Textron Cessna 208B User manual

Caravan SERVICE KIT
SK208-179B
TITLE
LOW-PROFILE TKS ICE PROTECTION SYSTEM INSTALLATION FOR MODEL 208B AIRPLANES WITH
PROVISIONS
EFFECTIVITY
Model Serial Numbers
208B 208B2014, 208B2016, 208B2032, 208B2056,
208B2105, 208B2115, 208B2120, 208B2133,
208B2168, 208B2171, 208B2182, 208B2202,
208B2208, 208B2211, 208B2250
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.
REFERENCE
SSP11-01R1
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 before and after this Service Kit has been accomplished.
MODEL ................. 208B
WEIGHT INCREASE ......... +76.69 pounds
ARM .................... +141.70 inches
RESULTANTMOMENT ....... +10866.97 inch-pounds
MOMENT/1000 ............ +10.87 inch-pounds
February 7, 2013
Original Issue: December 28, 2010 Page 1 of 119
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. [phone], Facsimile [phone]
COPYRIGHT © 2010

SERVICE KIT
SK208-179B
MATERIAL INFORMATION
The parts below cover installation for one airplane.
NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSI-
TION
SK208-179B 1Kit, consisting of the
following parts:
AN525-10R10 49 Screw None None
AN525-10R11 5Screw None None
AN525-10R12 4 Screw
AN525-10R7 57 Screw None None
AN525-10R8 36 Screw None None
AN525-832R7 16 Screw
AN737TW22 2 Clamp None None
C15Green 3Switch, Green Tip
CR3522-4-4 12 Rivet
H610026 8feet Tubing, Nylon None None
M39029/22-192 9 Contact
M39029/5-115 30 Contact Socket
M81824/1-1 1 Splice None None
M83248/1-021 1 O-ring None None
M85049/52-1-08N 1 Strain Relief
M85528/2-12-A 1 Mounting Flange
M85528/2-16-B 1 Mounting Flange
MN101-12 3 Sleeve