exterior of the MLG fairings. (b) Make marks for nine holes to attach each MLG Fairing Plate to the MLG fairing skin. (c) Match drill nine Number 40 (0.098-inch diameter) holes in the two positions on the MLG fairing skin and in each of the two MLG Fairing Plates. (d) Temporarily attach the two plates in position on the interior of the skin and use a marker to trace the circumference of the holes on to the plates to help put the MLG Fairing Plugs in the correct position. (e) Remove the plates and align the plugs with the circles that you made on the plates. (f) Make marks for six holes to attach each of the two MLG Fairing Plugs to the MLG Fairing Plates. (g) Match drill six Number 40 (0.098-inch diameter) holes in each MLG Fairing Plug and in each MLG Fairing Plate. (h) Deburr and countersink all holes and apply Alodine to bare metal. (i) With U Sealant, do a fay surface seal between the MLG Fairing Plates and the two MLG Fairing Plugs. (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather, and High-Temperature Sealing - Maintenance Practices.) (j) With 12 CM3827AD3-3 Rivets, attach the two MLG Fairing Plugs to the MLG Fairing Plates. (k) With 18 CM3827AD3-3 Rivets, attach the two MLG Fairing Plugs to the MLG fairing skin. 5. Make changes to the structure of the airplane for the ice protection system installation as follows: A. (Refer to Figure 6, View D-D.) Drill three drain holes in the tailcone at FS as follows: (1) Drill three 0.25-inch diameter holes through the airplane skin 2.40 inches aft of FS Put one hole at RBL 1.75, one hole at RBL 9.00 and one hole at LBL (2) Deburr and apply Alodine and epoxy primer to bare metal. B. (Airplanes that have holes installed in the wings for the optional boot anti-ice system) (Refer to Figure 10, Detail A.) Repair the four pneumatic line holes in the leading edges of the wings at WS and WS with patches as follows: NOTE: The pnuematic line holes in the wing struts do not have to be patched. The TKS porous panels will cover the holes. (1) Put the four Wing Plates in position on the exterior surface of the wings. (2) Make marks for 11 holes to attach each Wing Plate to the wing skin. NOTE: On the left inboard wing patch, you can trim the edge of the wing plate as necessary to prevent interference with a wing leading edge rib. If necessary, do not use two of the rivet locations as shown. (3) Match drill 11 Number 40 (0.098-inch diameter) holes at each position on the wing skin and in each Wing Plate. (4) Temporarily attach the wing plate in position on the interior of the skin and use a marker to trace the circumference of the hole on to the plate to help put the plug in the correct position. Page 22

33 (5) Remove the wing plate and align the plug with the marked circle. (6) Make marks for nine holes to attach each Wing Plug to the Wing Plate. (7) Match drill nine Number 40 (0.098-inch diameter) holes in each Wing Plug and in each Wing Plate. (8) Deburr and countersink all holes and apply Alodine to bare metal. (9) With U Sealant, do a fay surface seal between the Wing Plates and the Wing Plugs. (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather, and High-Temperature Sealing - Maintenance Practices.) (10) With U Sealant, do a fay surface seal between the four Wing Plates and the wing skins (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather, and High-Temperature Sealing - Maintenance Practices.) (11) With 36 CM3827AD3-3 Rivets, attach the four Wing Plugs to the four Wing Plates. (12) With 44 CM3827AD3-3 Rivets, attach the four Wing Plates to the inside wing skins. C. (Airplanes that have holes installed in the horizontal stabilizers for the optional boot anti-ice system) (Refer to Figure 10, Detail B.) If installed, put a patch in the pneumatic line holes at SS in the left side and the right side of the horizontal stabilizer as follows: (1) Put the two Stabilizer Plates in position on the exterior of the horizontal stabilizer. On the left side the Stabilizer Plate is installed on the top of the horizontal stabilizer and on the right side the Stabilizer Plate is installed on the bottom of the horizontal stabilizer. (2) Make marks for nine holes to attach each Stabilizer Plate to the horizontal stabilizer skin. (3) Match drill nine Number 40 (0.098-inch diameter) holes in the two positions on the horizontal stabilizer skin and in each of the two Stabilizer Plates. (4) Temporarily attach the two stabilizer plates in position on the interior of the skin and use a marker to trace the circumference of the holes on to the plates to help put the plugs in the correct position. (5) Remove the stabilizer plates and align the plugs with the circles that you made on the plates. (6) Make marks for six holes to attach each of the two Stabilizer Plugs to the Stabilizer Plates. (7) Match drill six Number 40 (0.098-inch diameter) holes in each Stabilizer Plug and in each Stabilizer Plate. (8) Deburr and countersink all holes and apply Alodine to bare metal. (9) With U Sealant, do a fay surface seal between the Stabilizer Plates and the two Stabilizer Plugs. (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather, and High-Temperature Sealing - Maintenance Practices.) (10) With U Sealant, do a fay surface seal between Stabilizer Plates and the horizontal stabilizer skin (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather, and High-Temperature Sealing - Maintenance Practices.) (11) With 12 CM3827AD3-3 Rivets, attach the two Stabilizer Plugs to the Stabilizer Plates. (12) With 18 CM3827AD3-3 Rivets, attach the two Stabilizer Plates to the inside horizontal stabilizer skin. Page 23

34 D. (Airplanes that have holes installed in the vertical stabilizer for the optional boot anti-ice system) (Refer to Figure 10, Detail C.) If installed, put a patch in the pneumatic line hole at WL in the right side of the vertical stabilizer as follows: (1) Put the Vertical Stabilizer Plate in position on the exterior of the vertical stabilizer. (2) Make marks for nine holes to attach the Vertical Stabilizer Plate to the vertical stabilizer skin. (3) Match drill nine Number 40 (0.098-inch diameter) holes in the wing skin and in the Vertical Stabilizer Plate. (4) Temporarily attach the stabilizer plate in position on the interior of the skin and use a marker to trace the circumference of the holes on to the plate to help put the plug in the correct position. (5) Remove the stabilizer plate and align the plug with the circle that you made on the plate. (6) Make marks for six holes to attach the Vertical Stabilizer Plug to the Vertical Stabilizer Plate. (7) Match drill six Number 40 (0.098-inch diameter) holes in the Vertical Stabilizer Plug and the Vertical Stabilizer Plate. (8) Deburr and countersink all holes and apply Alodine to bare metal. (9) With U Sealant, do a fay surface seal between the Vertical Stabilizer Plate and the Vertical Stabilizer Plug. (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather, and High-Temperature Sealing - Maintenance Practices.) (10) With U Sealant, do a fay surface seal between the Vertical Stabilizer Plate and the vertical stabilizer skin (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather, and High-Temperature Sealing - Maintenance Practices.) (11) With six CM3827AD3-3 Rivets, attach the Vertical Stabilizer Plug to the Vertical Stabilizer Plate. (12) With nine CM3827AD3-3 Rivets, attach the Vertical Stabilizer Plate to the inside vertical stabilizer skin. E. (Refer to Figure 10, View A-A.) Install three plug buttons in the rib at the left wing root as follows: (1) Clean the area of the wing root where you will install the two CM J1S Plug Buttons and the one CM J1S Plug Button. (Refer to the 208 Maintenance Manual, Chapter 20, General Solvents/Cleaners - Maintenance Practices.) (2) Install the two CM J1S Plug Buttons and the one CM J1S Plug Button in the wing root. (3) With U Sealant, fillet seal around the edges of the two CM J1S Plug Buttons and the one CM J1S Plug Button in the wing rib root. (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather, and High-Temperature Sealing - Maintenance Practices.) F. (Refer to Figure 10, View B-B.) Install a plug button in the rib at the right wing root as follows: (1) Clean the area of the wing rib root where you will install the CM J1S Plug Button. (Refer to the 208 Maintenance Manual, Chapter 20, General Solvents/Cleaners - Maintenance Practices.) (2) Install the CM J1S Plug Button in the wing rib root. (3) With U Sealant, fillet seal around the edges of the CM J1S Plug Button in the wing rib root. (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather, and High-Temperature Sealing - Maintenance Practices.) Page 24

35 G. (Refer to Figure 9.) Remove and replace the cargo pod aft bulkhead at FS as follows: (1) (Airplanes with the IHAS omnidirectional antenna installed on the bottom of the cargo pod) (Refer to Figure 13.) Remove and discard the Cable Cover Assembly and the Cable Cover Assembly. Keep the attachment hardware. (2) (Airplanes with the IHAS omnidirectional antenna installed on the bottom of the cargo pod) Move the cable assembly that connects to the antenna (IHAS Omnidirectional or TAS) a small distance away from the bulkhead. (3) (Refer to Figure 9.) Remove and discard the Bulkhead Assembly, 28 MS Flat Lock Washers, and two Angles. Keep the 28 AN525-10R9 Screws and the 28 S3923S3 Nuts. (a) As necessary, drill the butts off of approximately seven Number 3 tack rivets that hold the bulkhead assembly in position. (b) Once the bulkhead is removed, sand the remaining parts of the tack rivets flush. (4) (Refer to Figure 9, View D-D.) If the forward pod section has a metal plate on the bottom flange where it attaches to the stretch pod section, remove the surface film for a good electrical bond between the end plate and the head of the screw that you will install. (5) (Refer to Figure 9, View B-B, View C-C, and View D-D.) Put the Bulkhead Assembly, with the attached Side Angles and the Bottom Angle, in position in the pod. (6) Match drill 28 Number 10 (0.193-inch diameter) holes in the bulkhead attach angles around the perimeter of the bulkhead. Use the existing holes in the pod as a pattern. If there are pilot holes on the new bulkhead attach angles, do not use these pilot holes when you match drill the Number 10 holes. (7) Attach the bulkhead assembly to the pod with the kept hardware and 28 MS Flat Lock Washers. Install the flat lock washers under the nuts. (8) Attach the MS BB6 Jumper Assembly on the bulkhead to a hole on the airplane belly skin where a jumper assembly was previously attached. (9) Do a check of the electrical bond. (Refer to the 208 Maintenance Manual, Chapter 20, Electrical Bonding - Maintenance Practices.) (a) (Refer to Figure 9, View D-D.) If there is no metal plate on the bottom flange where the forward pod section attaches to the stretch pod section, do a check of the electrical bond between the Bulkhead Assembly and the airplane. (b) If the forward pod section has a metal plate on the bottom flange where it attaches to the stretch pod section, do a check of the electrical bond between the pod sections, Bulkhead Assembly, and the airplane. H. (Refer to Figure 9, View E-E.) Install the four NAS1835A3M Inserts for the cargo net mounting points as follows: CAUTION: Make sure that when you drill the holes for the inserts that you do not do damage to the opposite outer layer. (1) Use a drill with a stop on it to make four thru inch diameter holes that are 0.43 inch in depth. Do a countersink of the holes to 100 X 0.01 inch. (2) With a core cut-back tool, under cut the core 0.25 inch all around the circumference of the four holes as follows: NOTE: You can use a tool that you make as follows: 1. Use a inch rod and make a 90 bend 0.25 inch from one end. 2. Sharpen the end that is bent. Page 25

36 3. Put the end of the rod that is not sharp in a drill motor and turn the drill motor at a low RPM. 4. Use the tool in a vertical position to make the tool cut and tear the core as you go around in the hole and up and down in the hole to under cut the core. CAUTION: Make sure that when you remove the core that you do not also remove the outer layer.ifyouremovetheouterlayer,youwilldodamagetothecargopod. (3) With a spot facer, remove the core in the bottom of the hole. Remove only the core. Do not remove the outer layer. (4) Mix the U Adhesive in accordance with the instructions on the adhesive package. (5) Apply sufficient adhesive to fill the hole in the panel where you will install the insert, work entrapped air out of the adhesive, and push the four NAS1835A3M inserts into the holes. (6) Clean unwanted adhesive from the structure and other surfaces with a cloth soaked in isopropyl alcohol. CAUTION: Do not use a heat cure to decrease cure time. If you use a heat cure to decrease cure time, the cargo net can come loose from the structure after installation. (7) Let the installation cure for five to seven days at 75 F (23.89 C) before you install the Cargo Net Assembly. Do not use a heat cure to decrease the cure time. I. (Refer to Figure 24.) Lay out the hole patterns and drill the holes in the leading edge of the left wing for the TKS ports as follows: (1) Measure along the contour from the lower leading edge skin overlap at the wing stations shown and snap a chalk at the measured positions along the full length of the wing leading edge. This line will show the correct position of the lower edges of the Left Outboard Wing Porous Panel, Left Mid-Wing Porous Panel, and Left Inboard Wing Porous Panel. (2) (Refer to Figure 24, View G-G. ) Hold the Left Mid Wing Porous Panel in position against the wing leading edge with the lower edge of the porous panel on the chalk line, and the cutout for the stall warning detector centered over the cutout in the leading edge of the wing. (3) Make marks on the leading edge of the wing at the inboard and the outboard ends of the Left Mid Wing Porous Panel. NOTE: The inboard edge of the Left Mid Wing Porous panel should approximately align with the visible leading edge skin lap. (4) While you hold the Left Mid Wing Porous Panel in the correct position, make marks on the wing leading edge where the vent tube and fluid inlet tube touch the leading edge. This will determine the inboard and outboard location of the two 1.00-inch diameter holes that you must drill. (5) (Refer to Figure 23.) Use a flexible scale to find the vertical location of each 1.00-inch diameter hole you must make in the wing leading edge. Transfer this measurement to the wing leading edge. Page 26

37 CAUTION: Do not do damage to the ice protection system with solvents or paints that are not approved for use on or near the porous panels. Most solvents and all paints can cause damage to the plastic membrane in the porous panels. Use only approved solvents on or near the porous panels. Never use MEK, acetone, or lacquer thinner. Always use masking material when you use paint or unapproved solvents near the porous panels. CAUTION: After you remove and before you install a porous panel, apply P Tape or equivalent low-residue masking material on the panel to give it protection. (6) (Refer to Figure 24, View A-A. View B-B, View F-F, and View K-K.) Hold the Left Outboard Wing Porous Panel and the Left Inboard Wing Porous Panel in position. Align the ends of each panel inch away from the marks you made in Step 5I(3) and put the lower edge of each panel along the chalk line. (7) Make marks at the locations for the seven remaining inch diameter holes along the wing leading edges. Use the same procedure to make these marks that you used for the Left Mid Wing Porous Panel. (8) Drill nine 1.00-inch diameter holes at the marks that you made on the wing leading edge for the Left Outboard Wing Porous Panel, Left Mid-Wing Porous Panel, and Left Inboard Wing Porous Panel. (9) Deburr and apply Alodine and primer to bare metal. J. (Airplanes with Weather Radar) (Refer to Figure 25, View C-C, View G-G, and View L-L.) Lay out the hole patterns and drill the holes in the leading edge of the right wing for the TKS ports as follows: (1) Measure along the contour from the lower leading edge skin overlap at the wing stations shown and make a chalk line at the measured positions along the full length of the wing leading edge. This line will show the correct installation position of the lower edges of the Right Outboard Wing Porous Panel, Mid-Wing Radar Porous Panel, and Right Inboard Wing Porous Panel. (2) Hold the Right Outboard Wing Porous Panel, Mid-Wing Radar Porous Panel, and Right Inboard Wing Porous Panel in position at the correct wing stations shown. Keep a distance of.0625 inch between the ends of adjacent panels and put the lower edge of each panel along the chalk line. NOTE: The inboard edge of the Mid-Wing Radar Porous Panel should approximately align with the visible leading edge skin lap. (3) Make marks on the right wing at each of the nine hole locations. Use the same method you used on the left wing. (4) Drill nine 1.00-inch diameter holes at the marks that you made on the leading edge of the right wing for the Right Outboard Wing Porous Panel, Mid-Wing Radar Porous Panel, and Right Inboard Wing Porous Panel. (5) Deburr and apply Alodine and primer to bare metal. K. (Airplanes not equipped with Weather Radar) (Refer to Figure 26, View C-C, View G-G, and View L-L.) Lay out the hole patterns and drill the holes in the leading edge of the right wing for the TKS portsasfollows: (1) Measure along the contour from the lower leading edge skin overlap at the wing stations shown and snap a chalk at the measured positions along the full length of the wing leading edge. This line will show the correct installation position of the Right Outboard Wing Porous Panel, Right Mid-Wing Porous Panel, and Right Inboard Wing Porous Panel. Page 27

38 (2) Make marks on the leading edge of the wing at the inboard and the outboard ends of the Right Mid-Wing Porous Panel. NOTE: The inboard edge of the Right Mid-Wing Porous Panel should approximately align with the visible leading edge skin lap. (3) Hold the Right Outboard Wing Porous Panel, Right Mid-Wing Porous Panel, and Right Inboard Wing Porous Panel in position at the correct wing stations shown. Keep a distance of.0625 inch between the ends of adjacent panels and put the lower edge of each panel along the chalk line. (4) Make marks on the right wing at each of the nine hole locations. Use the same method you used on the left wing. (5) Drill nine 1.00-inch diameter holes at the marks that you made on the leading edge of the right wing for the Right Outboard Wing Porous Panel, Right Mid-Wing Porous Panel, and Right Inboard Wing Porous Panel. (6) Deburr and apply Alodine and primer to bare metal. L. (Refer to Figure 7.) Lay out the hole patterns and drill the holes in the leading edge of the left and the right horizontal stabilizers for the TKS ports as follows: (1) Make chalk-line marks to show the correct installation position of the lower edges of the Left Horizontal Stabilizer Porous Panel and the Right Horizontal Stabilizer Porous Panel. (2) (Refer to Figure 7, View C-C.) Hold the Left Horizontal Stabilizer Porous Panel and the Right Horizontal Stabilizer Porous Panel in position on the leading edge at the correct stabilizer stations shown. (3) (Refer to Figure 7, View D-D.) Use the method you used on the wings to make marks on the horizontal stabilizers at each of the four hole locations (two on the left horizontal stabilizer and two on the right horizontal stabilizer). (4) Drill four 0.75-inch diameter holes at the marks that you made (two on each horizontal stabilizer). (5) Deburr and apply Alodine and primer to bare metal. M. (Refer to Figure 7.) Lay out the hole patterns and drill the holes in the leading edge of the vertical stabilizer for the TKS ports as follows: (1) Make chalk line-marks to show the correct installation position of the edges of the Vertical Stabilizer Porous Panel. (2) (RefertoFigure7,ViewB-B.)Makeamarkontheverticalstabilizerateachofthetwohole locations. (3) (Refer to Figure 7, View A-A.) Put the Vertical Stabilizer Porous Panel in position on the leading edge and perpendicular to the leading edge of the root and the tip of the vertical stabilizer panels at the correct stabilizer stations shown. (4) Make sure that the two inlet port and air bleed valve locations on the Vertical Stabilizer Porous Panel align with the marks that you made for the hole locations on the vertical stabilizer. Adjust the location of the marks as necessary. (5) Drill two 0.75-inch diameter holes at the marks that you made on the vertical stabilizer. (6) Deburr and apply Alodine and primer to bare metal. N. (Refer to Figure 24.) Lay out the hole patterns and drill the holes in the leading edge of the left and the right wing struts for the TKS ports as follows: (1) (Refer to Figure 24, View R-R.) Make chalk-line marks to show the correct installation position of the Left Wing Strut Porous Panel and the Right Wing Strut Porous Panel. Page 28

39 (2) Make a mark on the left and the right wing struts at each of the four hole locations (two on the left wing strut and two on the right wing strut) and each of the two slot locations (one on each wing strut). (3) (Refer to Figure 24, View P-P.) Put the Left Wing Strut Porous Panel and the Right Wing Strut Porous Panel in position on the leading edge and perpendicular to the leading edge at the inboard and the outboard ends of the wing struts at the correct position shown. (4) Make sure that the four inlet port and air bleed valve locations on the Left Wing Strut Porous Panel and the Right Wing Strut Porous Panel align with the marks that you made for the hole locations on the wing struts. Adjust the location of the marks as necessary. (5) Drill two 0.75-inch diameter holes at the applicable marks that you made on each of the wing struts. (6) Make two slots of the dimensions shown at the applicable marks that you made on each of the wing struts. (7) Deburr and apply Alodine and primer to bare metal. O. (Refer to Figure 7, Detail A and View A-A.) Install a new access panel on the right surface of the vertical stabilizer as follows: (1) Make one 3.00-inch cutout with one flat edge in the skin of the vertical stabilizer at the location shown. (2) Put the S1446-1S Doubler Assembly in position on the exterior of the vertical stabilizer. (3) Match drill six Number 40 (0.098-inch diameter) holes in the vertical stabilizer skin for the rivets that attach the S1446-1S Doubler Assembly. (4) Match drill three inch diameter holes in the vertical stabilizer skin for the screws that attach the S1447-1S Plate. (5) Countersink the 6 rivet holes. (6) Deburr and apply Alodine and primer to bare metal. (7) Clean the area around the hole. (Refer to the 208 Maintenance Manual, Chapter 20, General Solvents/Cleaners - Maintenance Practices.) (8) With U Sealant, do a fay surface seal between the vertical stabilizer skin and the S1446-1S Doubler Assembly. (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather, and High-Temperature Sealing - Maintenance Practices.) CAUTION: You can bend the S1446-1S Doubler Assembly as you install it, but do not crimp it. (9) With six CM3827AD3-3 Rivets, attach the S1446-1S Doubler Assembly to the interior of the vertical stabilizer skin. NOTE: When you install the new access panel (S1447-1S Plate), you will use the three S1021Z8-6 Screws. P. (Airplanes that do not have an access panel installed on the left and the right horizontal stabilizers) (Refer to Figure 7, Detail A and View C-C.) Install an access panel on the left horizontal stabilizer and an access panel on the right horizontal stabilizer as shown: (1) Make one 3.00-inch cutout with one flat edge in the skin of each horizontal stabilizer at the locations shown. (2) Deburr and apply Alodine and primer to bare metal. (3) Clean the area around the holes. (Refer to the 208 Maintenance Manual, Chapter 20, General Solvents/Cleaners - Maintenance Practices.) Page 29

40 (4) Put the two S1446-1S Doubler Assemblies in position on the exterior of the horizontal stabilizers. (5) Match drill six Number 40 (0.098-inch diameter) holes in each of the two horizontal stabilizer skins for the rivets that attach the S1446-1S Doubler Assemblies. (6) Match drill three inch diameter holes in each of the two horizontal stabilizer skins for the screws that attach the S1447-1S Plates. (7) Countersink the 12 rivet holes. (8) Deburr and apply Alodine and primer to bare metal. (9) With U Sealant, do a fay surface seal between the two S1446-1S Doubler Assemblies and the horizontal stabilizer skin. (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather, and High-Temperature Sealing - Maintenance Practices.) (10) With twelve MS20426AD3-3A Rivets, attach the two S1446-1S Doubler Assemblies to the interior of the horizontal stabilizer skins. NOTE: When you install the new access panels (S1447-1S Plates), you will use the six S1021Z8-6 Screws. Q. Install connectors, clips, doublers, and brackets that attach TKS system tank to the airplane as follows: (1) (Refer to Figure 5.) Attach the Rear Attach Clips and the Front Attach Clips to the bottom of the airplane as follows: (a) (Refer to Figure 5, Detail A, Detail B, and View A-A.) Attach the Left Internal Attach Clip and the Right Internal Attach Clip to the structure as follows: 1 (Refer to Figure 5, Detail A and Detail B.) Remove four fasteners that are installed where you will install the Left Internal Attach Clip and the Right Internal Attach Clip. 2 (Refer to Figure 5, Detail A and Detail B.) Drill four Number 21 (0.159 inch diameter) holes in the ends of the flange of the Left Internal Attach Clip and the Right Internal Attach Clip to match the holes in the skin where you removed the fasteners. 3 (Refer to Figure 5, Detail A and Detail B.) Drill 10 Number 30 (0.128-inch diameter) holes in the bottom skin to match the Number 40 pilot holes in the Left Internal Attach Clip and the Right Internal Attach Clip. 4 (Refer to Figure 5, View C-C.) Drill thru inch diameter holes in the Bulkhead Segments to match the Number 40 pilot holes in the Left Internal Attach Clip and the Right Internal Attach Clip. NOTE: If there is interference, you can move the mount for the brake line to the opposite side of the bulkhead or move the mount to a location where there is no interference with the bracket. (b) Find, mark, remove, and discard the remaining 42 fasteners that are now installed where you will install the two Rear Attach Clips and the two Front Attach Clips. (c) (Refer to Figure 5, View A-A.) Put the two Rear Attach Clips and the two Front Attach Clips in position on the bottom skin of the airplane. (d) In the Number 30 pilot holes, match drill thru inch diameter holes in each of the two Rear Attach Clips. (e) In the Number 30 pilot holes, match drill thru inch diameter holes in each of the two Front Attach Clips. (f) Deburr and apply Alodine to bare holes. Page 30

41 (g) (Refer to Figure 5, View C-C.) With 14 HL20PB5-2 Pins and HL86-5 Collars, attach one flange of the Left Internal Attach Clip and one flange of the Right Internal Attach Clip to the Bulkhead Segment. (h) With the 16 HL20PB6-4 Pins in the outboard holes, 14 HL20PB6-3 Pins and two HL20PB6-5 Pins in the inboard holes, and 32 HL86-6 Collars, attach the two Front Attach Clips to the airplane structure. (i) With the 10 HL20PB5-4 Pins in the forward holes, 10 HL20PB5-3 Pins in the aft holes, and 20 HL86-5 Collars, attach the two Rear Attach Clips to the airplane structure. Put the pins and collars in the positions necessary for best access. (j) Install four MS20470AD5-6A Rivets in the ends of the flanges of the Left Internal Attach Clip and the Right Internal Attach Clip. (2) (Refer to Figure 5.) Install the Left Fuselage TKS Doubler, Right Fuselage TKS Doubler, and Tail Prop Unit Doubler as follows: (a) (Refer to Figure 5, Detail A.) Install the Right Fuselage TKS Doubler to the bottom of the airplane as follows: 1 Put the Right Fuselage TKS Doubler in position on the bottom of the airplane on the inner surface of the skin. 2 Use the pilot holes for correct position to drill 33 Number 30 (0.128-inch diameter) holes in the Right Fuselage TKS Doubler and the airplane skin. 3 Drill one 0.68-inch diameter hole and one 1.11-inch diameter hole in the airplane bottom skin to match the large holes in the Right Fuselage TKS Doubler. 4 Deburr and apply Alodine to the holes. 5 With U Sealant, do a fay surface seal between the Right Fuselage TKS Doubler and the airplane skin. (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather, and High-Temperature Sealing - Maintenance Practices.) 6 (Refer to Figure 5, Detail A.) Attach the Right Fuselage TKS Doubler with the 33 MS20470AD4-3A5 Rivets. (b) (Refer to Figure 5, Detail B.) Install the Left Fuselage TKS Doubler on the bottom of the airplane as follows: 1 Put the Left Fuselage TKS Doubler in position on the bottom of the airplane on the inner surface of the skin. 2 Use the pilot holes for correct position to match drill 33 Number 30 (0.128-inch diameter) holes in the Left Fuselage TKS Doubler and the airplane skin. 3 (Refer to Figure 4, View V-V.) Drill one 0.44-inch diameter hole and one 0.87-inch diameter hole in the airplane bottom skin to match the Left Fuselage TKS Doubler. 4 Deburr and apply Alodine to the holes. 5 With U Sealant, do a fay surface seal between the Left Fuselage TKS Doubler and the airplane skin. (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather, and High-Temperature Sealing - Maintenance Practices.) 6 (Refer to Figure 5, Detail A.) Attach the Left Fuselage TKS Doubler with the 33 MS20470AD4-3A5 Rivets. (c) (Refer to Figure 5, View B-B.) Install the Tail Prop Unit Doubler as follows: 1 Find, mark, remove, and discard the eight fasteners that are installed where you will install the Tail Proportioning Unit Doubler. 2 Put the Tail Proportioning Unit Doubler in position. Page 31

42 3 Use the pilot holes for correct position to match drill eight Number 40 (0.098-inch diameter) holes in the Tail Proportioning Unit Doubler. 4 Match drill the inboard and outboard flanges of the doubler to match the holes in the tailcone skin. 5 With U Sealant, do a fay surface seal between the Tail Proportioning Unit Doubler and the airplane skin and the stringers. (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather, and High-Temperature Sealing - Maintenance Practices.) 6 Attach the Tail Proportioning Unit Doubler to the airplane skin and the stringers with the 12 MS20470AD3-3A5 Rivets and four MS20470AD4-3A5 Rivets. 6. (Airplanes equipped with the IHAS system that have an antenna on the bottom of the cargo pod adjacent to the Bulkhead Assembly) (Refer to Figure 13.) Do the IHAS antenna modification as follows: A. (Refer to Figure 13, View B-B.) Put the H Grommet in position on the Bulkhead Assembly and make marks to show where you will cut off the unwanted part of the H Grommet. B. Cut the H Grommet to the correct length. C. With U064092S Adhesive, install the H Grommet on the new Bulkhead Assembly. D. (Refer to Figure 13, View B-B.) Remove the three rivets shown. E. Do a countersink of the three holes for the CM3827AD4-4-5 Rivets. F. Deburr and apply Alodine to bare metal. G. Install three CM3827AD4-4-5 Rivets. H. Match drill four inch diameter holes in the Bulkhead Assembly to attach the Cable Cover Assembly. I. Drill two inch diameter holes in the Bulkhead Assembly and the Cable Cover. J. Drill four Number 40 (0.098-inch diameter) holes in the Bulkhead Assembly to attach the two MS21069L08K Nutplates. K. Make dimples in the four Number 40 (0.098-inch diameter) holes. L. Deburr and apply Alodine to the 10 holes. M. Install the two MS21069L08K Nutplates in the Bulkhead Assembly with the four MS20426AD3-4A Rivets. N. Put the antenna (IHAS omnidirectional) cable in position on the Bulkhead Assembly. O. (Refer to Figure 13, Detail A and View B-B.) Install the Cable Cover to the Bulkhead Assembly with the two kept MS Screws. P. Install the Cable Cover Assembly to the Bulkhead Assembly with the four kept MS Screws. 7. (Refer to Figure 12.) Install the Drip Pan and the S Fluid Tank and Equipment Pack in the Cargo Pod as follows: A. Remove the Bulkhead Assembly from the cargo pod. B. (Refer to Figure 12, View N-N and View H-H.) Make a 3.25-inch diameter hole in the left side of the Cargo Pod. Put the center of the hole 0.70 inch forward of the aft edge of the cutout in the Front Attach Clip. C. Drill eight Number 10 (0.193-inch diameter) holes in the Cargo Pod to match the Filler Cap Flange. Make sure that the spout on the inboard side of the filler cap points down. Page 32

43 D. (Refer to Figure 12, Detail B and View P-P.) Put the Filler Cap Flange, two Filler 8-Bolt Gaskets, and S Filler Door Assembly in position on the left side of the Cargo Pod. E. With the eight MS24694-C53 Screws, NAS1149C0363R Washers, and MS21083C3 Nuts, attach the Filler Cap Flange, two Filler 8-Bolt Gaskets, and S Filler Door Assembly to the Cargo Pod. F. Install the Filler Cap. G. (Refer to Figure 12, View H-H and View K-K.) Align the forward and the aft edges of the two Front Attach Clips with the two Forward Shear Plate Assemblies and the two Aft Shear Plate Assemblies. H. Match drill six inch diameter holes in each of the two Front Attach Clips to align with the nutplates in the two Forward Shear Plate Assemblies and the two Aft Shear Plate Assemblies. I. (Refer to Figure 12, View R-R.) Match drill three inch diameter holes in each of the two Rear Attach Clips to align with the nutplates in the Right Rear Shear Plate Assembly and the Left Rear Shear Plate Assembly. J. Deburr and apply Alodine to bare metal. K. (Refer to Figure 12, View H-H, View K-K, and View R-R.) Attach the two Forward Shear Plate Assemblies, two Aft Shear Plate Assemblies, Left Rear Shear Plate Assembly, and Right Rear Shear Plate Assembly to the Rear Attach Clips and the Front Attach Clips with the 18 AN4-5A Bolts and the 18 NAS1149F0432P Washers. L. (Refer to Figure 12, View B-B, View C-C, and View R-R.) Put the S Fluid Tank and Equipment Pack in position with the equipment mounting side aft. Make sure that the tank is level from one side to the other and from forward to aft in relation to the airplane. M. Match drill eight inch diameter holes in the S Fluid Tank and Equipment Pack to align with the holes in the two Forward Shear Plate Assemblies and the two Aft Shear Plate Assemblies. N. Match drill six inch diameter holes in the S Fluid Tank and Equipment Pack to align with the holes in the Left Rear Shear Plate Assembly and the Right Rear Shear Plate Assembly. O. Temporarily remove the Fluid Tank and Equipment Pack to install a hose mount on it and also install the drip pan on the Pod floor. Temporarily remove the fluid tank and equipment pack to install a hose mount on it and to install the drip pan on the pod floor. P. (Refer to Figure 12, View A-A.) Put the Drip Pan in position. Q. (Refer to Figure 12, View D-D and View E-E.) Make marks on the bottom of the cargo pod for the correct position of the five holes for the Tube Drains. R. Drill three 0.44-inch diameter holes and two 0.31-inch diameter holes in the bottom of the Cargo Pod at the positions that you marked. S. Solvent clean and then make sure that it is dry around the five holes that you drilled in the bottom of the Cargo Pod. (Refer to the 208 Maintenance Manual, Chapter 20, General Solvents/Cleaners - Maintenance Practices.) T. Apply U Adhesive or equivalent to fill fiber around the edge of the five holes that you drilled in the bottom of the Cargo Pod, clean off unwanted adhesive, and allow to cure. (Refer to the 208 Maintenance Manual, Chapter 20, Adhesive and Solvent Bonding - Maintenance Practices.) U. (Refer to Figure 12, View M-M.) With U or equivalent, fay seal between the Drip Pan and the bottom of the cargo pod to attach the forward end of the drip pan to the cargo pod. (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather and High-Temperature Sealing - Maintenance Practices.) Page 33

44 V. (Refer to Figure 12, View A-A.) Put the Drip Pan in position with the drain tubes correctly placed through the holes in the bottom of the cargo pod. W. (Refer to Figure 12, View D-D and View E-E.) With U Sealant or equivalent, fillet seal around the five drain tubes attached to the Drip Pan where they come through the bottom of the cargo pod. (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather and High-Temperature Sealing - Maintenance Practices.) X. (Refer to Figure 12, View A-A and Detail A.) Drill one Number 30 (0.128-inch diameter) hole in the S Fluid Tank and Equipment Pack to install the S Mount. Y. Deburr holes and apply Alodine to bare metal. Z. (Refer to Figure 12, View A-A.) Install the S Mount with one S3899A4-8N Rivet. AA. Put the fluid tank and equipment pack back into the pod AB. (Refer to Figure 12, View H-H, View K-K, and View R-R.) Attach the two Forward Shear Plate Assemblies, two Aft Shear Plate Assemblies, Left Rear Shear Plate Assembly, and Right Rear Shear Plate Assembly to the tank with the 14 AN4-5A Bolts, eight NAS1149F0463P Washers, and six NAS1149F0432P Washers. AC. (Refer to Figure 12, View A-A.) Cut the F Duct to the correct length. Use pliers to pull the wire from each end of the duct and cut it back sufficiently to make a smooth surface for the clamps. AD. With the two S Clamps, attach the F Duct to the elbows on the S Fluid Tank and Equipment Pack and on the S Filler Door. AE. (Refer to Figure 12, View Q-Q.) Cut the P Protective Conduit and the H Nylon Tubing to the correct length. AF. Install the P Protective Conduit over the H Nylon Tubing. AG. Put the H Nylon Tubing in position at the smaller hole in the TKS Left Fuselage Doubler and install one MN4856 Nut, MN Sleeve, and S Sealing Ring. AH. Install the other end of the H Nylon Tubing on the tank at the windshield pump with one MN4856 Nut, MN Sleeve, and S Sealing Ring. AI. Cut the H Nylon Tubing to the correct length. AJ. Put the H Nylon Tubing in position at the larger hole in the TKS Left Fuselage Doubler and install one MN6201 Nut, MN Sleeve, and Seal. AK. Install the MN6838 Elbow Assembly and the Seal on the S Fluid Tank and Equipment Pack. AL. Install the H Nylon Tubing at the MN6838 Elbow Assembly with one MN6201 Nut, MN Sleeve, and Seal. AM. (Refer to Figure 12, View A-A.) Install one AN840-6D Adapter and AN912-2D Bushing on each access plate on top of the S Fluid Tank and Equipment Pack. AN. Refer to Figure 12, View A-A and View F-F.) Cut the R Hose provided to the correct lengths to make two vent lines that run from the left and right outboard drip pan drain tubes up across the airplane belly skin to the opposite side hose adapters on top of the TKS fluid tank. AO. (Refer to Figure 12, View A-A, View B-B, View F-F, and View J-J.) Route the vent lines as shown and install with four S Clamps. AP. (Refer to Figure 12, View F-F) Cut a portion of R Hose to make a drain line that will connect from the tank drain valve to the drip pan drain tube. AQ. Do the routing of the drain line and install the drain as shown with two S Clamps AR. (Refer to Figure 12, View A-A.) With one S Tie, attach the R Tank Drain Tube to the S Mount that you installed. Page 34

45 AS. (Refer to Figure 12, View G-G, View J-J, View L-L, and View Q-Q.) In the 16 positions shown, attach the tubing to the structure with 16 S Adhesive-Back Mounts and 16 S Ties. AT. Bundle and secure the tubing as necessary with S Ties. 8. (Refer to Figure 11.) Do the installation of the cargo net as follows: A. (Refer to Figure 11, View A-A and View C-C.) On the right side of the cargo pod, install the two Anchor Plates in the NAS1835A3M Inserts with the four NAS514P Screws. B. (Refer to Figure 11, View A-A.) On the left side of the cargo pod, remove and discard the four AN525-10R18 Screws and remove and keep the four S3923S3 Nuts from the Center Door Doubler. C. (Refer to Figure 11, View A-A and View B-B.) Install the two Cargo Net Fittings and the Cargo Net Assembly in the Center Door Doubler with the four AN525-10R20 Screws and the MS Flat Lock Washers, and the kept S3923S3 Nuts. D. (Refer to Figure 11, View D-D.) Attach the F Velcro Loop Strip to the Drip Pan with U000787S Adhesive. E. Connect the Cargo Net Assembly to the F Velcro Loop Strip. CAUTION: If you tighten the Cargo Net Assembly too much, you can do damage to the cargo net installation. F. Tighten the Cargo Net Assembly to the correct tension, but do not tighten it too much. 9. (Refer to Figure 8, View A-A and View B-B.) Install the windshield spray bar on the left side of the windshield as follows: A. (Refer to Figure 8, View B-B.) Make a mark for and drill a 0.50-inch diameter hole in the removed Upper Center Cowl Assembly. B. Deburr and apply Alodine to bare holes. C. Install the Upper Center Cowl Assembly. (Refer to the 208 Maintenance Manual, Chapter 71, Engine Cowling and Nose Cap - Maintenance Practices.) D. Remove and discard the remaining MS Screws that attach the Windshield Retainer to the structure in the area where the p-clips will be installed. E. (Refer to Figure 8, View A-A.) Attach the five P-Clips to the Spray Bar Assembly an equal distance apart. F. Put the Spray Bar Assembly in position. G. Make sure that the P-Clips are not in a position that will cause a blockage of spray from the holes in the spray bar. H. Find the correct position for the Deflector and make marks to show this correct position. I. (Refer to Figure 8, View B-B.) Make marks on the Deflector for five holes what will align with the windshield attachment screw holes. J. Drill five Number 30 (0.128-inch diameter) holes in the Deflector. K. Deburr and apply Alodine to bare holes. L. (Refer to Figure 8, View A-A and View B-B.) With Clecos, hold the Deflector, P-Clips, and Spray Bar Assembly tightly in position. M. Install the Deflector, five P-Clips, and Spray Bar Assembly with the five new MS Screws. N. (Refer to Figure 8, View A-A.) Install a ZN6756 Back Nut on the fitting end of the Spray Bar Assembly. Page 35

46 O. (Refer to Figure 8, View C-C.) Clean around the edges and ends and along the length of the Deflector. (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather and High-Temperature Sealing - Maintenance Practices.) P. Fillet seal around the edges and ends and along the length of the Deflector with U Sealant. (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather and High-Temperature Sealing - Maintenance Practices.) CAUTION: Mask the Spray Bar Assembly to make sure that no paint causes a blockage of the spray holes. Q. Apply paint (of the same color as the adjacent skin on the airplane) to the Deflector. 10. (Refer to Figure 22.) Do the forward-of-firewall TKS installation: WARNING: If the existing propeller is to be modified, this modification must be done by an approved McCauley repair station. The propeller hub spring must be removed to set the propeller blades to the low pitch necessary to adjust the TKS feed tubes. A static balance of the modified propeller must also be accomplished. A. Do the modification of the propeller to install TKS, or install a new propeller. (1) If you will do the modification of the propeller to install TKS, go to Step 10B. (2) If you will install a new P or P Propeller for operation with the TKS system installed, do as follows: (Refer to the 208 Maintenance Manual, Chapter 30, TKS Propeller - Maintenance Practices and Chapter 61, Propeller (McCauley) - Maintenance Practices.) (a) (b) (Refer to Figure 22, View F-F and View H-H.) Install the Propeller Nozzle Bracket on the engine as follows: 1 Remove and keep the attachment hardware where you will install the Propeller Nozzle Bracket on the engine. 2 Put the Propeller Nozzle Bracket in position, and with the removed hardware, attach it to the engine. 3 Torque the nuts on the propeller thrust bearing cover to 145 to 165 inch-pounds. Install the new TKS-equipped P or P Propeller and then go to Step 10C. (Refer to the 208 Maintenance Manual, Chapter 30, TKS Propeller - Maintenance Practices and Chapter 61, Propeller(McCauley) - Maintenance Practices.) B. (Refer to Figure 22, Detail A, View J-J, and View K-K.) Do the modification of the propeller to install TKS as follows: CAUTION: Do not operate the propeller if the spinner is not installed. Damage to the fillet assembly will occur. (1) (Refer to Figure 22, View F-F and View H-H.) Install the Propeller Nozzle Bracket ontheengineasfollows: (a) (b) (c) Remove and keep the attachment hardware where you will install the Propeller Nozzle Bracket on the engine. Put the Propeller Nozzle Bracket in position, and with the removed hardware, attach it to the engine. Torque the nuts on the propeller thrust bearing cover to 145 to 165 inch-pounds. (2) Remove the propeller anti-ice boots, if installed, from the propeller. (Refer to the 208 Maintenance Manual, Chapter 30, Propeller Anti-Ice - Maintenance Practices.) Page 36

47 (3) Do the modification of the propeller with the D-7858 Mod Kit - C703 TKS. (Refer to the 208 Maintenance Manual, Chapter 30, TKS Propeller - Maintenance Practices and Chapter 61, Propeller (McCauley) - Maintenance Practices.) (a) (b) (c) Remove and discard the screws and washers that attach the propeller bulkhead to the D-6398 Mounting Plate. Keep the three fillet assemblies and the screws and washers that attach them. On airplanes with anti-ice installation, remove the screws that attach the anti-ice leads to the slip ring and remove the screws that attach the lead clamps to the bulkhead. Remove and discard the spinner bulkhead. (d) Install the three C Feed Shoes on the propeller blades. (Refer to the 208 Maintenance Manual, Chapter 30, TKS Anti-Ice Propeller (McCauley) - Maintenance Practices.) (e) (f) (g) (h) (i) (j) (k) (l) NOTE: The three C Feed Shoes are part of the D-7858 Mod Kit - C703 TKS. Put the new E-7856 Spinner Bulkhead Assembly in position on the existing mounting plate or slip ring. NOTE: The E-7856 Spinner Bulkhead Assembly is part of the D-7858 Mod Kit - C703 TKS. With the 12 A Screws and A Washers, attach the new E-7856 Spinner Bulkhead Assembly to the existing D6398 Mounting Plate on the propeller. Torque to 20 to 25 inch-pounds and install the MS20995C25 Lockwire. NOTE: The A Screws and A Washers are part of the D-7858 Mod Kit - C703 TKS. Make sure that the clearance between each feed tube and the blade shank or the feed shoe through the full range of blade travel is no less than inch and no more than inch. Carefully bend the feed tubes as necessary. WARNING: The propeller hub spring must be removed to set the propeller blades to low pitch. Due to the significant force necessary, removal of the spring is considered a dangerous operation and must be accomplished by an approved McCauley repair station. Make sure that each feed tube aligns with the second groove in the feed shoe while the propeller is at low pitch. Carefully bend the feed tubes as necessary. Temporarily install the propeller spinner to make sure that there is no interference between the feed tubes and the spinner and that the feed tubes will not be blocked by the edges of the spinner. Slightly adjust the feed tubes if necessary but be careful to keep the necessary clearances and alignment. Remove the spinner. Do a static balance of the propeller. (Refer to the McCauley Series C700 Propeller Overhaul Manual, No. MPC 700.) Install the propeller and the spinner. (Refer to the Model 208 Maintenance Manual Chapter 61, McCauley Propeller - Maintenance Practices) NOTE: Dynamic balancing of the propeller must be done, and will be accomplished later in this Service Kit. C. (Refer to Figure 22, View A-A.) Put the Hose Assembly in position on the airplane. D. (Refer to Figure 22, View G-G.) At the Upper Center Cowl Assembly, connect the Hose Assembly to the Windshield Spray Bar Assembly. Page 37

48 E. (Refer to Figure 22, View A-A.) With the two MS21919WDG14 Clamps, MS21919WDG12 Clamps, AN525-10R8 Screws, and MS Nuts, attach the Hose Assembly to the fuel heater supply hose in two positions near the firewall. F. (Refer to Figure 22, View A-A.) Allow the end of the Hose Assembly (that is not connected to the Windshield Spray Bar Assembly) to hang loosely in position where the ZN6261 Bulkhead Connector will be installed in the firewall. G. (Refer to Figure 22, View H-H.) Attach the ZN6261 Fitting to the Propeller Nozzle Bracket (that you installed earlier) with the ZN6079 Nut and the NAS1149F0563P Washer. H. Attach the Propeller Nozzle to the ZN6261 Fitting with the ZN4856 Nut. I. (Refer to Figure 12, View F-F and View H-H.) Adjust the angle of the Propeller Nozzle as necessary to the tolerance shown and then tighten and safety wire the nut. J. Attach the Hose Assembly to the ZN6261 Fitting. K. (Refer to Figure 22, View E-E.) With the MS21919WDG17 Clamp, MS21919WDG12 Clamp, AN525-10R8 Screw, and MS Nut, attach the Hose Assembly in the position shown. L. (Refer to Figure 22, View D-D.) With the MS21919WDG12 Clamp, attach the Hose Assembly to the clamp on the S B0600 Hose Assembly that is adjacent to the oil line bracket. M. (Refer to Figure 22, View C-C.) With the MS21919WDG17 Clamp, MS21919WDG12 Clamp, AN525-10R8 Screw, and MS Nut, attach the Hose Assembly to the oil cooler hose assembly adjacent to the air box assembly. N. (Refer to Figure 22, View B-B.) With the MS21919WDG12 Clamp, attach the Hose Assembly to the installed clamps adjacent to the mixer muffler assembly. O. Let the end of the Hose Assembly (that is not connected to the Propeller Nozzle) to hang loosely in position where the ZN6829 Bulkhead Connector will be installed in the firewall. 11. Do a dry fit of the TKS system porous panels as follows: CAUTION: Do not do damage to the ice protection system with solvents or paints that are not approved for use on or near the porous panels. Most solvents and all paints can cause damage to the plastic membrane in the porous panels. Use only approved solvents on or near the porous panels. Never use MEK, acetone, or lacquer thinner. Always use masking material when you use paint or unapproved solvents near the porous panels. CAUTION: After you remove and before you install a porous panel, apply P Tape or equivalent low-residue masking material on the panel to give it protection. A. (Refer to Figure 6 and Figure 7.) Do a dry fit of the Vertical Stabilizer Porous Panel: (1) (RefertoFigure6.) Replacetherivetsinstalledontheleadingedgeoftheverticalstabilizer that can prevent correct installation of the Vertical Stabilizer Porous Panel as follows: (a) (Refer to Figure 6, View C-C.) Remove the two rivets on the right surface of the vertical stabilizer and the two rivets on the left surface of the vertical stabilizer. (b) Remove one rivet on the right surface of the vertical stabilizer tip assembly and one rivet on the left surface of the vertical stabilizer tip assembly. NOTE: If the holes where you removed the rivets are not of the correct size for the new rivets, you must make them larger to the correct dimension. (c) Do a countersink of the six rivet holes. (d) Deburr and apply Alodine to the six rivet holes. Page 38

49 (e) Install two CR Rivets on the left surface of the vertical stabilizer and two CR Rivets on the right surface of the vertical stabilizer. (f) (Refer to Figure 6, View E-E.) Install one CR Rivet on the left surface of the vertical stabilizer tip assembly and one CR Rivet on the right surface of the vertical stabilizer tip assembly. (2) (Refer to Figure 7, View A-A.) Put the Vertical Stabilizer Porous Panel in position on the vertical stabilizer. (3) (Refer to Figure 7, View B-B.) If necessary for clearance of the bleed port tubing, lightly make a dimple in the skin at the location shown. Deformation must not be more than 0.08 inch. There must be no sharp transitions in the skin or surface damage at the dimple. (4) At all dimples that you make in the skin, do a surface eddy current inspection for cracks. (Refer to the Model 208 Nondestructive Testing Manual, Chapter 20, Eddy Current Surface Techniques - General - Description and Operation.) (a) If there are cracks, refer to the Model 208 Structural Repair Manual for repair instructions. (b) If there are cracks and you have specific questions about the cracks that are not answered in the Model 208 Structural Repair Manual, contact Cessna Customer Service for more instructions: Telephone , or FAX (c) Make sure after you do the repair that you have the necessary clearance for bleed port tubing. (5) Put the Vertical Stabilizer Porous Panel in position for a good fit at the top and the bottom trailing edges of the Vertical Stabilizer Porous Panel. (6) Push hard and hold the Vertical Stabilizer Porous Panel tightly against the leading edge. (7) Make sure that all of the edges of the Vertical Stabilizer Porous Panel continuously touch the vertical stabilizer skin. (8) Make sure that all of the edges of the Vertical Stabilizer Porous Panel continuously touch the chalk-line marks that show where the edges of the porous panel must be when the porous panel is installed. (9) Use P Tape or equivalent as necessary to hold the porous panels tightly against the leading edge. (10) (Refer to Figure 7, View A-A.) When you are sure that the Vertical Stabilizer Porous Panel is held in the correct position, make marks for the four rivet holes in the Vertical Stabilizer Porous Panel. CAUTION: When you make holes for the rivets, do not drill into a rib. (11) Match drill four Number 30 (0.128-inch diameter) holes in the Vertical Stabilizer Porous Panel and the vertical stabilizer for the rivets. (12) Make marks for the six MS Screws that attach the Vertical Stabilizer Porous Panel to the vertical stabilizer tip assembly. (13) Match drill six inch diameter holes in the skin and the Vertical Stabilizer Porous Panel. (14) Remove the porous panel from the vertical stabilizer. (15) Do a countersink of the four rivet holes in the Vertical Stabilizer Porous Panel. (16) Remove the Tip Assembly from the vertical stabilizer. Keep the attachment screws. (17) Drill 12 Number 40 (0.098-inch diameter) holes in the Tip Assembly for the nutplates. (18) Countersink the 12 rivet holes in the Tip Assembly. Page 39

50 (19) With the 12 CCR244SS-3-02 Rivets, install the six MS21047L08 Nutplates to the Tip Assembly. B. (Refer to Figure 6 and Figure 7.) Do a dry fit of the Left Horizontal Stabilizer Porous Panel and the Right Horizontal Stabilizer Porous Panel: CAUTION: Do not do damage to the ice protection system with solvents or paints that are not approved for use on or near the porous panels. Most solvents and all paints can cause damage to the plastic membrane in the porous panels. Use only approved solvents on or near the porous panels. Never use MEK, acetone, or lacquer thinner. Always use masking material when you use paint or unapproved solvents near the porous panels. CAUTION: After you remove and before you install a porous panel, apply P Tape or equivalent low-residue masking material on the panel to give it protection. (1) (Refer to Figure 6.) Remove the rivets installed on the leading edge of the horizontal stabilizers that can prevent correct installation of the porous panels as follows: (a) (b) (Refer to Figure 6, View A-A.) Remove the 11 rivets on the top surface of the left horizontal stabilizer and the 11 rivets on the top surface of the right horizontal stabilizer. (Refer to Figure 6, View B-B.) Remove the 11 rivets on the bottom surface of the left horizontal stabilizer and the 11 rivets on the bottom surface of the right horizontal stabilizer. (2) Replace the rivets that you removed on the leading edge of the horizontal stabilizers as follows: (a) (b) (c) (d) (e) (Refer to Figure 6, View A-A.) On the top surface of the left and the right horizontal stabilizers where you will install the S and S Rivets, make the 16 rivet holes larger to Number 27 (0.144-inch diameter). Do a countersink of the 44 rivet holes. Deburr and apply Alodine to the 44 rivet holes. (Refer to Figure 6, View A-A.) Install two CR Rivets, one CR Rivet, seven S Rivets, and one S Rivet on the top surface of the left horizontal stabilizer and two CR Rivets, one CR Rivet, seven S Rivets, and one S Rivet on the top surface of the right horizontal stabilizer. (Refer to Figure 6, View B-B.) Install nine CR Rivets and two CR Rivets on the bottom surface of the left horizontal stabilizer and nine CR Rivets and two CR Rivets on the bottom surface of the right horizontal stabilizer. (3) (Refer to Figure 7, View C-C.) Put the Left Horizontal Stabilizer Porous Panel and the Right Horizontal Stabilizer Porous Panel in position on the horizontal stabilizers. Align the lower edge of each panel with the chalk line that you made. (4) (Refer to Figure 7, View D-D.) If necessary for clearance of the bleed port tubing, lightly make a dimple in the skin at the location shown. Deformation must not be more than 0.08 inch. There must be no sharp transitions in the skin or surface damage at the dimple. (5) At all dimples that you make in the skin, do a surface eddy current inspection for cracks. (Refer to the Model 208 Nondestructive Testing Manual, Chapter 20, Eddy Current Surface Techniques - General - Description and Operation.) (a) (b) If there are cracks, refer to the Model 208 Structural Repair Manual for repair instructions. If there are cracks and you have specific questions about the cracks that are not answered in the Model 208 Structural Repair Manual, contact Cessna Customer Service for more instructions: Telephone , or FAX Page 40

51 (c) Make sure after you do the repair that you have the necessary clearance for bleed port tubing. (6) Push and hold the Left Horizontal Stabilizer Porous Panel and the Right Horizontal Stabilizer Porous Panel tightly in the correct position. (7) Make sure that all of the edges of the Left Horizontal Stabilizer Porous Panel and the Right Horizontal Stabilizer Porous Panel continuously touch the horizontal stabilizer skins. (8) Make sure that the lower edges of the Left Horizontal Stabilizer Porous Panel and the Right Horizontal Stabilizer Porous Panel continuously touch the chalk-line marks. (9) Use P Tape or equivalent as necessary to hold the porous panels tightly against the leading edge. (10) When you are sure Left Horizontal Stabilizer Porous Panel and the Right Horizontal Stabilizer Porous Panel are in the correct position, make marks for the six rivet holes in each of the two porous panels. CAUTION: When you make holes for the rivets, do not drill into a rib. (11) Match drill six Number 30 (0.128-inch diameter) holes in the Left Horizontal Stabilizer Porous Panel and six Number 30 (0.128-inch diameter) holes in the Right Horizontal Stabilizer Porous Panel and in the two horizontal stabilizers for the rivets. (12) Remove the Left Horizontal Stabilizer Porous Panel and the Right Horizontal Stabilizer Porous Panel from the horizontal stabilizer. (13) Countersink the 12 rivet holes in the Left Horizontal Stabilizer Porous Panel and the Right Horizontal Stabilizer Porous Panel. C. (Refer to Figure 24.) Do a dry fit of the Left Wing Strut Porous Panel and the Right Wing Strut Porous Panel as follows: (1) (Refer to Figure 24, View P-P, View Q-Q, and View R-R.) Put the Left Wing Strut Porous Panel and the Right Wing Strut Porous Panel in position on the wing struts. Align the upper and lower edges of each panel with the chalk lines. (2) (Refer to Figure 24, View P-P.) If necessary for clearance of the bleed port tubing, lightly make a dimple in the skin at the location shown. Deformation must not be more than 0.08 inch. There must be no sharp transitions in the skin or surface damage at the dimple. (3) At all dimples that you make in the skin, do a surface eddy current inspection for cracks. (Refer to the Model 208 Nondestructive Testing Manual, Chapter 20, Eddy Current Surface Techniques - General - Description and Operation.) (a) If there are cracks, refer to the Model 208 Structural Repair Manual for repair instructions. (b) If there are cracks and you have specific questions about the cracks that are not answered in the Model 208 Structural Repair Manual, contact Cessna Customer Service for more instructions: Telephone , or FAX (c) Make sure after you do the repair that you have the necessary clearance for bleed port tubing. (4) Push and hold the Left Wing Strut Porous Panel and the Right Wing Strut Porous Panel tightly in the correct position. (5) Make sure that all of the edges of the Left Wing Strut Porous Panel and the Right Wing Strut Porous Panel continuously touch the wing strut skins. (6) Make sure that all of the edges of the Left Wing Strut Porous Panel and the Right Wing Strut Porous Panel continuously touch the chalk-line marks that show where the edges of the porous panels must be when the porous panels are installed. Page 41

52 (7) Use P Tape or equivalent as necessary to hold the panels tightly against the leading edge. (8) (Refer to Figure 24, View Q-Q.) When you are sure that the porous panels are in the correct positions, make marks for the rivet holes in the Left Wing Strut Porous Panel and the Right Wing Strut Porous Panel. (9) Match drill four Number 30 (0.128-inch diameter) holes in the skin and in each of the two porous panels for the rivets. (10) Remove the porous panels from the wing struts. (11) Countersink the eight rivet holes in the Left Wing Strut Porous Panel and the Right Wing Strut Porous Panel. D. (Refer to Figure 24, View A-A.) Do a dry fit of the Left Outboard Wing Porous Panel, Left Mid-Wing Porous Panel, and Left Inboard Wing Porous Panel as follows: (1) Put the Left Outboard Wing Porous Panel, Left Mid-Wing Porous Panel, and Left Inboard Wing Porous Panel in position on the left wing. Align the lower edges of each panel with the chalk-line. (2) (Refer to Figure 24, View C-C.) If necessary for clearance of the bleed port tubing, lightly make a dimple in the skin at the locations shown. Deformation must not be more than 0.08 inch. There must be no sharp transitions in the skin or surface damage at the dimple. (3) At all dimples that you make in the skin, do a surface eddy current inspection for cracks. (Refer to the Model 208 Nondestructive Testing Manual, Chapter 20, Eddy Current Surface Techniques - General - Description and Operation.) (a) If there are cracks, refer to the Model 208 Structural Repair Manual for repair instructions. (b) If there are cracks and you have specific questions about the cracks that are not answered in the Model 208 Structural Repair Manual, contact Cessna Customer Service for more instructions: Telephone , or FAX (c) Make sure after you do the repair that you have the necessary clearance for bleed port tubing. (4) Hold the Left Outboard Wing Porous Panel, Left Mid-Wing Porous Panel, and Left Inboard Wing Porous Panel tightly in the correct position. (5) Make sure that all of the edges of the Left Outboard Wing Porous Panel, Left Mid-Wing Porous Panel, and Left Inboard Wing Porous Panel continuously touch the wing skins. (6) Make sure that all of the lower edges of the Left Outboard Wing Porous Panel, Left Mid-Wing Porous Panel, and Left Inboard Wing Porous Panel continuously touch the chalk-line marks. CAUTION: Make sure that when you tighten the ratcheting straps you do no damage to the flap. Use foam or blankets to protect the airplane structure and do not use too much force when you tighten the straps. (7) Put ratcheting straps on the Left Inboard Wing Porous Panel only to tightly conform the contour of the panel to the wing leading edge prior to drilling the panel to the leading edge skin. (8) Use P Tape or equivalent as necessary to hold the remaining panels tightly against the leading edge. (9) (Refer to Figure 24, View B-B, View F-F, and View K-K.) When you are sure that the Left Outboard Wing Porous Panel, Left Mid-Wing Porous Panel, and Left Inboard Wing Porous Panel are in the correct positions, make marks for the 16 rivet holes in the porous panels. Page 42

53 CAUTION: When you make holes for the rivets, do not drill into a rib. (10) Match drill 16 Number 30 (0.128-inch diameter) holes in the skin and the Left Outboard Wing Porous Panel, Left Mid-Wing Porous Panel, and Left Inboard Wing Porous Panel for the rivets. (11) Remove the ratchet straps from the inboard wing porous panel. (12) Remove the porous panels from the left wing. (13) Countersink the 16 rivet holes in the Left Outboard Wing Porous Panel, Left Mid-Wing Porous Panel, and Left Inboard Wing Porous Panel. E. (Airplanes with Weather Radar) (Refer to Figure 25, View A-A.) Do a dry fit of the Right Outboard Wing Porous Panel, Mid-Wing Radar Porous Panel, and Right Inboard Wing Porous Panel as follows: (1) Put the Right Outboard Wing Porous Panel, Mid-Wing Radar Porous Panel, and Right Inboard Wing Porous Panel in position on the right wing. (2) (Refer to Figure 25, View L-L.) If necessary for clearance of the bleed port tubing, lightly make a dimple in the skin at the location shown. Deformation must not be more than 0.08 inch. There must be no sharp transitions in the skin or surface damage at the dimple. (3) At all dimples that you make in the skin, do a surface eddy current inspection for cracks. (Refer to the Model 208 Nondestructive Testing Manual, Chapter 20, Eddy Current Surface Techniques - General - Description and Operation.) (a) (b) If there are cracks, refer to the Model 208 Structural Repair Manual for repair instructions. If there are cracks and you have specific questions about the cracks that are not answered in the Model 208 Structural Repair Manual, contact Cessna Customer Service for more instructions: Telephone , or FAX (c) Make sure after you do the repair that you have the necessary clearance for bleed port tubing. (4) Hold the Right Outboard Wing Porous Panel, Mid-Wing Radar Porous Panel, and Right Inboard Wing Porous Panel tightly in the correct position. (5) Make sure that all of the edges of the Right Outboard Wing Porous Panel, Mid-Wing Radar Porous Panel, and Right Inboard Wing Porous Panel continuously touch the wing skins. (6) Make sure that the lower edges of the Right Outboard Wing Porous Panel, Mid-Wing Radar Porous Panel, and Right Inboard Wing Porous Panel continuously touch the chalk-line marks. CAUTION: Make sure that when you tighten the ratcheting straps you do no damage to the flap. Use foam or blankets to protect the airplane structure and do not use too muchforcewhenyoutightenthestraps. (7) Put ratcheting straps on the Right Inboard Wing Porous Panel only to tightly conform the contour of the panel to the wing leading edge before you drill the panel to the leading edge skin. (8) Use P Tape or equivalent as necessary to hold the remaining panels tightly against the leading edge. (9) (Refer to Figure 25, View B-B, View F-F, and View K-K.) When you are sure that the Right Outboard Wing Porous Panel, Mid-Wing Radar Porous Panel, and Right Inboard Wing Porous Panel are in the correct positions, make marks for the 16 rivet holes. Page 43

54 CAUTION: When you make holes for the rivets, do not drill into a rib. (10) Match drill 16 Number 30 (0.128-inch diameter) holes in the skin and the Right Outboard Wing Porous Panel, Mid-Wing Radar Porous Panel, and Right Inboard Wing Porous Panel for the rivets. (11) Remove the ratchet straps from the inboard wing porous panel. (12) Remove the porous panels from the right wing. (13) Countersink the 16 rivet holes in the Right Outboard Wing Porous Panel, Mid-Wing Radar Porous Panel, and Right Inboard Wing Porous Panel. (14) Clean the leading edges of the wings and the rear sides of the Right Outboard Wing Porous Panel, Mid-Wing Radar Porous Panel, and Right Inboard Wing Porous Panel to remove all grease and FOD. (Refer to the 208 Maintenance Manual, Chapter 20, General Solvents/Cleaners - Maintenance Practices.) F. (Airplanes not equipped with Weather Radar) (Refer to Figure 26, View A-A.) Do a dry fit of the Right Outboard Wing Porous Panel, Right Mid-Wing Porous Panel, and Right Inboard Wing Porous Panel as follows: (1) (Refer to Figure 26, View D-D, View E-E, View H-H, View J-J, and View N-N.) Put the Right Outboard Wing Porous Panel, Right Mid-Wing Porous Panel, and Right Inboard Wing Porous Panel in position on the right wing. (2) (Refer to Figure 26, View C-C.) If necessary for clearance of the bleed port tubing, lightly make a dimple in the skin at the locations shown. Deformation must not be more than 0.08 inch. There must be no sharp transitions in the skin or surface damage at the dimple. (3) At all dimples that you make in the skin, do a surface eddy current inspection for cracks. (Refer to the Model 208 Nondestructive Testing Manual, Chapter 20, Eddy Current Surface Techniques - General - Description and Operation.) (a) If there are cracks, refer to the Model 208 Structural Repair Manual for repair instructions. (b) If there are cracks and you have specific questions about the cracks that are not answered in the Model 208 Structural Repair Manual, contact Cessna Customer Service for more instructions: Telephone , or FAX (c) Make sure after you do the repair that you have the necessary clearance for bleed port tubing. (4) Hold the Right Outboard Wing Porous Panel, Right Mid-Wing Porous Panel, and Right Inboard Wing Porous Panel tightly in the correct position. Align the lower edges of each panel with the chalk-line. (5) Make sure that all of the edges of the Right Outboard Wing Porous Panel, Right Mid-Wing Porous Panel, and Right Inboard Wing Porous Panel continuously touch the wing skins. (6) Make sure that the lower edges of the Right Outboard Wing Porous Panel, Right Mid-Wing Porous Panel, and Right Inboard Wing Porous Panel continuously touch the chalk-line marks. CAUTION: Make sure that when you tighten the ratcheting straps you do no damage to the flap. Use foam or blankets to protect the airplane structure and do not use too much force when you tighten the straps. (7) Put ratcheting straps on the Right Inboard Wing Porous Panel only to tightly conform the contour of the panel to the wing leading edge before you drill the panel to the leading edge skin. (8) Use P Tape or equivalent as necessary to hold the remaining panels tightly against the leading edge. Page 44

55 (9) (Refer to Figure 26, View B-B, View F-F, and View K-K.) When you are sure that the Right Outboard Wing Porous Panel, Right Mid-Wing Porous Panel, and Right Inboard Wing Porous Panel are in the correct positions, make marks for the 16 rivet holes. CAUTION: When you make holes for the rivets, do not drill into a rib. (10) Match drill 16 Number 30 (0.128-inch diameter) holes in the skin and the Right Outboard Wing Porous Panel, Right Mid-Wing Porous Panel, and Right Inboard Wing Porous Panel for the rivets. (11) Remove the ratchet straps from the inboard wing porous panel. (12) Remove the porous panels from the right wing. (13) Countersink the 16 rivet holes in the Right Outboard Wing Porous Panel, Right Mid-Wing Porous Panel, and Right Inboard Wing Porous Panel. CAUTION: Do not do damage to the nylon tubing in the ice protection system. There must be no tension or strain on the nylon tubing, as these forces when applied to the nylon tubing can cause damage. CAUTION: Do not do damage to the nylon tubing in the ice protection system. Cut and install the nylon tubing in lengths that take into consideration the effects of tension and strain. When you cut the nylon tubing, add no less than 3% (1 inch for each 3 feet) to the necessary length for thermal shrinkage and airframe flexure, as too much shrinkage of the nylon tubing and airframe flexure can cause damage. CAUTION: Donotdodamagetothenylontubingintheiceprotectionsystem. Assemblethenylon tubing and the couplings in accordance with best shop practices. CAUTION: Use tie straps as necessary during the routing of the nylon tubing to make sure that there is sufficient clearance from and that they do not rub against other equipment. If there is not sufficient clearance from other equipment, damage to the nylon tubing can result. CAUTION: Remember before you do the installation of the porous panels that the TKS porous panels must be installed on primed or painted surfaces. 12. Alodine, prime, and paint as necessary the leading edges of the wings, wing struts, horizontal and vertical stabilizers, gear legs, and front of cargo pod with polyurethane enamel. (Refer to the 208 Maintenance Manual, Chapter 20, Interior and Exterior Finish - Cleaning and Painting.) 13. Apply primer and paint to the horizontal and the vertical stabilizer inspection panels (if new). 14. (Refer to Figures 2, 3, and 4.) Do the routing and the installation of the nylon tubing and attachment parts for the tubing in the TKS system as follows: NOTE: Refer to Steps 2F(8) thru 2F(10) and Figure 27 to do the installation of the tubing correctly. A. Do the routing and the installation of the nylon tubing supply system for the left wing and the left wing strut, and then repeat for the right wing and the right wing strut on airplanes not equipped with Weather Radar: NOTE: Airplanes with Weather Radar, go to Step 12B and Figure 3 to do the routing and the installation of the nylon tubing supply system for the right wing and right wing strut after you do the routing and the installation of the nylon tubing supply system for the left wing and the left wing strut. (1) (Refer to Figure 2, View K-K and View Z-Z.) Match drill two Number 10 (0.193-inch diameter) holes in the Intercostal Assembly to install the Bracket. (2) With two AN3-3A Bolts, four NAS1149F0332P Washers, and two MS21044N3 Nuts, attach the Bracket to the Intercostal Assembly. Page 45

56 (3) (Refer to Figure 2, View M-M and View Q-Q.) At the two pilot holes in the Left Proportioning Unit Bracket ( Right Proportioning Unit Bracket), match drill two Number 10 (0.193-inch diameter) holes in the Left Proportioning Unit Bracket ( Right Proportioning Unit Bracket) and the Rib. NOTE: The proportioning units come to you installed on the proportioning unit brackets. (4) With the two AN3-3A Bolts, four NAS1149F0332P Washers, and two MS21044N3 Nuts, install the Left Proportioning Unit ( Right Proportioning Unit ) to the outboard side of the Rib with the inlet pointed inboard. (5) (Refer to Figure 2, View AA-AA) Attach the S Mount to the forward side of the wing strut. (6) (For airplanes that were equipped with the optional anti-ice system) Install the seven S Mounts as follows: (a) (RefertoFigure2,ViewH-H,ViewL-L,ViewM-M,ViewR-R,ViewT-T,ViewW-W,and View Z-Z.) Drill seven Number 30 (0.128-inch diameter) holes for the rivets that install the S Mounts. (b) With three S Rivets, and four MS20470A4-7N Rivets, attach the seven S Mounts to the airplane structure. (7) (For airplanes that were not equipped with the optional anti-ice system) Install the nine S Mounts as follows: (a) (RefertoFigure2,ViewH-H,ViewL-L,ViewM-M,ViewR-R,ViewS-S,ViewT-T,View W-W, View X-X, and View Z-Z.) Drill 9 number 30 (0.128 inch diameter) holes for the rivets that install the S Mounts. (b) With the three S Rivets, and six MS20470A4-7N Rivets, attach the nine S Mounts to the airplane structure. (8) (Refer to Figure 2, View A-A, View B-B, and View Y-Y.) Put the H Nylon Tubing, H Nylon Tubing, H Nylon Tubing, and P Protective Conduit in position in the wing with marks on the nylon tubing to show correct panel connection or correct proportional unit connection. Do the routing of the nylon tubing through the upper lightening holes in each rib and then out the applicable hole in the leading edge of the wing. (9) Pull the ends of the tubing through the slots in the strut leading edge, and make sure that the tube is of sufficient length to connect to the porous panel before the panel is in position on the strut. (10) (Refer to Figure 2, View AA-AA.) Install the MN4859 Back Nut and the MN6288 Reducing Bulkhead on the Bracket. (11) (Refer to Figure 2, View AA-AA.) Install the MN6079 Back Nut 1/8 BSP and the MN6235 Short Bulkhead Connector on the Bracket. (12) (Refer to Figure 2, View A-A.) Install the MN Sleeve, MN6201 Nut, and Seal on the H Nylon Tubing at the wing root. (13) (Refer to Figure 2, View B-B.) Install the five ZN Sleeves, S Sealing Rings, and ZN4855 Nuts on the H Nylon Tubing at Ports 1, 2, 3, 4, and 5 where the porous panels will be installed. (14) (Refer to Figure 2, View M-M, View N-N, View P-P, and View Q-Q.) Install the six MN4855 Nuts, MN Sleeves, and S Sealing Rings on the H Nylon Tubing at the Left Proportioning Unit ( Right Proportioning Unit). (15) (Refer to Figure 2, View P-P and View Q-Q.) Install the MN4856 Nut, MN Sleeve, and S Sealing Ring on the H Nylon Tubing at the Left Proportioning Unit ( Right Proportioning Unit). Page 46

57 (16) (Refer to Figure 2, View M-M and View N-N.) Install the MN6201 Nut, MN Sleeve, and Seal on the H Nylon Tubing at the Left Proportioning Unit ( Right Proportioning Unit). (17) (Refer to Figure 2, View AA-AA.) Install the three MN4856 Nuts, MN Sleeves, and S Sealing Rings on the H Nylon Tubing in the wing above the wing strut. (18) Install the MN4855 Nut, MN Sleeve, and S Sealing Ring on the HS10025 Nylon Tubing in the wing above the wing strut. (19) (Refer to Figure 2, View Y-Y.) Install the two ZN4856 Nuts, ZN Olives for 3/16 Nylon, and S Sealing Rings on the H Nylon Tubing in each wing strut. (20) (Refer to Figure 2, View C-C, View D-D, View E-E, View F-F, View G-G, View H-H, View J-J, View L-L, View M-M, View N-N, View R-R, View S-S, View T-T, View W-W, View X-X, View Z-Z, and View AA-AA.) With the S Ties, attach the nylon tubing at the S Mount and the S Mounts. (21) (Refer to Figure 2, View B-B.) Install P Protective Conduit over the H Nylon Tubing at the inboard wing area. B. Do the routing and the installation of the nylon tubing supply system for the right wing and the right wing strut on airplanes equipped with Weather Radar: (1) (Airplanes with Configuration Module for the RDR 2000 Bendix/King Weather Radar installed on the wing rib at WS ) (Refer to Figure 3, View P-P.) Change the location of the Configuration Module for the Bendix/King Weather Radar as follows: (a) (b) Remove the Configuration Module from the Strap Assembly. Keep the Configuration Module and the two screws and washers. Discard the nuts. Remove and discard the Strap Assembly and the attachment hardware from the wing rib. (2) (Refer to Figure 3, View Y-Y.) Match drill two Number 10 (0.193-inch diameter) holes in the Intercostal Assembly to install the Bracket. (3) With two AN3-3A Bolts, four NAS1149F0332P Washers, and two MS21044N3 Nuts, install the Bracket to the Intercostal Assembly. (4) (Refer to Figure 3, View N-N.) At the two pilot holes in the Right Proportioning Unit, match drill two Number 10 (0.193-inch diameter) holes in the Right Proportioning Unit and in the Rib. (5) With the two AN3-3A Bolts, four NAS1149F0332P Washers, and two MS21044N3 Nuts, install the Right Proportioning Unit to the inboard side of the Rib with the inlet pointed inboard. (6) (Airplanes that had the Configuration Module for the RDR 2000 Bendix/King Weather Radar installed on the wing rib at WS ) With the kept screws and washers and the two MS21044N06 Nuts, install the Configuration Module to the Right Proportioning Unit. (7) (For airplanes that were equipped with the optional anti-ice system installation) Install the six S Mounts as follows: (a) (RefertoFigure3,ViewH-H,ViewL-L,ViewS-S,ViewV-V,ViewW-W,andViewY-Y.) Drill six Number 30 (0.128-inch diameter) holes for the rivets that install the S Mounts. (b) With the three S and three MS20470A4-7N Rivets, attach the six S Mounts to the airplane structure. Page 47

58 (8) (For airplanes that were not equipped with the optional anti-ice system) Install the eight S Mounts as follows: (a) (RefertoFigure3,ViewH-H,ViewL-L,ViewQ-Q,ViewR-R,ViewS-S,ViewV-V,View W-W, and View Y-Y.) Drill eight Number 30 (0.128-inch diameter) holes for the rivets that install the S Mounts. (b) With the three S and five MS20470A4-7N Rivets, attach the eight S Mounts to the airplane structure. (9) (Refer to Figure 3, View Y-Y.) Install the S Mount to the forward side of the wing strut. (10) (Refer to Figure 3, Detail A, View B-B, and View X-X.) Put the H Nylon Tubing, H Nylon Tubing, H Nylon Tubing, and P Protective Conduit in position in the wing. Do the routing of the nylon tubing through the upper lightening holes in each rib and then out the applicable hole in the leading edge of the wing. (11) (Refer to Figure 3, View Z-Z.) Install the MN4859 Back Nut and the MN6288 Reducing Bulkhead on the Bracket. (12) (Refer to Figure 3, View Z-Z.) Install the MN6079 Back Nut 1/8 BSP and the MN6235 Short Bulkhead Connector on the Bracket. (13) (Refer to Figure 3, View A-A.) Install the MN Sleeve, MN6201 Nut, and Seal on the H Nylon Tubing at the wing root. (14) (Refer to Figure 3, B-B.) Install the five ZN Sleeves, S Sealing Rings, and ZN4855 Nuts on the H Nylon Tubing. (15) (Refer to Figure 3, View M-M and View N-N.) Install the six MN4855 Nuts, MN Sleeves, and S Sealing Rings on the H Nylon Tubing at the Right Proportioning Unit. (16) (Refer to Figure 3, View N-N.) Install the MN4856 Nut, MN Sleeve, and S Sealing Ring on the H Nylon Tubing at the Right Proportioning Unit. (17) (Refer to Figure 3, View M-M.) Install the MN6201 Nut, MN Sleeve, and Seal on the H Nylon Tubing at the Right Proportioning Unit. (18) (Refer to Figure 3, View Z-Z.) Install the three MN4856 Nuts, MN Sleeves, and S Sealing Rings on the H Nylon Tubing in the wing above the wing strut. (19) Install the MN4855 Nut, MN Sleeve, and S Sealing Ring on the HS10025 Nylon Tubing in the wing above the wing strut. (20) (Refer to Figure 3, View X-X.) Install the two ZN4856 Nuts, ZN Olives for 3/16 Nylon, and S Sealing Rings on the H Nylon Tubing in the wing strut. (21) (Refer to Figure 3, View C-C, View D-D, View E-E, View F-F, View G-G, View H-H, View J-J, View L-L, View M-M, View Q-Q, View R-R, View S-S, View V-V, View W-W, and View Y-Y.) With the S Ties, attach the nylon tubing at the S Mount and the S Mounts. (22) (Refer to Figure 3, View B-B.) Install P Protective Conduit over the H Nylon Tubing at the inboard wing area. C. (Refer to Figure 4.) Do the routing and the installation of the nylon tubing supply system for the fuselage: (1) (Refer to Figure 4, Detail A, View AL-AL, and View AV-AV.) Drill four Number 16, (0.177-inch diameter) holes in the Tailcone Bulkhead to install the two P041LH2015 Pressure Switches. (2) Drill eight Number 40 (0.098-inch diameter) holes in the Bulkhead to attach the four MS21075L08N Nutplates. (3) Deburr the holes and apply Alodine to bare metal. Page 48

59 (4) Install the four MS21075L08N Nutplates on the Bulkhead with the eight CCR244SS-3-02 Rivets. (5) (Refer to Figure 4, View AL-AL, View AR-AR, and View AV-AV.) Install the two P041LH2015 Pressure Switches on the bulkhead with the four MS Screws and NAS43DD3-31FC Spacers. (6) (Refer to Figure 4, View AL-AL, View AM-AM and View AN-AN.) At the junction of WL and FS on the left fuselage and on the right fuselage, drill two inch diameter holes in each Rib and two inch diameter holes in the tailcone skin if there are no holes there. (7) If you had to drill four inch diameter holes, install an S Ferrule in each of them. (8) (Refer to Figure 4, View AH-AH.) Drill four Number 10 (0.193-inch diameter) holes in the airplane skin to match the doubler for the tail proportioning unit. (9) Deburr the holes and apply Alodine to bare metal. (10) With the four AN525-10R6 Screws, install the Bracket Assembly to the Tail Proportioning Unit Doubler. NOTE: The Bracket Assembly comes to you with the proportioning unit installed on the bracket assembly. (11) (Refer to Figure 4, Detail A, View AJ-AJ, View AL-AL, and View AR-AR.) With the eight MN4855 Nuts, MN Sleeves, and S Sealing Rings, install the tubing from the fluid inlet hole in each horizontal stabilizer into the tailcone to each P041LH2015 Pressure switch and then down to the left and right ports on the tail proportioning unit. (12) (Refer to Figure 4, View C-C, View D-D, View H-H, View J-J, View K-K, View L-L View M-M, View N-N, View P-P, View Q-Q, View T-T, View U-U, View X-X, View Y-Y, View Z-Z, View AA-AA, View AB-AB, View AC-AC, View AD-AD, View AE-AE, View AF-AF, View AG-AG, View AK-AK, View AW-AW, View AX-AX, View AY-AY, View AZ-AZ, and View BA-BA.) Drill 36 Number 30 (0.128-inch diameter) holes as necessary for the rivets that install the S Mounts. NOTE: If mounts have been installed for the air conditioning lines at one or more of these positions, use the installed mounts and you do not have to install new ones. (13) With 30 S Rivets and six MS20470A4-7N Rivets, attach the 36 S Mounts to the airplane structure as necessary. NOTE: If mounts have been installed for the air conditioning lines at one or more of these positions, use the installed mounts and you do not have to install new ones. (14) (Refer to Figure 4, View N-N and View T-T.) Match drill four Number 30 (0.128-inch diameter) holes in the structure for the rivets that install the two S Brackets. (15) Deburr the holes and apply Alodine to bare metal. (16) With the four S Rivets, install the two S Brackets. (17) (Refer to Figure 4, View M-M.) Match drill two Number 30 (0.128-inch diameter) holes in the structure for the rivets that install the D8EP Clamp. (18) Deburr the holes and apply Alodine to bare metal. (19) With the two S Rivets, install the D8EP Clamp. (20) (Refer to Figure 4, View AL-AL.) Drill eight Number 21 (0.159-inch diameter) holes for the rivets that install the eight S Anchors. (21) Deburr the holes and apply Alodine to bare metal. (22) With the eight S3899A5-5N Rivets, install the eight S Anchors. Page 49

60 (23) (Refer to Figure 4, Sheet 1, Sheet 2, Sheet 3, View W-W, View AL-AL, and View AP-AP.) Put the H Nylon Tubing, H Nylon Tubing, and H Nylon Tubing in position in the fuselage, with the P Plastic and the P Protective Conduit over the H Nylon Tubing as shown. (24) (For airplanes that were equipped with the optional anti-ice system) (Refer to Figure 4, View AP-AP.) You can push the H TKS fluid tube (that routes up through the vertical stabilizer) through the S Anti-ice Hose up into the vertical stabilizer and then to the vertical tip assembly as necessary. (25) (Refer to Figure 4, View V-V and View W-W.) With one MN4856 Nut, MN Sleeve, S Sealing Ring, MN6079 Back Nut 1/8 BSP, and MN6235 Short Bulkhead Connector, attach the H Nylon Tubing to the skin that is under the floorboards. (26) (Refer to Figure 4, View V-V and View W-W.) With the four MN6201 Nuts, four MN Sleeves, four Seals, one MN6210 Bulkhead Equal Tee, two MN6211 Back Nuts, one MN6216 Bulkhead Unequal Tee, and one MN6782 5/16 Blanking Cap, attach the H Nylon Tubing to the skin that is under the floorboards. (27) (Refer to Figure 4, View AJ-AJ.) With one MN4855 Nut, MN Sleeve, and S Sealing Ring, attach the vertical tail feed to the tail proportioning unit. (28) With one MN6201 Nut, MN Sleeve, and Seal, attach the tail proportioning unit inlet feed tube to the large port on the tail proportioning unit. (29) (Refer to Figure 4, View A-A.) At the junction of RBL and WL 80.25, drill a inch diameter hole in the engine firewall. (30) Make a mark 1.25 inch outboard of the inch diameter hole at WL and drill a inch diameter hole in the engine firewall. (31) Deburr the holes and apply Alodine to bare metal. (32) Install a ZN6829 Fitting and a ZN6756 Back Nut in the engine firewall in the inch diameter hole. (33) (Refer to Figure 4, View B-B.) Attach the nylon tubing at the inch diameter hole in the firewall with one ZN4855 Nut, ZN Sleeve, and S Sealing Ring. (34) (Refer to Figure 4, View A-A.) Install a ZN6261 Fitting and a ZN6079 Nut in the firewall in the inch diameter hole. (35) Refer to Figure 4, View B-B.) Attach the nylon tubing at the inch diameter hole in the firewall with one ZN4856 Nut, ZN Olive for 3/16 Nylon, and S Sealing Ring. (36) Install and tighten the and Hoses (that hang loose in the engine compartment) to the firewall fittings on the engine firewall. (37) (Refer to Figure 4, View E-E, View F-F, View G-G, View AS-AS, and View AT-AT.) With U064092S Adhesive, install five H Caterpillar Grommet Strips at FS , at FS , at LBL 13.97, at RBL 23.47, and at FS as shown. (38) (Refer to Figure 4, View AP-AP.) With U064092S Adhesive, install one S Grommet to the forward end of the Rib at WL on the vertical stabilizer tip assembly that you removed. (39) (Refer to Figure 4, View L-L and View M-M.) At the D8EP Clamp at the junction of FS and WL 83.95, install the PU320AC160 Proportioning Unit to the nylon tubing with two MN4855 Nuts, MN Sleeves, and S Sealing Rings, and attach to the D8EP Clamp with the MS Screw. Make sure that the PU320AC160 Proportioning Unit is installed in the correct direction. (40) (Refer to Figure 4, View L-L and View N-N.) At the S Bracket at FS , install the MN6216 Bulkhead Unequal Tee, two MN6201 Nuts, two MN Sleeves, two Seals, one MN4855 Nut, one MN Sleeve, and one S Sealing Ring to the nylon Page 50

61 tubing, and attach to the S Bracket with one MS21919WDG13 Clamp, MS Screw, and MS Nut. (41) (Refer to Figure 4, View T-T.) At the S Bracket at the junction of WL and LBL 16.10, install the MN6210 Bulkhead Equal Tee, three MN6201 Nuts, MN Sleeves, and Seals to the nylon tubing, and attach to the S Bracket with one MS21919WDG13 Clamp, MS Screw, and MS Nut. (42) (Refer to Figure 4, View R-R.) At the junction of FS and WL , make the existing hole larger to inch in the left wing rib or drill a new hole. (43) (Refer to Figure 4, View S-S.) At the junction of FS and WL , make the existing hole larger to inch in the left wing rib or drill a new hole (44) Deburr the holes and apply Alodine to bare metal. (45) (Refer to Figure 4, View R-R and View S-S.) Install one MN6835 Bulkhead Fitting in each of the two inch diameter holes in the wing ribs. (46) (Refer to Figure 4, View P-P.) Install two MN6211 Back Nuts, one MN6201 Nut, one MN Sleeve, and one Seal on each of the two MN6835 Bulkhead Fittings in the wing ribs. (47) (Refer to Figure 4, View AP-AP and View AQ-AQ and Figure 27.) At WL on the centerline of the vertical stabilizer, drill a inch diameter hole in the Rib. (48) Deburr the hole and apply Alodine to bare metal. (49) (Refer to Figure 4, View AP-AP.) Install an MN6288 Reducing Bulkhead and an MN4859 Back Nut in the inch diameter hole in the Rib. (50) Attach the nylon tubing to the MN6288 Reducing Bulkhead with an MN4856 Nut, MN Sleeve, S Sealing Ring, MN4855 Nut, MN Sleeve, and S Sealing Ring. (51) At the position where you will install the Vertical Stabilizer Porous Panel, install one ZN4856 Nut, ZN Olive for 3/16 Nylon, and S Sealing Ring to the nylon tubing. Before the panel is in position on the vertical stabilizer, make sure that the tubing is of sufficient length to connect to the porous panel. (52) (Refer to Figure 4, View AP-AP.) Put the kept Tip Assembly Panel in position at the top of the vertical stabilizer and pull the nylon tubing through the hole. (53) (Refer to Figure 7, View A-A.) Install the Tip Assembly with the kept screws. (54) (Refer to Figure 4, View P-P and View X-X.) At FS and FS , do the routing of the nylon tubing with the Fuel Line Assembly and attach as necessary with S Ties. (55) (Refer to Figure 4, View C-C, View D-D, View H-H, View J-J, View K-K, View L-L, View M-M, View N-N, View P-P, View Q-Q, View T-T, View U-U, View X-X, View Y-Y, View Z-Z, View AA-AA, View AB-AB, View AC-AC, View AD-AD, View AE-AE, View AF-AF, View AG-AG, View AK-AK, View AW-AW, View AX-AX, View AY-AY, View AZ-AZ, and View BA-BA.) Attach the nylon tubing to the 36 S Mounts with the 36 S Ties. (56) (Refer to Figure 4, View AL-AL.) Attach the nylon tubing to the eight S Anchors with the eight S Ties. D. Use S Ties to attach the tubing to the structure and to other attach points as necessary to make sure that there will be no chafing and that there will be sufficient clearance for the tubing. E. (Refer to Figure 4, View P-P, and Figure 2, View A-A or Figure 3, View A-A.) Attach the H NylonTubingthatyouinstalledinthetwowingrootstotheMN6835BulkheadElbowsthat you installed on the fuselage root ribs. Use the two MN Sleeves, MN6201 Nuts, and Seals that you installed. Page 51

62 F. Attach the H Nylon Tubing to the MN6235 Short Bulkhead Connector at the TKS Left Fuselage Doubler with the MN4856 Nut, MN Sleeve, and S Sealing Ring that you installed. G. Attach the H Nylon Tubing to the MN6216 Bulkhead Unequal Tee at the TKS Left Fuselage Doubler with the MN6201 Nut, MN Sleeve, and Seal that you installed. WARNING: Before you install the porous panels, make sure that the paint on the leading edges of the airplane has fully cured in accordance with the manufacturer's specifications. 15. Before you install the porous panels, make sure that the paint on the leading edges of the airplane has fully cured in accordance with the manufacturer's specifications. 16. (Refer to Figure 30.) Temporarily install the porous panels and apply masking tape (or equivalent) on the airplane skin around the perimeter of the porous panels. This will allow you to fillet seal the edges of the porous panels later. 17. Remove the porous panels. 18. (Refer to Figure 33.) Install the porous panels as follows (Refer to the 208 Maintenance Manual, Chapter 30, TKS Anti-Ice Leading Edge Porous Panel - Maintenance Practices.): CAUTION: Do not do damage to the ice protection system with solvents or paints that are not approved for use on or near the porous panels. Most solvents and all paints can cause damage to the plastic membrane in the porous panels. Use only approved solvents on or near the porous panels. Never use MEK, acetone, or lacquer thinner. Always use masking material when you use paint or unapproved solvents near the porous panels. CAUTION: After you remove and before you install a porous panel, apply P Tape or equivalent low-residue masking material on the panel to give it protection. CAUTION: Be careful when you remove and install the porous panels, as you can do damage during removal and installation. Use nonmetallic tools when you can to prevent tears, gouges, scratches, and other damage. A. Clean the airplane leading edges (where you will install the porous panels) and the rear surfaces of the porous panels to remove all grease and FOD. (Refer to the Model 208 Maintenance Manual, Chapter 20, General Solvents/Cleaners - Maintenance Practices.) B. In the areas that have masking tape around them (where you will install the porous panels), lightly abrade the airplane leading edges with a Scotch Brite pad. C. Use a 50/50 mixture of denatured alcohol and water with a sponge or medium-hard short bristle brush to clean the area of the leading edge where you will install the porous panel. D. Use a clean, lint-free cloth to dry the area before the cleaning solution dries. E. Use a clean, lint-free cloth that is wet with denatured alcohol (no water) to clean the rear surface of the porous panel as necessary. F. Use a clean, lint-free cloth to dry the area before the cleaning solution dries. G. (Refer to Figure 34.) With U544042S Sealant, prepack seal the voids between the backplate joggles and edges of the porous panels. (Refer to the Model 208 Maintenance Manual, Chapter 20, Fuel, Weather and High-Temperature Sealing - Maintenance Practices.) H. (Refer to Figure 34.) Apply a 0.50-inch (inboard wing panels) or a 0.25-inch diameter bead (all other panels) of U544042S Sealant that is equivalent to a prepack seal along the centerline of the backplate of the porous panel. (Refer to the Model 208 Maintenance Manual, Chapter 20, Fuel, Weather and High-Temperature Sealing - Maintenance Practices.) I. On the inboard wing porous panels only, apply U544042S Sealant as a prepack seal along the full width of the inboard 48 inches of the backplate. Page 52

63 CAUTION: When you apply sealant to the inboard 48 inches of the inboard wing panels, you must fill all of the space between the inboard wing porous panels and the wing leading edges with sealant. Sealant squeeze out along the upper and the lower edges of the inboard wing porous panels in this area is a sign that sufficient sealant has been applied. J. (Refer to Figure 34.) Apply U544042S Sealant as a prepack seal around all fluid inlet ports or air bleed ports on the porous panels. (Refer to the Model 208 Maintenance Manual, Chapter 20, Fuel, Weather and High-Temperature Sealing - Maintenance Practices.) K. Put the porous panels adjacent to the applicable leading edge and connect the fluid tubes to the inlet ports. CAUTION: Make sure that you install the fluid tubes to each porous panel correctly with an o-ring installed on each fitting, and make sure that you use approved procedures to torque the TKS fittings as described in the first steps of this Service Kit. Once the porous panels are installed, there will be no access to the fluid port fittings on some porous panels. L. Put the porous panels on the applicable leading edges and use temporary fasteners (Clecos) in the rivet holes to hold the panels in the correct position. M. Apply aftward pressure to the forward edges of the porous panels to make sure that they are held tightly against the leading edges. CAUTION: Make sure that when you tighten the ratcheting straps you do no damage to the flap. Use foam or blankets to protect the airplane structure and do not use too much force when you tighten the straps. N. (For installation of and Inboard Wing Porous Panels only) After the panels have been put into position with the temporary fasteners, use ratchet straps around the flap and between the fastener positions to pull the inboard wing porous panel edges against the contour of the wing leading edge. Look for sealant that squeezes out around all edges of the porous panels as an indication that you applied sufficient sealant to the inboard wing porous panels. O. Apply pressure to the edges of the panel as necessary to remove all gaps between the edges of the panel and the leading edge skin. P. Install strips of P Tape across the remaining panels to apply pressure after the panels are in the correct position and do not remove the tape until the sealant is fully cured. CAUTION: Always use P Tape or equivalent low-residue masking material to make sure that unapproved materials do not touch the porous panels. Q. (Refer to Figure 7, Figure 24, and Figure 25.) With U544042S Sealant, shank seal the CR Rivets and the MS Screws (screws on Vertical Stabilizer Porous Panel only) before you install them. (Refer to the Model 208 Maintenance Manual, Chapter 20, Fuel, Weather and High-Temperature Sealing - Maintenance Practices.) R. Remove the temporary fasteners and install the porous panels with the CR Rivets, MS Screws, and NAS1515H08L Washers (screws on Vertical Stabilizer Porous Panel only). CAUTION: Always use P Tape or equivalent low-residue masking material to make sure that unapproved materials do not touch the porous panels. CAUTION: You must allow the sealant to cure before you remove the strips of tape and the ratcheting straps from the porous panels. S. After the panels are cured in position, remove the ratchet straps or tape that you used to apply pressure to the porous panels. Page 53

64 T. (Refer to Figure 30) Fillet seal around the edges of the porous panels with U Sealant. (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather, and High - Temperature Sealing - Maintenance Practices. U. Remove the masking tape from around the perimeter of the porous panels. V. Make sure that the maximum resistance value of the electrical bond between the porous panels and the structure is no more than ohms. If the maximum resistance value is more than ohms, you must contact Cessna Customer Service at (Refer to the 208 Maintenance Manual, Chapter 20, Electrical Bonding - Maintenance Practices.) 19. Fay seal each horizontal and vertical stabilizer access panel with U544035S Sealant. 20. Install the access panels on the horizontal and the vertical stabilizers. Do not install the wing access panels at this time. 21. (Refer to Figure 21, View A-A, View B-B, and View C-C.) Install the 3D5304 Vortex Generators (VG) on the left wing and the right wing as follows: A. Makealinewithchalkfromtherootofthewingtothetipofthewinginthepositionshown. B. (Refer to Figure 21,) Make marks at the 10 positions on the left wing and the 10 positions on the right wing where you will install the 20 3D5304 Vortex Generators. You will install the 3D5304 Vortex Generators parallel to the wing stations with the point turned to the aft part of the wing. If necessary, move the mark position a very small distance, as you must not install a 3D5304 Vortex Generator on a rivet. C. Lightly abrade the paint on the airplane skin where you will install the 3D5304 Vortex Generators to remove the glossy surface only. Make sure that you do not remove the paint. CAUTION: Do not do damage to the ice protection system with solvents or paints that are not approved for use on or near the porous panels. Most solvents and all paints can cause damage to the plastic membrane in the porous panels. Use only approved solvents on or near the porous panels. Never use MEK, acetone, or lacquer thinner. Always use masking material when you use paint or unapproved solvents near the porous panels. D. With isopropyl alcohol, clean the area where you will install the 3D5304 Vortex Generators. E. Apply U000787S Adhesive on the bottom of one 3D5304 Vortex Generator and install it at the intersection of the chalk line and WS on the left wing. Do not install it on a rivet. F. Apply U000787S Adhesive on the bottom of one 3D5304 Vortex Generator and install it at the intersection of the chalk line and WS on the right wing. Do not install it on a rivet. G. One vortex generator at a time, apply U000787S Adhesive on the bottom of the 18 remaining 3D5304 Vortex Generators and install them in their correct positions on the upper surfaces of the wings. Do not install a 3D5304 Vortex Generator on a rivet. CAUTION: Do not do damage to the ice protection system with solvents or paints that are not approvedforuseonornear the porous panels. Most solvents and all paints can cause damage to the plastic membrane in the porous panels. Use only approved solvents on or near the porous panels. Never use MEK, acetone, or lacquer thinner. Always use masking material when you use paint or unapproved solvents near the porous panels. H. With a fine-bristle brush, edge seal the 0.15-inch flange of each 3D5304 Vortex Generator with no less than two layers of paint (of the same color that is used on the airplane wing). Page 54

65 22. (Refer to Figure 14, View A-A and View B-B.) Move the installation position of the stall vane to align with the cutout in the Left Mid-Wing Porous Panel and install the kept Lift Transducer as follows: A. Increase the forward length of the slots in the leading edge skin no more than 0.20 inch to get the 0.03-inch dimension shown. B. Put the Lift Transducer in position at the most forward position in the holes on the wing and measure to see if you must add NAS1149FN816P Washer(s) and/or NAS1149FN832P Washer(s) to make the forward edge of the Lift Transducer flush with the outer surface of the Left Mid-Wing Porous Panel. The forward edge of the Lift Transducer must be flush with the outer surface of the Left Mid-Wing Porous Panel or inset no more than inch. C. With the two MS24694-S6 Screws, two MS24694-S5 Screws, NAS1149FN816P and/or NAS1149FN832P Washer(s) as necessary, and four MS21044N08 Nuts and NAS1149FN832P Washers (installed under the nut), install the Lift Transducer in the most forward position in the holes. D. Make sure that the Lift Transducer is at the most forward position in the holes, that the Lift Transducer is flush with the outer surface of the Left Mid-Wing Porous Panel, and that the top edge of the Lift Transducer is flush with the outer surface of the Left Mid-Wing Porous Panel or inset no more than inch. E. Look at the Serial Effectivity Section of Cessna Service Bulletin CAB08-8 Stall Warning Margin Adjustment/Reset (latest revision) and see if your airplane is one of the serial numbers affected by that Service Bulletin. If your airplane is affected, review logbook entries to make sure that CAB08-8 has been complied with, and if not, comply with CAB08-8 (latest revision). NOTE: You may have to set the lift transducer again later when you do a check for the correct operation of the lift transducer in a later instruction in this Service Kit. F. (Refer to Figure 14, Detail A.) Inject and fillet seal all around the mounting plate of the Lift Transducer with U Sealant. The sealant must not extend above the outermost line of the mounting plate face. 23. Install the Windshield Ice Indicator Assembly if it is not installed. Refer to CAB04-9 / SK (or latest revision), Ice Protection Modification to install the Windshield Ice Detector. 24. Install the Pilot Assist Handle if it is not installed. Refer to CAB04-9 / SK (or latest revision), Ice Protection Modification to install the Pilot Assist Handle. 25. (Airplanes 208B0001 thru 208B0213 that were not equipped with anti-ice equipment) (Refer to Figure 29.) Do the ice detector light installation as follows: A. Pull back the headliner as necessary to install the ice detector light. (Refer to the Model 208 Maintenance Manual, Chapter 25, Cabin Upholstery - Maintenance Practices.) B. Remove the Fairing from the airplane. Keep the screws. C. (Refer to Figure 29, View A-A.) Make a 3.00-inch diameter hole in the Fairing. D. Put the Housing Assembly in position on the Fairing with the center of the housing assembly on the 3.00-inch diameter hole. Turn the housing assembly to put the rivet holes at the positions shown. E. Match drill eight Number 30 (0.128-inch diameter) holes in the Fairing. F. Apply U Sealant as a fay seal between the housing assembly flange and the fairing assembly. (Refer to the Model 208 Maintenance Manual, Chapter 20, Fuel, Weather and High-Temperature Sealing - Maintenance Practices.) G. With the eight MS20470A4-4N Rivets, install the Housing Assembly to the Fairing. H. (Refer to Figure 29, View D-D.) With the two MS20470AD4-4A Rivets, install the Bracket to the Housing Assembly. Page 55

66 I. (Refer to Figure 29, View A-A and View D-D.) Install the MS21919WDG2 Clamp and the S Socket on the Bracket with the two MS Screws, NAS1149FN832P Washers, and MS Nuts. Install the washers under the screw heads. J. (Refer to Figure 29, View A-A and View C-C.) Install the A-7079B-24 Lamp in the S Socket. K. Put the Cover and the Lens in position with the three MS24693S27 Screws to see how many Shims you will need to make a flush mount of the cover to the surface of the fairing. The maximum permitted mismatch is or inch. L. Apply U544035S Sealant as a fay seal between the lens and the housing assembly (with the shims as necessary). Apply the separating agent to the lens side. (Refer to the Model 208 Maintenance Manual, Chapter 20, Fuel, Weather and High-Temperature Sealing - Maintenance Practices.) M. Install the Shim(s), Cover, and Lens with the three MS24693S27 Screws. N. Measure to see if there is a mismatch between the cover and the surface of the fairing and install or remove the Shims until the mismatch is within the permitted limits of or inch. O. Install the MS Grommet in the Root Rib. P. (Refer to Figure 29, View B-B.) Install the MS Switch and the C15Green Tip Switch on the new LAA Switch Plate Assembly. (Refer to the Model 208 Maintenance Manual, Chapter 33, External Light Switches - Maintenance Practices.) Q. Install the S Circuit Breaker in the Circuit Breaker Panel. (Refer to the Model 208 Maintenance Manual, Chapter 24, Electrical Distribution System - Maintenance Practices.) R. (Refer to Figure 29.) Do the wiring installation for the ice detector light. (Refer to the 208 Wiring Diagram Manual, Chapter 33, Ice Detector Light.) NOTE: You will use the parts that follow as you do the wiring installation: LH1 Wire LH2 Wire LH3 Wire LH7 Wire LH8 Wire S Housing S Housing. S. Fillet seal around the MS Grommet and the LH6 Wire with U470642Sealant. (Refer to the Model 208 Maintenance Manual, Chapter 20, Fuel, Weather and High-Temperature Sealing - Maintenance Practices.) T. Install the or Fairing on the airplane with the kept screws. 26. (Refer to Figure 16, Figure 19, and Table 1.) Do the electrical installation as follows: TABLE 1 WIRE INFORMATION Wire Code Gage Material Terminals HA S S HA S S HA S S HA S S HA S S HA S S Page 56

67 TABLE 1 WIRE INFORMATION Wire Code Gage Material Terminals HA S S HA S S HA S S HA S S HA S S HA S S HA S S HA S S HA S S HA S S HA S S HA S S HA S S HA S S HA S S HA S S HA S S HA S M39029/5-115 HA S M39029/5-115 HA MS39029/ M39029/5-115 HA S M39029/5-115 HA S M39029/5-115 HA S M39029/5-115 HA S M39029/5-115 HA S M39029/5-115 HA S M39029/5-115 HA S M39029/5-115 HA S M39029/5-115 HA S M39029/5-115 HA S M39029/5-115 HA S M24308/10-1 HA S M39029/5-115 HA M24308/10-1 S HA S S Page 57

68 TABLE 1 WIRE INFORMATION Wire Code Gage Material Terminals HA MS39029/ S HA S M39029/5-115 HA S M39029/5-115 HA S MS39029/ HA MS39029/ S HA S M39029/5-115 HA MS39029/ M39029/5-115 HA M39029/5-115 S HA M39029/5-115 S HA M39029/5-115 S HA S M39029/5-115 HA S M39029/5-115 HA S S HA S S HA153 (White) 22 M ML3T08 M24308/10-1 M39029/5-115 HA153 (Blue) 22 M ML3T08 M24308/10-1 M39029/5-115 HA153 (Orange) 22 M ML3T08 M24308/10-1 M39029/5-115 HD S S NOTE: All parts shown in TABLE 1 but not shown in the Material Section of this Service Kit, are part of the TKS Cable Assembly except the LAA Switch Plate Assembly. A. Remove the wires shown on Figure 16. B. Find the large JD005 connector and the smaller JD002 connector on the new TKS wire bundle. These connectors will have wires pinned into them. C. Prepare the surface of the skin below the floorboards on the right side of the cabin for an electrical bond. D. Electrically bond the JD005 and JD002 bulkhead connectors and the doubler, and make sure that the maximum resistance value is no more than ohms after the connectors are installed. (Refer to the 208 Maintenance Manual, Chapter 20, Electrical Bonding - Maintenance Practices.) E. Install the JD005 bulkhead connector with four MS Screws and one M85528/2-16-B Mounting Flange and the JD002 bulkhead connector with four MS Screws and one M85528/2-12-A Mounting Flange. F. In the cargo pod, install the connectors from the TKS fluid and equipment pack to JD005 and JD002. G. Inside the cabin and from the JD005 connector, do the routing of the HA146, HA147, and HA148 wires aft along existing wire bundles and supports to the tailcone proportioning unit. H. Inside the cabin and from the JD005 and JD002 connector, do the routing of all other wires forward along existing wire bundles and supports and up through the floor forward of the circuit breaker box. I. (Refer to Figure 16, Figure 19 View B-B, and Table 1.) Install one S Circuit Breaker (CB410) and one S Circuit Breaker (CB409) in #4 Bus Bar. Use the hex nut provided with Page 58

69 the circuit breaker as the face nut and use the knurled nut as the base nut adjacent to the circuit breaker body. (Refer to the 208 Wiring Diagram Manual, Chapter 20, Standard Practices - Airframe.) J. Install one S Circuit Breaker (CB309) and one S Circuit Breaker (CB310) in #3 Bus Bar. Use the hex nut provided with the circuit breaker as the face nut and use the knurled nut as the base nut adjacent to the circuit breaker body. K. Install new Bus Bars (BB3 and BB4) as necessary if the bus bars that are installed are not of sufficient length to go to the new circuit breakers. L. Attach the HA57, HA25, and HA16 Wires (part of the TKS Cable Assembly) at the applicable circuit breaker and at the circuit breaker panel connector. M. Attach the existing HD1 wire to the S Circuit Breaker (CB410). N. Where possible, do the routing of the new wires along existing wiring and use existing supports. O. Install the LAA Switch Plate Assembly as follows: NOTE: This plate assembly is a part that you must install when you accomplish the SK B, Low Airspeed Awareness System Installation for Airplanes with TKS. It is a part that comes with the SK B2 Kit. (1) Remove the screws and the washers that attach the Switch Panel to the instrument panel. Discard the switch panel and keep the attachment hardware. (Refer to the Model 208 Maintenance Manual, Chapter 31, Instrument and Control Panels - Maintenance Practices.) (2) Move all switches from the Switch Panel to the LAA Switch Plate Assembly, but do not move the two MS Switches and the one MS Switch that were installed in the W/S PRIMARY, W/S SECONDARY, and BOOT PRESS locations. P. (Refer to Figure 16, Figure 19, Detail D and View A-A, and Table 1.) Install the Cockpit Annunciator (CU8) on the instrument panel. (1) (Airplanes 208B0001 thru 208B1086) Make a cutout for the Cockpit Annunciator as follows: (a) (b) Make a cutout in the position shown. Deburr, remove sharp edges, and apply Alodine as necessary. CAUTION: Use caution when you touch, install, or remove the Cockpit Annunciator. It is an electrostatic-sensitive device, and damage can result if you do not use approved procedures to touch, remove, and install it. (2) Install the Cockpit Annunciator in the applicable cutout on the instrument panel. (Refer to the Model 208 Wiring Diagram Manual, Chapter 20, Electrical Safety Precautions - Description and Operation.) (3) Attach the HA92, HA110, HA113, HA115, and HA117 Wires to the Switch Light Connector (PK25). (4) Plug the Switch Light Connector into the Cockpit Annunciator. (5) Attach the HA113 Wire to the annunciator panel (Pin 3 of PK24). (6) Splice the HA112 Wire into the wire that is installed at the annunciator panel (Pin 9 of PK24). (7) Attach the HA115 Wire to the DAY/NIGHT switch (S76). (8) Install the wires along the installed wires and with installed supports that are adjacent to the installed wiring. Q. Install the Post Light Assembly (L2) on the instrument panel if it is not installed. Page 59

70 R. (Refer to Figure 16, Figure 19, View A-A and Detail B, and Table 1.) Install the TKS Fluid Quantity Gage (L48) on the instrument panel. (1) If a cover plate is installed at the location on the instrument panel where you must install the TKS Fluid Quantity Gage, remove the cover plate and do the modification shown. (2) Make a 1.25-inch diameter hole in the instrument panel. (3) Drill four inch diameter holes in the instrument panel. (4) Deburr, remove sharp edges, and apply Alodine as necessary. S. Attach the HA103, HA108, and HA153 Wires (part of the TKS Cable Assembly) to the M24308/2-1 (PK26) Connector for the fluid quantity gage. NOTE: The HA153 Wire is a shielded triple conductor. T. Install the M84059/ Backshell on the M24308/2-1 Connector (PK26). U. Plug the M24308/2-1 Connector (PK26) into the fluid quantity gage. V. With the four MS Screws, install the TKS Fluid Quantity Gage on the instrument panel. W. Attach the HA70, HA71, HA89, HA91, HA93, HA94, HA95, HA96, HA97, HA98, HA99, HA100, HA101, and HA102 Wires (part of the TKS Cable Assembly) to the S (JI003) Connector and the S Clamp. X. Attach the HA73, HA74, HA75, HA76, and HA77 Wires (part of the TKS Cable Assembly) to the MS BACKUP Switch (S1024). NOTE: The MS BACKUP Switch (S1024) is found on the far right of the three TKS switches. Y. Attach the HA78, HA79, HA80, and HA81 Wires (part of the TKS Cable Assembly) to the MS MAX FLOW Switch (S1023). NOTE: The MS MAX FLOW Switch (S1023) is the middle switch of the three TKS switches. Z. Attach the HA72, HA82, HA83, HA84, HA85, HA86, and HA87 Wires (part of the TKS Cable Assembly) to the MS PRIMARY Switch (S1022). Splice the wires as shown. NOTE: The MS PRIMARY Switch (S1022) is found on the far left of the three TKS switches. AA. (Refer to Figure 19, Detail C.) Install the MS BACKUP Switch (S1024) and the C15Green Tip on the LAA Switch Plate Assembly. AB. Install the MS MAX FLOW Switch (S1023) and the C15Green Tip on the LAA Switch Plate Assembly. AC. Install the MS PRIMARY Switch (S1022) and the C15Green Tip on the LAA Switch Plate Assembly. AD. Attach the S Connector (PI003) and the S Clamp to the HA72, HA73, HA74, HA75, HA76, HA77 HA78, HA79, HA80, HA81, HA83, HA84, HA85, and HA87 Wires. AE. Attach the S Connector (JI003) to the S Connector (PI003). AF. With the kept attachment hardware, install the LAA Switch Plate Assembly. (Refer to the Model 208 Maintenance Manual, Chapter 31, Instrument and Control Panels - Maintenance Practices.) AG. Splice the HA107 and the HA109 Wires to the HA108 Wire as shown. AH. (Refer to Figure 16, Figure 19, Detail A, and Table 1.) Install the HA89, HA90, and HA109 Wires (part of the TKS Cable Assembly) to the J66 and J9 ground blocks. NOTE: The J66 and J9 ground blocks are found near to the firewall behind the pilot's instrument panel. Page 60

71 AI. Attach the HA69, HA70, HA71, and HA103 Wires to the circuit breaker panel. Install the wires along installed wiring and with the installed supports that are adjacent to the installed wiring. AJ. (Refer to Figure 19, View C-C and View D-D.) In the tailcone, install the Low Pressure Switch Wire Harness to the tail proportioning unit bracket with the four MS21044N06 Nuts, NAS1149FN632P Washers, and MS Screws. AK. Install the HA146, HA147, HA151, HA152, and HA148 Wires (part of the TKS Cable Assembly), S Plug (PT003), and S Backshell to the tail proportioning unit bracket. Splice wires as shown. Make the HA151 and HA152 wires from existing wire and label them. AL. (Refer to Figure 16 and Figure 19.) Make sure that the TKS Cable Assembly is connected correctly at all positions. 27. Accomplish SK B Low Airspeed Awareness System Installation for Airplanes with TKS. NOTE: Part Number SK B, which includes SK B2, is a separate item and is not included with TKS Ice Protection System. 28. (Refer to Figure 20.) Install the necessary placards for the TKS anti-ice system installation as follows: A. (Refer to Figure 20, View A-A, View B-B, and Detail B.) Install one Solvent Caution Placard on the bottom of each wing and one Solvent Caution Placard on the bottom of each horizontal stabilizer as follows: (1) Clean areas where placard is to be installed with isopropyl alcohol. (Refer to the Maintenance Manual, Chapter 20, Solvents, Sealants and Adhesives - Maintenance Practices.) (2) Install the four Solvent Caution Placards on the left and the right wings and on the left and the right horizontal stabilizers in the positions shown. (3) Edge seal the Solvent Caution Placards with clear polyurethane enamel topcoat. (Refer to the Maintenance Manual, Chapter 20, Exterior Finish - Cleaning/Painting.) B. (Refer to Figure 20, Detail A.) Install the Filler Cap Placard on the left side of the cargo pod as follows: (1) Clean area where placard is to be installed with isopropyl alcohol. (Refer to the Maintenance Manual, Chapter 20, Solvents, Sealants and Adhesives - Maintenance Practices.) (2) Install the Filler Cap Placard on the left side of the cargo pod in the position shown. (3) Edge seal the Filler Cap Placard with clear polyurethane enamel topcoat. (Refer to the Maintenance Manual, Chapter 20, Exterior Finish - Cleaning/Painting.) C. (Airplanes 208B0001 thru 208B1234 that have not incorporated CAB07-3 (or latest revision) Pilot's Operating Handbook Supplement S1 Revision and Operational Limitation Placard Installation) (Refer to Figure 20, View F-F.) Install the Icing Warning Placard on the top of the pedestal as follows: (1) If installed, remove the Icing Warning Placard, Icing Warning Placard, and Icing Warning Placard from the airplane. (2) Clean the area where the placard is to be installed with isopropyl alcohol. (Refer to the Maintenance Manual, Chapter 20, Solvents, Sealants and Adhesives - Maintenance Practices.) (3) Install the Icing Warning Placard on the top of the pedestal in the position shown. (4) Edge seal the Icing Warning Placard with clear polyurethane enamel topcoat. (Refer to the Maintenance Manual, Chapter 20, Exterior Finish - Cleaning/Painting.) D. (Refer to Figure 20, View C-C and Detail C.) Install the Operational Limitations Placard adjacent to the overhead console as follows: (1) Remove the installed operational limitations placard that is adjacent to the overhead console. (2) Clean the area where the new placard is to be installed with isopropyl alcohol. (Refer to the Maintenance Manual, Chapter 20, Solvents, Sealants and Adhesives - Maintenance Practices.) Page 61

72 (3) Install the Operational Limitations Placard adjacent to the overhead console in the approximate position shown. E. (Refer to Figure 20, View E-E and Detail F.) Install the Icing Conditions Placard on the instrument panel as follows: (1) Remove the installed icing conditions placard that is on the instrument panel. (2) Clean the area where the new placard is to be installed with isopropyl alcohol. (Refer to the Maintenance Manual, Chapter 20, Solvents, Sealants and Adhesives - Maintenance Practices.) (3) Install the Icing Conditions Placard on the instrument panel in the position shown. F. (Refer to Figure 20, View D-D and Detail D.) Install the Windshield Anti-Ice Placard on the instrument panel as follows: (1) Clean the area where the new placard is to be installed with isopropyl alcohol. (Refer to the Maintenance Manual, Chapter 20, Solvents, Sealants and Adhesives - Maintenance Practices.) (2) Install the Windshield Anti-Ice Placard on the instrument panel in the position shown. G. (Refer to Figure 20, View G-G.) Install the Circuit Breaker Panel Placard and the Circuit Breaker Panel on the circuit breaker panel as follows: (1) Remove the two installed circuit breaker panel placards that are on rows 3 and 4 of the circuit breaker panel. (2) Clean the areas where the new placards are to be installed with isopropyl alcohol. (Refer to the Maintenance Manual, Chapter 20, Solvents, Sealants and Adhesives - Maintenance Practices.) (3) Install the Circuit Breaker Panel Placard and the Circuit Breaker Panel on the circuit breaker panel in the positions shown. H. (Refer to Figure 20, View D-D and Detail E.) Install the TKS Operational Limit Placard on the pilot side of the instrument panel as follows: (1) Clean area where placard is to be installed with isopropyl alcohol. (Refer to the Maintenance Manual, Chapter 20, Solvents, Sealants and Adhesives - Maintenance Practices.) (2) Install the TKS Operational Limit Placard on the pilot side of the instrument panel in the position shown. (3) Edge seal the TKS Operational Limit Placard with clear polyurethane enamel topcoat. (Refer to the Maintenance Manual, Chapter 20, Exterior Finish - Cleaning/Painting.) I. (Refer to Figure 20, View H-H and Detail G.) Install the TKS Operational Limit Placard on the front of the TKS tank as follows: (1) Clean area where placard is to be installed with isopropyl alcohol. (Refer to the Maintenance Manual, Chapter 20, Solvents, Sealants and Adhesives - Maintenance Practices.) (2) Install the TKS Operational Limit Placard on the front of the TKS tank in the position shown. (3) Edge seal the TKS Operational Limit Placard with clear polyurethane enamel topcoat. (Refer to the Maintenance Manual, Chapter 20, Exterior Finish - Cleaning/Painting.) 29. Remove the D1329S1 Pilot's Operating Handbook Supplement from the airplane. 30. Clean, electrically bond, and do a resistance check of the ice protection system. (Refer to the 208 Maintenance Manual, Chapter 20, Electrical Bonding - Maintenance Practices.) 31. Review and incorporate the Pilot's Operating Handbook Supplement S61, D1329-S61-02, or later revision. 32. Do the operational tests necessary to make sure that all of the systems that you changed or worked in while you installed this TKS system operate correctly. (Refer to the applicable chapters of the 208 Maintenance Manual.) Page 62

73 33. Make sure that the stall warning margin is set correctly and do an operational check of the lift transducer. (Refer to the 208 Maintenance Manual, Chapter 27, Stall Warning System - Maintenance Practices.) 34. Do a visual inspection for correct installation of the TKS system tubes and connections and the electrical connections. A. Look at the system nylon tubing in the fuselage (cabin and tailcone), engine compartment, wing, wing strut, horizontal stabilizer, and vertical stabilizer to make sure that there are no kinks or sharp bends. B. Make sure that the tubing connections are attached correctly in all areas. Make sure that you check the tubing connections in the engine compartment. C. Make sure that the electrical connections are attached correctly. 35. Do a test of the wiring for the circuit breaker panel as follows: A. Disengage one circuit breaker. B. Make sure that power is removed from the system the circuit breaker is a part of. C. Engage the circuit breaker. (1) Make sure that there is power to the system. (a) For systems that have switches and that are easily visible (cockpit lights or vent blowers for example), you can use visual or tactile information to make sure that the system operates correctly. (b) For systems that start automatically or when operation cannot be seen (stall heat or pitot heat for example), you can look at the instrument panel ammeter for changes in current draw to make sure that the system operates correctly D. Repeat Step 31A thru 31C(1)(b) for each circuit breaker, one circuit breaker at a time. 36. Do the leakage and functional tests. A. Do the preparation for the leakage and functional tests as follows: (1) Make sure that the airplane is level. (Refer to the Model 208 Maintenance Manual, Chapter 8, Leveling - Maintenance Practices.) NOTE: Make sure that the cargo pod doors are open before you do the jacking of the airplane. Access may be needed to the TKS tank while the airplane is on jacks. (2) Engage the applicable circuit breakers as shown in Table 2: TKS Circuit Breaker PRIMARY ANTI-ICE W/S ANTI-ICE BACKUP ANTI-ICE ANTI-ICE gage TABLE 2: TKS CIRCUIT BREAKERS Reference Designator (CB309) (CB409) (CB410) (CB310) (3) Set initial conditions in accordance with Table 3. TABLE 3 INITIAL CONDITIONS Name Ground Power Supply Position 28, +0.5 VDC or 0.5 VDC Page 63

74 TABLE 3 INITIAL CONDITIONS Name External Power Battery (DC Power) Switch Fluid Control - Primary Fluid Control - Max Flow Fluid Control - Backup TKS Fluid Tank Position OFF OFF OFF OFF OFF Empty (4) (Refer to Figure 2, View N-N and View P-P.) Disconnect the left and the right wing 0.50-inch fluid supply lines from the wing connection point on each proportioning unit. (5) Connect the test lines to the left and the right wing supply lines. NOTE: You can make test lines of unused TKS tubing. Shutoff valves or nylon balls and nuts as recorded in the Material Information Section of this Service Kit can be used to modulate flow through the test lines. It is necessary to install a psi fluid gauge in the empennage test line only. (6) Open the shutoff valves (or remove the nylon ball/nut caps if you used them) and put the ends of the test lines in five-gallon buckets. (7) (Refer to Figure 22, View A-A.) Find the windshield and propeller supply lines on the lower right side of the engine firewall. (8) Disconnect the propeller and the windshield fluid supply lines at the firewall and connect the windshield and propeller test lines to the bulkhead fittings. (9) Open the shutoff valve for the propeller test tube and put the ends of the two test lines in a five-gallon bucket. NOTE: You can keep the windshield test line shutoff valve closed, or put a cap on the end. No fluid should flow from this line during this initial test. (10) (Refer to Figure 4, View AH-AH and View AJ-AJ.) Disconnect the empennage 0.50-inch fluid supply line from the empennage connection point on the tailcone proportioning unit and connect the test line, with the union and the pressure gage, to the supply line. (11) Open the shutoff valve and put the other end of the test line in a five-gallon bucket. (12) Make sure that the EXTERNAL POWER switch on the pilot's switch panel is in the OFF position. (13) Make sure that the PRIMARY switch on the ANTI-ICE switch panel is in the OFF position. (14) Get access to the two low pressure switches in the tailcone. (15) Disconnect the connectors to the two low pressure switches. (16) Put a five-gallon bucket below the TKS fluid tank and equipment pack drain line (under the cargo pod on the left side of the airplane). B. Do the fluid indication systems check as follows: (1) Put the EXTERNAL POWER switch to the BUS position. (2) Push the system annunciator test button and make sure that the ANTI-ICE ON, CAUT, and WARN lights come on. (3) Make sure that the fluid quantity gage shows E. (4) Put the FLUID CONTROL PRIMARY switch to the NORM position. Page 64

75 (5) Make sure that the amber CAUT light comes on to show a low level of fluid. (6) Put the FLUID CONTROL PRIMARY switch to the OFF position. (7) Add gallons (41.63 liters) of TKS fluid to the tank and wait no less than one minute. (Refer to the 208 Maintenance Manual, Chapter 12, TKS Anti-Ice System - Servicing.) (8) With the minimum dispatch mark at eye level, make sure that the bottom of the float ball in the fluid sight glass is not above the top of the minimum dispatch mark. (9) Put the FLUID CONTROL PRIMARY switch to the NORM position. (10) Make sure that the white ANTI-ICE ON light comes on. (11) Put the FLUID CONTROL PRIMARY switch to the OFF position. (12) Fill the tank with fluid until the fluid level ball is just above the minimum dispatch quantity line. (13) Do a check for accuracy of the fluid quantity gage and make sure that the gage shows within 1.50 gallons of the 11.7 mark. The tip of the pointer must be within 1.50 gallons of 11.7 (the minimum limit is the 10-gallon mark and the maximum limit is the point that is halfway between the 11.7-gallon mark and the 15-gallon mark). (a) If the gage shows within 1.50 gallons of the 11.7 mark, go to Step 32C. (b) If the gage does not show within 1.50 gallons of the 11.7 mark, do the steps that follow to recalibrate the level sender: NOTE: The level sender is mounted on the top of the TKS fluid tank. The "FULL" adjustment screw is labeled on the level sender. 1 Disengage the ANTI-ICE GAGE circuit breaker (CB310). 2 Connect one lead of the voltmeter to the SEND post and the other lead of the voltmeter to the NEG post of the level sender. 3 Engage the ANTI-ICE GAGE circuit breaker (CB310). 4 Remove the protective coating from the FULL adjustment screw on the left side (left side of the airplane) of the level sender. 5 With a screwdriver, turn the FULL adjustment screw until 3.45 VDC, +0.1 or 0.1 VDC, shows on the voltmeter. 6 Disengage the ANTI-ICE GAGE circuit breaker (CB310). 7 Disconnect the leads of the voltmeter from the level sender. 8 Put torque putty on the adjustment screw. 9 Engage the ANTI-ICE GAGE circuit breaker (CB310). 10 Do a check for the accuracy of the fluid quantity gage to make sure that the gage shows within 1.50 gallons of the 11.7 mark. The tip of the pointer must be within 1.50 gallons of 11.7 (the minimum limit is the 10-gallon mark and the maximum limit is the point that is halfway between the 11.7-gallon mark and the 15-gallon mark). C. Do the pump operation systems check as follows: CAUTION: During this check, if you see leakage of fluid at one or more connections in the system, turn the anti-ice system off, repair connections, and remove all leakage. (1) Make sure that the shutoff valves are open and that the other ends of the two test lines are in five-gallon buckets. (2) Make sure that the EXTERNAL POWER switch is at the BUS position. Page 65

76 (3) Put the FLUID CONTROL PRIMARY switch to the HIGH position and let the metering pump #1 operate until fluid flows into each bucket. (a) If the pump does not fill, you must do as follows: 1 Put the FLUID CONTROL PRIMARY switch to the OFF position. 2 Remove the 0.50-inch diameter line that goes into the fuselage from the cargo pod and put it in a bucket. 3 Put the FLUID CONTROL PRIMARY switch to the HIGH position. 4 After the fluid begins to flow out, put the FLUID CONTROL PRIMARY switch to the OFF position. 5 Put the FLUID CONTROL BACKUP switch to the ON position. 6 After the fluid begins to flow out again, put the FLUID CONTROL BACKUP switch to the OFF position. 7 Connect the 0.50-inch diameter line. 8 Put the FLUID CONTROL PRIMARY switch to the HIGH position and let the metering pump #1 operate until fluid flows into each bucket. (b) If fluid does not flow from every test line, or if fluid flows only from the empennage test line do as follows: 1 With the FLUID CONTROL PRIMARY switch in the HIGH position, close the shutoff valve in the empennage test line to force fluid out of the other test lines. 2 Work from the rear to the front and close the shutoff valve in the left or the right wing test lines to force fluid out of the opposite line that has no flow of fluid. 3 After you have made sure that fluid has flowed from each test line, open all of the test line shutoff valves and continue with the functional test. (4) Collect fluid that comes out of the lines for one minute and make sure that the fluid you collected is 34 ounces, 3.38 ounces or ounces (1000 ml, 100 ml or +200 ml). NOTE: During this test, it is possible that fluid will not flow equally out of all of the test lines. (5) Make sure that the white ANTI-ICE ON light comes on. (6) Disengage the PRIMARY ANTI-ICE circuit breaker. (7) Make sure that the pump goes off. (8) Put the FLUID CONTROL PRIMARY switch to the OFF position. (9) Engage the PRIMARY ANTI-ICE circuit breaker. (10) Put the FLUID CONTROL BACKUP switch to the ON position and let the metering pump #2 operate until fluid flows into each bucket. (11) Collect the fluid that comes out of the lines for one minute and make sure that the fluid you collected is 34 ounces, 3.38 ounces or ounces (1000 ml, 100 ml or +200 ml). (12) Disengage the BACKUP ANTI-ICE circuit breaker and make sure that the pump shuts off. (13) Put the FLUID CONTROL BACKUP switch to the OFF position. (14) Engage the BACKUP ANTI-ICE circuit breaker. (15) Put the FLUID CONTROL PRIMARY switch to the NORMAL position and start the timer. (16) Make sure that the two metering pumps are on for 20 seconds +3 seconds or 3 seconds and then off for 100 seconds +10 seconds or 10 seconds. Page 66

77 (17) When the two pumps turn off, wait 30 seconds and then put the MAX FLOW switch to the AIRFRAME position and release the spring-loaded switch. (18) Make sure that the two pumps operate at the same time for 120 seconds +10 seconds or 10 seconds. (19) Put the FLUID CONTROL PRIMARY switch to the OFF position. (20) Put the MAX FLOW switch to the WINDSHIELD position and release the spring-loaded switch. (21) Make sure that the windshield pump makes the fluid flow while the switch is in the WINDSHIELD position and for 4 seconds +2 seconds or 2 seconds after you release the spring-loaded switch. (22) Disengage the W/S ANTI-ICE circuit breaker. (23) Put the MAX FLOW switch to the WINDSHIELD position and hold the switch. (24) Make sure that the windshield pump is off. (25) Release the MAX FLOW switch. (26) Engage the W/S ANTI-ICE circuit breaker. D. Do the test of the low pressure switch as follows: WARNING: During this test the TKS system operation pressure will go above 80 psig. (1) Put the EXTERNAL POWER switch to the BUS position. (2) Put the FLUID CONTROL PRIMARY switch to the HIGH position. (3) After the metering pump operates for no less than 15 seconds, connect the right side low pressure switch connector. (4) Make sure that the red WARN annunciator comes on. (5) Disconnect the right side low pressure switch connector. (6) Make sure that the red WARN annunciator goes off. (7) Connect the left side low pressure switch connector. (8) Make sure that the red WARN annunciator comes on. (9) Disconnect the left side low pressure switch connector. (10) Make sure that the red WARN annunciator goes off. (11) Put the FLUID CONTROL PRIMARY switch to the OFF position. (12) Put the FLUID CONTROL BACKUP switch to the ON position. (13) After the metering pump operates for no less than 15 seconds, connect the right side low pressure switch connector. (14) Make sure that the red WARN annunciator comes on. (15) Disconnect the right side low pressure switch connector. (16) Make sure that the red WARN annunciator goes off. (17) Connect the left side low pressure switch connector. (18) Make sure that the red WARN annunciator comes on. (19) Connect the left side low pressure switch connector. (20) Make sure that the red WARN annunciator goes off. (21) Put the FLUID CONTROL BACKUP switch to the OFF position. Page 67

78 (22) Connect the two low pressure switches in the tailcone. E. Do the leak test and high pressure switch test as follows: NOTE: If is possible that the red WARN annunciator will come on momentarily during this test. This is okay. (1) Close the shutoff valves in the wings and in the propeller test tube assemblies. (2) Make sure that the empennage test tube assembly is open. (3) Put the EXTERNAL POWER switch to the BUS position. (4) Put the FLUID CONTROL PRIMARY switch to the HIGH position. (5) Limit fluid flow through the empennage shutoff valve until the pressure gage shows 60 psi +15 psi or 15 psi. (6) Do an inspection for leaks of the pressurized fluid lines and connections in the airplane. (7) If there are leaks, you must put the FLUID CONTROL PRIMARY switch in the OFF position, release the pressure in the lines, and repair the leaks before you continue with this test. (8) Close the empennage shutoff valve. (9) When the pressure gage shows more than 150 psi, put the FLUID CONTROL PRIMARY switch to the OFF position. (10) Make sure that the amber CAUT comes on. (11) Once again, do an inspection for leaks of the pressurized fluid lines and connections in the airplane. If there are leaks, you must release the pressure in the lines and repair the leaks before you continue with this test. (12) Slowly open all of the test tube shutoff valves to release the fluid pressure. (13) Put the EXTERNAL POWER switch to the OFF position. (14) Disconnect all of the five test tube assemblies. (15) Install new sealing rings and seals (three Seals at the proportioning units, one S Sealing Ring at the propeller supply line, and one S Sealing Ring at the windshield supply line) and connect the five fluid supply lines to their correct connections on the proportioning units and engine firewall. CAUTION: Before you begin the panel purge, you must make sure that the fay seal cures for 72 hours and you must make sure that the fillet seal is no longer tacky. 37. Do the panel purge and complete system functional test as follows: A. Do the preparation for the panel purge and complete system functional test as follows: (1) Put a label on each wing tube assembly to make sure that you attach it to the correct related proportioning tube port after you complete the functional test. Refer to Table 4. TABLE 4: TKS PANEL / RELATED PROPORTIONING UNIT PORT TKS Panels Proportioning Unit Port Left Inboard Wing Panel 1, 5 Left Mid Wing Panel 2 Left Outboard Wing Panel 3, 4 Left Wing Strut Panel 6, 7 Right Inboard Wing Panel 1, 5 Page 68

79 TABLE 4: TKS PANEL / RELATED PROPORTIONING UNIT PORT TKS Panels Right Mid Wing Panel 2 Right Outboard Wing Panel 3, 4 Right Wing Strut Panel 6, 7 Proportioning Unit Port B. Purge the panels as follows: NOTE: It is not necessary to use electrical power for the purge of the panels. (1) Remove the P Protective Tape from the surface of the porous panels. (2) (Refer to Figure 35.) In Figure 35, look for examples of fluid flow through the porous panels that is sufficient and of fluid flow that is not sufficient. You must know how to tell if fluid flow through the porous panels is sufficient before you accomplish this panel purge operation. If you need help to know how to tell if a panel is purged correctly, contact Cessna Customer Service at WARNING: During this test the TKS system operation pressure will be as high as 75 psig. (3) Attach the fluid collector system (plastic guttering) below the area of the panels. (4) Fill the TKS system test cart reservoir with approximately 5.50 gallons (20.82 liters) of TKS fluid and attach the cart to an air source. Do not fill the reservoir until it is full. NOTE: You will fill the reservoir more than once as you do this procedure. (5) Follow the operation and safety instructions that are supplied with the test cart, found in the "Panels Installed on Aircraft TKS Panel Test section of the TKS Ice Protection Panel Flow Check Procedure Using TKS System Test Cart" publication. (6) Disconnect the two left inboard wing porous panel supply lines from ports 1 and 5 of the wing proportioning unit. NOTE: The inboard and outboard wing panels have two supply tubes. It is necessary to disconnect the second tube and put a cap or plug in the tube end to keep sufficient pressure in the panel. (7) Connect the test cart supply tube to the left inboard wing porous panel as near to the panel as you can. (8) Apply pressure of 10 psi, do a check for leaks in the line, and repair all leaks. (9) Apply pressure of 20 psi to slowly start the fluid flow through the panel. (10) Wait until the fluid starts to come out all the holes at the same rate along the full length of the panel and increase the pressure to 65 psi. (11) (Refer to Figure 35.) Continue the fluid purge until the panel is correctly purged in accordance with Figure 35. (12) Make sure that there is no leakage at the tube connections and around the perimeter of the panel. (13) Stop the fluid supply. (14) Wait until the fluid pressure is released. (15) Slowly disconnect the test cart fluid supply tube from the left inboard wing porous panel. (16) Install new sealing rings (two S Sealing Rings) and connect the two left inboard wing panel supply lines to ports 1 and 5 on the wing proportioning unit. Page 69

80 (17) Disconnect the center TKS panel supply line from port 2 on the wing proportioning unit. (18) Connect the purge tank line to the left mid wing TKS panel as near to the panel as you can. (19) Apply pressure of 10 psi, do a check for leaks in the line, and repair all leaks. (20) Apply pressure of 20 psi to slowly start the fluid flow through the left mid wing panel. (21) Wait until the fluid starts to come out all the holes at the same rate along the full length of the left mid wing panel and increase the pressure to 60 psi. (22) (Refer to Figure 35.) Continue the fluid purge until the panel is correctly purged in accordance with Figure 35. (23) Stop the fluid supply. (24) Wait until the fluid pressure is released. (25) Slowly disconnect the test cart fluid supply tube from the left mid wing panel. (26) Install a new S Sealing Ring and connect the left mid wing panel supply line to port 2 on the wing proportioning unit. (27) Disconnect the left outboard wing TKS panel supply lines from ports 3 and 4 on the wing proportioning unit. (28) Connect the purge tank line to the outboard wing TKS panel as near to the panel as you can. (29) Apply pressure of 10 psi, do a check for leaks in the line, and repair all leaks. (30) Apply pressure of 20 psi to slowly start the fluid flow through the panel. (31) Wait until the fluid starts to come out all the holes at the same rate along the full length of the panel and increase the pressure to 65 psi. (32) (Refer to Figure 35.) Continue the fluid purge until the panel is correctly purged in accordance with Figure 35. (33) Stop the fluid supply. (34) Wait until the fluid pressure is released. (35) Slowly disconnect the test cart fluid supply tube from the left outboard wing TKS panel. (36) Disconnect the two wing strut TKS panel supply lines from ports 6 and 7 on the wing proportioning unit. (37) Connect the purge tank line to the section of the wing strut TKS panel that supplies fluid by the line that was attached to port 6. NOTE: The strut panel has two membranes (upper and lower). Each membrane has a fluid supply tube. You can install a tee fitting and connect the test cart supply tube to each membrane. (38) Apply pressure of 10 psi, do a check for leaks in the line, and repair all leaks. (39) Apply pressure of 20 psi to slowly start the fluid flow through the panel. (40) Wait until the fluid starts to come out all the holes at the same rate along the full length of the panel and increase the pressure to 70 psi. (41) (Refer to Figure 35.) Continue the fluid purge until the panel is correctly purged in accordance with Figure 35. (42) Stop the fluid supply. (43) Wait until the fluid pressure is released. (44) Disconnect the purge tank lines. Page 70

81 (45) Connect the purge tank line to the section of the wing strut TKS panel that supplies fluid by the line that was attached to port 7. NOTE: The strut panel has two membranes (upper and lower). Each membrane has a fluid supply tube. You can install a tee fitting and connect the test cart supply tube to each membrane. (46) Apply pressure of 10 psi, do a check for leaks in the line, and repair all leaks. (47) Apply pressure of 20 psi to slowly start the fluid flow through the panel. (48) Wait until the fluid starts to come out all the holes at the same rate along the full length of the panel and increase the pressure to 75 psi. (49) (Refer to Figure 35.) Continue the fluid purge until the panel is correctly purged in accordance with Figure 35. (50) Stop the fluid supply. (51) Wait until the fluid pressure is released. (52) Disconnect the purge tank lines. (53) Install new sealing rings (one S Sealing Ring at port 6 and one S Sealing Ring at port 7) and connect the wing strut TKS supply lines to ports 6 and 7 on the wing proportioning unit. (54) Disconnect the two right inboard wing porous panel supply lines from ports 1 and 5 of the wing proportioning unit. NOTE: The inboard and outboard wing panels have two supply tubes. It is necessary to disconnect the second tube and put a cap or plug in the tube end to keep sufficient pressure in the panel. NOTE: If your airplane is equipped with the weather radar system, the airplane has only one access panel to get to the right wing proportioning unit. You can disconnect the panel feed lines at the body of the proportioning valve and then safety them with safety wire when you connect them again, or you can remove the radar to get access. (55) Connect the test cart supply tube to the inboard panel as near to the panel as you can. (56) Apply pressure of 10 psi, do a check for leaks in the line, and repair all leaks. (57) Apply pressure of 20 psi to slowly start the fluid flow through the panel. (58) Wait until the fluid starts to come out all the holes at the same rate along the full length of the panel and increase the pressure to 65 psi. (59) (Refer to Figure 35.) Continue the fluid purge until the panel is correctly purged in accordance with Figure 35. (60) Stop the fluid supply. (61) Wait until the fluid pressure is released. (62) Slowly disconnect the test cart fluid supply tube from the inboard panel. (63) Install new sealing rings (two S Sealing Rings) and connect the two right inboard wing panel supply lines to ports 1 and 5 on the wing proportioning unit. (64) Disconnect the center TKS panel supply line from port 2 on the wing proportioning unit. (65) Connect the purge tank line to the center TKS panel as near to the panel as you can. (66) Apply pressure of 10 psi, do a check for leaks in the line, and repair all leaks. (67) Apply pressure of 20 psi to slowly start the fluid flow through the panel. Page 71

82 (68) Wait until the fluid starts to come out all the holes at the same rate along the full length of the panel and increase the pressure to 60 psi. (69) (Refer to Figure 35.) Continue the fluid purge until the panel is correctly purged in accordance with Figure 35. (70) Stop the fluid supply. (71) Wait until the fluid pressure is released. (72) Slowly disconnect the test cart fluid supply tube from the inboard panel. (73) Install a new S Sealing Ring and connect the center TKS inboard wing panel supply line to port 2 on the wing proportioning unit. (74) Disconnect the right outboard wing TKS panel supply lines from ports 3 and 4 on the wing proportioning unit. (75) Connect the purge tank line to the outboard TKS panel as near to the panel as you can. (76) Apply pressure of 10 psi, do a check for leaks in the line, and repair all leaks. (77) Apply pressure of 20 psi to slowly start the fluid flow through the panel. (78) Wait until the fluid starts to come out all the holes at the same rate along the full length of the panel and increase the pressure to 65 psi. (79) (Refer to Figure 35.) Continue the fluid purge until the panel is correctly purged in accordance with Figure 35. (80) Stop the fluid supply. (81) Wait until the fluid pressure is released. (82) Slowly disconnect the test cart fluid supply tube from the left outboard wing TKS panel. (83) Disconnect the two wing strut TKS panel supply lines from ports 6 and 7 on the wing proportioning unit. (84) Connect the purge tank line to the section of the wing strut TKS panel that supplies fluid by the line that was attached to port 6. NOTE: The strut panel has two membranes (upper and lower). Each membrane has a fluid supply tube. You can install a tee fitting and connect the test cart supply tube to each membrane. (85) Apply pressure of 10 psi, do a check for leaks in the line, and repair all leaks. (86) Apply pressure of 20 psi to slowly start the fluid flow through the panel. (87) Wait until the fluid starts to come out all the holes at the same rate along the full length of the panel and increase the pressure to 70 psi. (88) (Refer to Figure 35.) Continue the fluid purge until the panel is correctly purged in accordance with Figure 35. (89) Stop the fluid supply. (90) Wait until the fluid pressure is released. (91) Disconnect the purge tank lines. (92) Connect the purge tank line to the section of the wing strut TKS panel that supplies fluid by the line that was attached to port 7. NOTE: The strut panel has two membranes (upper and lower). Each membrane has a fluid supply tube. You can install a tee fitting and connect the test cart supply tube to each membrane. (93) Apply pressure of 10 psi, do a check for leaks in the line, and repair all leaks. Page 72

83 (94) Apply pressure of 20 psi to slowly start the fluid flow through the panel. (95) Wait until the fluid starts to come out all the holes at the same rate along the full length of the panel and increase the pressure to 75 psi. (96) (Refer to Figure 35.) Continue the fluid purge until the panel is correctly purged in accordance with Figure 35. (97) Stop the fluid supply. (98) Wait until the fluid pressure is released. (99) Disconnect the purge tank lines. (100)Install new sealing rings (one S Sealing Ring at port 6 and one S Sealing Ring at port 7) and connect the wing strut TKS supply lines to ports 6 and 7 on the wing proportioning unit. (101)Disconnect the left horizontal stabilizer TKS panel supply line from the tailcone proportioning unit. NOTE: The empennage proportioning unit is part of the tail bracket assembly on the floor of the tailcone forward of the tailcone access panel. (102)Connect the purge tank lines to the left horizontal stabilizer TKS panel as near to the panel as you can. (103)Apply pressure of 10 psi, do a check for leaks in the line, and repair all leaks. (104)Apply pressure of 20 psi to slowly start the fluid flow through the panel. (105)Wait until the fluid starts to come out all the holes at the same rate along the full length of the panel and increase the pressure to 65 psi. (106)(Refer to Figure 35.) Continue the fluid purge until the panel is correctly purged in accordance with Figure 35. (107)Stop the fluid supply. (108)Wait until the fluid pressure is released. (109)Disconnect the purge tank lines. (110) Install a new S Sealing Ring and connect the left horizontal stabilizer TKS supply line to the tailcone proportioning unit. (111) Disconnect the right horizontal stabilizer TKS panel supply line from the tailcone proportioning unit. (112) Connect the purge tank lines to the right horizontal stabilizer TKS panel as near to the panel as you can. (113) Apply pressure of 10 psi, do a check for leaks in the line, and repair all leaks. (114) Apply pressure of 20 psi to slowly start the fluid flow through the panel. (115) Wait until the fluid starts to come out all the holes at the same rate along the full length of the panel and increase the pressure to 65 psi. (116) (Refer to Figure 35.) Continue the fluid purge until the panel is correctly purged in accordance with Figure 35. (117) Stop the fluid supply. (118) Wait until the fluid pressure is released. (119) Disconnect the purge tank lines. (120)Install a new S Sealing Ring and connect the right horizontal stabilizer TKS supply line to the tailcone proportioning unit. Page 73

84 (121)Disconnect the vertical stabilizer TKS panel supply line from the tailcone proportioning unit. (122)Connect the vertical stabilizer TKS panel supply line directly to the purge cart. (123)Apply pressure of 10 psi, do a check for leaks in the line, and repair all leaks. (124)Apply pressure of 20 psi to slowly start the fluid flow through the panel. (125)Wait until the fluid starts to come out all the holes at the same rate along the full length of the panel and increase the pressure to 75 psi. (126)(Refer to Figure 35.) Continue the fluid purge until the panel is correctly purged in accordance with Figure 35. (127)Stop the fluid supply. (128)Wait until the fluid pressure is released. (129)Disconnect the purge tank lines. (130)Install a new S Sealing Ring and connect the vertical stabilizer TKS supply line to the tailcone proportioning unit. C. Complete the system operational test as follows: (1) Make sure that the circuit breakers that follow in Table 5 are engaged. TABLE 5 TKS Circuit Breaker PRIMARY ANTI-ICE W/S ANTI-ICE BACKUP ANTI-ICE ANTI-ICE gage Reference Designator (CB309) (CB409) (CB410) (CB310) (2) Make sure that conditions are in accordance with Table 6. TABLE 6 INITIAL CONDITIONS Name Ground Power Supply External Power Battery (DC Power) Switch Fluid Control - Primary Fluid Control - Max Flow Fluid Control - Backup Position 28, +0.5 VDC or 0.5 VDC OFF OFF OFF OFF OFF (3) Put a five-gallon bucket below the prop slinger. Put one blade of the prop vertical and down and put the bucket under that blade. (4) Add TKS fluid to the tank as necessary until the indicator in the sight glass is above the minimum departure mark. (5) Put the EXTERNAL POWER switch to the BUS position. (6) Put the FLUID CONTROL PRIMARY switch to the HIGH position. (7) Wait until the fluid starts to come out all the holes along the full length of the panel. Page 74

85 (8) Make sure that the fluid comes out of all of the panels and the propeller slinger. NOTE: Actual fluid flow from the porous panels during this test will be different at different times as the ambient temperature changes. If there is no indication of fluid flow on one or more panels, that panel must be purged again. (9) Turn the propeller until each blade (one at a time) is vertical and down and make sure that fluid comes out of the feed tube at each blade. (10) Put the FLUID CONTROL PRIMARY switch to the OFF position. (11) Discard the TKS fluid from the buckets you collected it in during the fluid purge. (12) Put the FLUID CONTROL PRIMARY switch to the HIGH position. (13) Let the system operate for five minutes. (14) Put the FLUID CONTROL PRIMARY switch to the OFF position. (15) Measure the quantity of fluid that you collected from the left wing side of the airplane (left inboard wing panel, left mid wing panel, left outboard wing panel, and left wing strut panel). (16) Measure the quantity of fluid that you collected from the right wing side of the airplane (right inboard wing panel, right mid wing panel, right outboard wing panel, and right wing strut panel). (17) To make sure that there is the same flow from one wing to the other, make sure that you collected 52 ounces +20 or 10 ounces, (1550 ml +600 ml or 300 ml) from each wing. The quantity of fluid collected from one side of the airplane should be within 20 ounces (600 ml) of the quantity collected from the other side of the airplane. (18) Put the FLUID CONTROL PRIMARY switch to the OFF position. CAUTION: Do not operate the windshield pump for more than 10 seconds continuously and there must be no less than 10 seconds between pump operations. (19) Put the MAX FLOW switch to the WINDSHIELD position and release the spring-loaded switch. (20) Make sure that the fluid flows out of the windshield spray collection tube. NOTE: If the fluid does not flow out of the windshield spray collection tube, you can move the MAX FLOW switch to and from the WINDSHIELD position three or four times. (21) Put the EXTERNAL POWER switch to the OFF position. (22) Disconnect external power from the airplane. (23) Open the TKS fluid tank drain valve and let the tank drain completely. (24) Close the TKS fluid tank drain valve. (25) Clean TKS fluid and remove collection equipment from the airplane as necessary. (26) Remove the fluid collector system (plastic guttering) below the panels. (27) Install all access panels and equipment that you removed for access to do the tests. (Refer to the 208 Maintenance Manual.) 38. Install all of the equipment and upholstery that you removed for access. (Refer to applicable sections of the 208 Maintenance Manual.) A. Install the radar and the radome. (Refer to the 208 Maintenance Manual, Chapter 34, Garmin GWX-68 Weather Radar - Maintenance Practices.) B. Install all of the wing inspection panels and access plates that you removed from both wings. (Refer to the 208 Maintenance Manual, Chapter 6, Access Plates and Panels Identification - Description and Operation.) Page 75

86 C. Seal all of the access plates and panels on the bottoms of the wings with U544053S Sealant. (Refer to the 208 Maintenance Manual, Chapter 6, Access Plates and Panels Identification - Description and Operation, and Chapter 20, Fuel, Weather, and High-Temperature Sealing - Maintenance Practices.) 39. Install the left and right engine cowlings (Refer to the 208 Maintenance Manual, Chapter 71, Engine Cowling and Nose Cap - Maintenance Practices.) 40. Remove maintenance warning tags and connect the airplane battery. 41. Make sure that the airplane is level. (Refer to the Model 208 Maintenance Manual, Chapter 8, Leveling - Maintenance Practices.) 42. Weigh the airplane and calculate a final weight and balance. (Refer to the current applicable Pilots Operating Handbook and the Model 208 Maintenance Manual Chapter 8, Leveling and Weighing 43. Do the TKS anti-ice equipment preflight check that follows: A. To make sure of the condition and the security of all the components of the TKS system, do the PREFLIGHT INSPECTION checklist of the Known Icing Equipment Supplement. WARNING: Do not run the TKSiceprotectionsystemindry,coldair.Theiceprotectionfluid is designed to mix with water that impinges on the surface of the airplane during normal operation. If you run the system during dry, cold air conditions, the fluid becomes a gel that takes much time to clear, particularly from the windshield. B. With the airplane level and the TKS tank filled where the fluid level ball is just above the minimum dispatch quantity line, do a check for the accuracy of the fluid quantity gage. Make sure that the tip of the pointer is within 1.50 gallons of 11.7 (the minimum limit is the 10-gallon mark and the maximum limit is the point that is halfway between the 11.7-gallon mark and the 15-gallon mark). C. Remove the airplane from jacks. (Refer to the Model 208 Maintenance Manual, Chapter 8, Leveling - Maintenance Practices.) D. TurntheBACKUPswitchtoON. NOTE: During the initial operation of the TKS system, the low pressure WARN annunciator may initially come ON and then should go out as the system begins to flow and to build pressure. E. Walk around the airplane and make sure that there is a fluid flow to each porous panel that goes the full length of the panel. NOTE: At fluid temperatures that are above 59 F (15 C), fluid viscosity is such that the operating pressure may not cancel the low pressure WARN annunciator. At these fluid temperatures, you must make sure visually of the full-length fluid flow to each porous panel to make sure of correct operation of the system. After initial operation, the low pressure WARN annunciator should not come ON during in-flight system operation with the outside air temperature (OAT) below 46 F (8 C). 44. If not installed, install the propeller spinner. 45. Complete a dynamic balancing of the propeller. (Refer to the 208 Maintenance Manual, Chapter 61, Dynamic Balancing (McCauley) Adjustment/Test.) 46. Touch-up paint as necessary. (Refer to the Model 208 Maintenance Manual, Chapter 20, Exterior Finish - Cleaning/Painting.) 47. Make an entry in the airplane logbook stating this service kit has been installed. 48. After the accomplishment of this Service Kit you must perform Corrosion Prevention and Control Inspections based on the intervals specified for airplanes equipped with the TKS system. (Refer to the Model 208 Maintenance Manual, Chapter 5, Corrosion Prevention and Control Inspections (Airplanes with TKS Anti-Ice System.) Page 76

87 Figure 1. TKS Installation (Sheet 1) Page 77

88 Figure 1. TKS Installation (Sheet 2) Page 78

89 Figure 1. TKS Installation (Sheet 3) Page 79

90 Figure 2. Left Wing Tube Routing (All Airplanes), Right Wing Tube Routing (Airplanes without Bendix/King Weather Radar) (Sheet 1) Page 80

91 Figure 2. Left Wing Tube Routing (All Airplanes), Right Wing Tube Routing (Airplanes without Bendix/King Weather Radar) (Sheet 2) Page 81

92 Figure 2. Left Wing Tube Routing (All Airplanes), Right Wing Tube Routing (Airplanes without Bendix/King Weather Radar) (Sheet 3) Page 82

93 Figure 2. Left Wing Tube Routing (All Airplanes), Right Wing Tube Routing (Airplanes without Bendix/King Weather Radar) (Sheet 4) Page 83

94 Figure 2. Left Wing Tube Routing (All Airplanes), Right Wing Tube Routing (Airplanes without Bendix/King Weather Radar) (Sheet 5) Page 84

95 Figure 2. Left Wing Tube Routing (All Airplanes), Right Wing Tube Routing (Airplanes without Bendix/King Weather Radar) (Sheet 6) Page 85

96 Figure 2. Left Wing Tube Routing (All Airplanes), Right Wing Tube Routing (Airplanes without Bendix/King Weather Radar) (Sheet 7) Page 86

97 Figure 2. Left Wing Tube Routing (All Airplanes), Right Wing Tube Routing (Airplanes without Bendix/King Weather Radar) (Sheet 8) Page 87

98 Figure 2. Left Wing Tube Routing (All Airplanes), Right Wing Tube Routing (Airplanes without Bendix/King Weather Radar) (Sheet 9) Page 88

99 Figure 2. Left Wing Tube Routing (All Airplanes), Right Wing Tube Routing (Airplanes without Bendix/King Weather Radar) (Sheet 10) Page 89

100 Figure 2. Left Wing Tube Routing (All Airplanes), Right Wing Tube Routing (Airplanes without Bendix/King Weather Radar) (Sheet 11) Page 90

101 Figure 2. Left Wing Tube Routing (All Airplanes), Right Wing Tube Routing (Airplanes without Bendix/King Weather Radar) (Sheet 12) Page 91

102 Figure 2. Left Wing Tube Routing (All Airplanes), Right Wing Tube Routing (Airplanes without Bendix/King Weather Radar) (Sheet 13) Page 92

103 Figure 3. Right Wing Tube Routing (Airplanes with Bendix/King Weather Radar) (Sheet 1) Page 93

104 Figure 3. Right Wing Tube Routing (Airplanes with Bendix/King Weather Radar) (Sheet 2) Page 94

105 Figure 3. Right Wing Tube Routing (Airplanes with Bendix/King Weather Radar) (Sheet 3) Page 95

106 Figure 3. Right Wing Tube Routing (Airplanes with Bendix/King Weather Radar) (Sheet 4) Page 96

107 Figure 3. Right Wing Tube Routing (Airplanes with Bendix/King Weather Radar) (Sheet 5) Page 97

108 Figure 3. Right Wing Tube Routing (Airplanes with Bendix/King Weather Radar) (Sheet 6) Page 98

109 Figure 3. Right Wing Tube Routing (Airplanes with Bendix/King Weather Radar) (Sheet 7) Page 99

110 Figure 3. Right Wing Tube Routing (Airplanes with Bendix/King Weather Radar) (Sheet 8) Page 100

111 Figure 3. Right Wing Tube Routing (Airplanes with Bendix/King Weather Radar) (Sheet 9) Page 101

112 Figure 3. Right Wing Tube Routing (Airplanes with Bendix/King Weather Radar) (Sheet 10) Page 102

113 Figure 3. Right Wing Tube Routing (Airplanes with Bendix/King Weather Radar) (Sheet 11) Page 103

114 Figure 3. Right Wing Tube Routing (Airplanes with Bendix/King Weather Radar) (Sheet 12) Page 104

115 Figure 4. Fuselage Tube Routing (Sheet 1) Page 105

116 Figure 4. Fuselage Tube Routing (Sheet 2) Page 106

117 Figure 4. Fuselage Tube Routing (Sheet 3) Page 107

118 Figure 4. Fuselage Tube Routing (Sheet 4) Page 108

119 Figure 4. Fuselage Tube Routing (Sheet 5) Page 109

120 Figure 4. Fuselage Tube Routing (Sheet 6) Page 110

121 Figure 4. Fuselage Tube Routing (Sheet 7) Page 111

122 Figure 4. Fuselage Tube Routing (Sheet 8) Page 112

123 Figure 4. Fuselage Tube Routing (Sheet 9) Page 113

124 Figure 4. Fuselage Tube Routing (Sheet 10) Page 114

125 Figure 4. Fuselage Tube Routing (Sheet 11) Page 115

126 Figure 4. Fuselage Tube Routing (Sheet 12) Page 116

127 Figure 4. Fuselage Tube Routing (Sheet 13) Page 117

128 Figure 4. Fuselage Tube Routing (Sheet 14) Page 118

129 Figure 4. Fuselage Tube Routing (Sheet 15) Page 119

130 Figure 4. Fuselage Tube Routing (Sheet 16) Page 120

131 Figure 4. Fuselage Tube Routing (Sheet 17) Page 121

132 Figure 4. Fuselage Tube Routing (Sheet 18) Page 122

133 Figure 4. Fuselage Tube Routing (Sheet 19) Page 123

134 Figure 4. Fuselage Tube Routing (Sheet 20) Page 124

135 Figure 4. Fuselage Tube Routing (Sheet 21) Page 125

136 Figure 4. Fuselage Tube Routing (Sheet 22) Page 126

137 Figure 4. Fuselage Tube Routing (Sheet 23) Page 127

138 Figure 4. Fuselage Tube Routing (Sheet 24) Page 128

139 Figure 5. Center Fuselage Structure Modification (Sheet 1) Page 129

140 Figure 5. Center Fuselage Structure Modification (Sheet 2) Page 130

141 Figure 5. Center Fuselage Structure Modification (Sheet 3) Page 131

142 Figure 5. Center Fuselage Structure Modification (Sheet 4) Page 132

143 Figure 5. Center Fuselage Structure Modification (Sheet 5) Page 133

144 Figure 5. Center Fuselage Structure Modification (Sheet 6) Page 134

145 Figure 6. Tailcone and Tail Modification (Sheet 1) Page 135

146 Figure 6. Tailcone and Tail Modification (Sheet 2) Page 136

147 Figure 6. Tailcone and Tail Modification (Sheet 3) Page 137

148 Figure 6. Tailcone and Tail Modification (Sheet 4) Page 138

149 Figure 7. Vertical Stabilizer and Horizontal Stabilizer Porous Panel Installation (Sheet 1) Page 139

150 Figure 7. Vertical Stabilizer and Horizontal Stabilizer Porous Panel Installation (Sheet 2) Page 140

151 Figure 7. Vertical Stabilizer and Horizontal Stabilizer Porous Panel Installation (Sheet 3) Page 141

152 Figure 7. Vertical Stabilizer and Horizontal Stabilizer Porous Panel Installation (Sheet 4) Page 142

153 Figure 7. Vertical Stabilizer and Horizontal Stabilizer Porous Panel Installation (Sheet 5) Page 143

154 Figure 7. Vertical Stabilizer and Horizontal Stabilizer Porous Panel Installation (Sheet 6) Page 144

155 Figure 8. Spray Bar Installation (Sheet 1) Page 145

156 Figure 8. Spray Bar Installation (Sheet 2) Page 146

157 Figure 8. Spray Bar Installation (Sheet 3) Page 147

158 Figure 9. Cargo Pod Modification (Sheet 1) Page 148

159 Figure 9. Cargo Pod Modification (Sheet 2) Page 149

160 Figure 9. Cargo Pod Modification (Sheet 3) Page 150

161 Figure 9. Cargo Pod Modification (Sheet 4) Page 151

162 Figure 10. Anti-Ice Repair (Sheet 1) Page 152

163 Figure 10. Anti-Ice Repair (Sheet 2) Page 153

164 Figure 10. Anti-Ice Repair (Sheet 3) Page 154

165 Figure 10. Anti-Ice Repair (Sheet 4) Page 155

166 Figure 10. Anti-Ice Repair (Sheet 5) Page 156

167 Figure 11. Cargo Net Installation (Sheet 1) Page 157

168 Figure 11. Cargo Net Installation (Sheet 2) Page 158

169 Figure 11. Cargo Net Installation (Sheet 3) Page 159

170 Figure 12. Tank Installation (Sheet 1) Page 160

171 Figure 12. Tank Installation (Sheet 2) Page 161

172 Figure 12. Tank Installation (Sheet 3) Page 162

173 Figure 12. Tank Installation (Sheet 4) Page 163

174 Figure 12. Tank Installation (Sheet 5) Page 164

175 Figure 12. Tank Installation (Sheet 6) Page 165

176 Figure 12. Tank Installation (Sheet 7) Page 166

177 Figure 12. Tank Installation (Sheet 8) Page 167

178 Figure 12. Tank Installation (Sheet 9) Page 168

179 Figure 12. Tank Installation (Sheet 10) Page 169

180 Figure 12. Tank Installation (Sheet 11) Page 170

181 Figure 12. Tank Installation (Sheet 12) Page 171

182 Figure 13. IHAS Antenna Modification (Sheet 1) Page 172

183 Figure 13. IHAS Antenna Modification (Sheet 2) Page 173

184 Figure 13. IHAS Antenna Modification (Sheet 3) Page 174

185 Figure 14. Lift Transducer Modification (Sheet 1) Page 175

186 Figure 14. Lift Transducer Modification (Sheet 2) Page 176

187 Figure 15. Optional Anti-Ice System Removal (Sheet 1) Page 177

188 Figure 15. Optional Anti-Ice System Removal (Sheet 2) Page 178

189 Figure 15. Optional Anti-Ice System Removal (Sheet 3) Page 179

190 Figure 15. Optional Anti-Ice System Removal (Sheet 4) Page 180

191 Figure 15. Optional Anti-Ice System Removal (Sheet 5) Page 181

192 Figure 15. Optional Anti-Ice System Removal (Sheet 6) Page 182

193 Figure 15. Optional Anti-Ice System Removal (Sheet 7) Page 183

194 Figure 15. Optional Anti-Ice System Removal (Sheet 8) Page 184

195 Figure 15. Optional Anti-Ice System Removal (Sheet 9) Page 185

196 Figure 15. Optional Anti-Ice System Removal (Sheet 10) Page 186

197 Figure 15. Optional Anti-Ice System Removal (Sheet 11) Page 187

198 Figure 15. Optional Anti-Ice System Removal (Sheet 12) Page 188

199 Figure 15. Optional Anti-Ice System Removal (Sheet 13) Page 189

200 Figure 15. Optional Anti-Ice System Removal (Sheet 14) Page 190

201 Figure 16. Wiring Diagram (Sheet 1) Page 191

202 Figure 16. Wiring Diagram (Sheet 2) Page 192

203 Figure 16. Wiring Diagram (Sheet 3) Page 193

204 Figure 16. Wiring Diagram (Sheet 4) Page 194

205 Figure 16. Wiring Diagram (Sheet 5) Page 195

206 Figure 16. Wiring Diagram (Sheet 6) Page 196

207 Figure 16. Wiring Diagram (Sheet 7) Page 197

208 Figure 16. Wiring Diagram (Sheet 8) Page 198

209 Figure 16. Wiring Diagram (Sheet 9) Page 199

210 Figure 17. MLG Repair (Sheet 1) Page 200

211 Figure 18. Optional Double-Wide Anti-Ice Windshield Panel Removal (Sheet 1) Page 201

212 Figure 18. Optional Double-Wide Anti-Ice Windshield Panel Removal (Sheet 2) Page 202

213 Figure 18. Optional Double-Wide Anti-Ice Windshield Panel Removal (Sheet 3) Page 203

214 Figure 18. Optional Double-Wide Anti-Ice Windshield Panel Removal (Sheet 4) Page 204

215 Figure 18. Optional Double-Wide Anti-Ice Windshield Panel Removal (Sheet 5) Page 205

216 Figure 18. Optional Double-Wide Anti-Ice Windshield Panel Removal (Sheet 6) Page 206

217 Figure 19. Electrical Equipment Installation (Sheet 1) Page 207

218 Figure 19. Electrical Equipment Installation (Sheet 2) Page 208

219 Figure 19. Electrical Equipment Installation (Sheet 3) Page 209

220 Figure 19. Electrical Equipment Installation (Sheet 4) Page 210

221 Figure 19. Electrical Equipment Installation (Sheet 5) Page 211

222 Figure 19. Electrical Equipment Installation (Sheet 6) Page 212

223 Figure 19. Electrical Equipment Installation (Sheet 7) Page 213

224 Figure 20. Placard Installation (Sheet 1) Page 214

225 Figure 20. Placard Installation (Sheet 2) Page 215

226 Figure 20. Placard Installation (Sheet 3) Page 216

227 Figure 20. Placard Installation (Sheet 4) Page 217

228 Figure 20. Placard Installation (Sheet 5) Page 218

229 Figure 21. Vortex Generator Installation (Sheet 1) Page 219

230 Figure 21. Vortex Generator Installation (Sheet 2) Page 220

231 Figure 21. Vortex Generator Installation (Sheet 3) Page 221

232 Figure 22. Forward-of-Firewall Installation (Sheet 1) Page 222

233 Figure 22. Forward-of-Firewall Installation (Sheet 2) Page 223

234 Figure 22. Forward-of-Firewall Installation (Sheet 3) Page 224

235 Figure 22. Forward-of-Firewall Installation (Sheet 4) Page 225

236 Figure 22. Forward-of-Firewall Installation (Sheet 5) Page 226

237 Figure 22. Forward-of-Firewall Installation (Sheet 6) Page 227

238 Figure 22. Forward-of-Firewall Installation (Sheet 7) Page 228

239 Figure 22. Forward-of-Firewall Installation (Sheet 8) Page 229

240 Figure 23. Porous Panel Hole Location (Sheet 1) Page 230

241 Figure 24. Left Wing and Left/Right Wing Strut Porous Panel Installation (Sheet 1) Page 231

242 Figure 24. Left Wing and Left/Right Wing Strut Porous Panel Installation (Sheet 2) Page 232

243 Figure 24. Left Wing and Left/Right Wing Strut Porous Panel Installation (Sheet 3) Page 233

244 Figure 24. Left Wing and Left/Right Wing Strut Porous Panel Installation (Sheet 4) Page 234

245 Figure 24. Left Wing and Left/Right Wing Strut Porous Panel Installation (Sheet 5) Page 235

246 Figure 24. Left Wing and Left/Right Wing Strut Porous Panel Installation (Sheet 6) Page 236

247 Figure 24. Left Wing and Left/Right Wing Strut Porous Panel Installation (Sheet 7) Page 237

248 Figure 24. Left Wing and Left/Right Wing Strut Porous Panel Installation (Sheet 8) Page 238

249 Figure 24. Left Wing and Left/Right Wing Strut Porous Panel Installation (Sheet 9) Page 239

250 Figure 24. Left Wing and Left/Right Wing Strut Porous Panel Installation (Sheet 10) Page 240

251 Figure 24. Left Wing and Left/Right Wing Strut Porous Panel Installation (Sheet 11) Page 241

252 Figure 24. Left Wing and Left/Right Wing Strut Porous Panel Installation (Sheet 12) Page 242

253 Figure 25. Right Wing (Airplanes with Bendix/King Weather Radar) Porous Panel Installation (Sheet 1) Page 243

254 Figure 25. Right Wing (Airplanes with Bendix/King Weather Radar) Porous Panel Installation (Sheet 2) Page 244

255 Figure 25. Right Wing (Airplanes with Bendix/King Weather Radar) Porous Panel Installation (Sheet 3) Page 245

256 Figure 25. Right Wing (Airplanes with Bendix/King Weather Radar) Porous Panel Installation (Sheet 4) Page 246

257 Figure 25. Right Wing (Airplanes with Bendix/King Weather Radar) Porous Panel Installation (Sheet 5) Page 247

258 Figure 25. Right Wing (Airplanes with Bendix/King Weather Radar) Porous Panel Installation (Sheet 6) Page 248

259 Figure 25. Right Wing (Airplanes with Bendix/King Weather Radar) Porous Panel Installation (Sheet 7) Page 249

260 Figure 25. Right Wing (Airplanes with Bendix/King Weather Radar) Porous Panel Installation (Sheet 8) Page 250

261 Figure 26. Right Wing (Airplanes without Bendix/King Radar) Porous Panel Installation (Sheet 1) Page 251

262 Figure 26. Right Wing (Airplanes without Bendix/King Radar) Porous Panel Installation (Sheet 2) Page 252

263 Figure 26. Right Wing (Airplanes without Bendix/King Radar) Porous Panel Installation (Sheet 3) Page 253

264 Figure 26. Right Wing (Airplanes without Bendix/King Radar) Porous Panel Installation (Sheet 4) Page 254

265 Figure 26. Right Wing (Airplanes without Bendix/King Radar) Porous Panel Installation (Sheet 5) Page 255

266 Figure 26. Right Wing (Airplanes without Bendix/King Radar) Porous Panel Installation (Sheet 6) Page 256

267 Figure 26. Right Wing (Airplanes without Bendix/King Radar) Porous Panel Installation (Sheet 7) Page 257

268 Figure 26. Right Wing (Airplanes without Bendix/King Radar) Porous Panel Installation (Sheet 8) Page 258

269 Figure 26. Right Wing (Airplanes without Bendix/King Radar) Porous Panel Installation (Sheet 9) Page 259

270 Figure 26. Right Wing (Airplanes without Bendix/King Radar) Porous Panel Installation (Sheet 10) Page 260

271 Figure 27. Correct Tubing Coupling Procedures (Sheet 1) Page 261

272 Figure 27. Correct Tubing Coupling Procedures (Sheet 2) Page 262

273 Figure 27. Correct Tubing Coupling Procedures (Sheet 3) Page 263

274 Figure 28. Propeller Heat System Removal (Sheet 1) Page 264

275 Figure 28. Propeller Heat System Removal (Sheet 2) Page 265

276 Figure 28. Propeller Heat System Removal (Sheet 3) Page 266

277 Figure 28. Propeller Heat System Removal (Sheet 4) Page 267

278 Figure 29. Ice Detector Light Installation (Sheet 1) Page 268

279 Figure 29. Ice Detector Light Installation (Sheet 2) Page 269

280 Figure 29. Ice Detector Light Installation (Sheet 3) Page 270

281 Figure 30. Protective Tape Application (Sheet 1) Page 271

282 Figure 31. Single-Wide Windshield Anti-Ice Panel Removal (Sheet 1) Page 272

283 Figure 31. Single-Wide Windshield Anti-Ice Panel Removal (Sheet 2) Page 273

284 Figure 31. Single-Wide Windshield Anti-Ice Panel Removal (Sheet 3) Page 274

285 Figure 32. Cargo Pod Repair (Sheet 1) Page 275

286 Figure 32. Cargo Pod Repair (Sheet 2) Page 276

287 Figure 33. Porous Panels - Installation Location (Sheet 1) Page 277

288 Figure 34. Sealer Application (Sheet 1) Page 278

289 Figure 34. Sealer Application (Sheet 2) Page 279

290 Figure 35. Fluid Flow During Panel Purge (Sheet 1) Page 280

291 Figure 35. Fluid Flow During Panel Purge (Sheet 2) Page 281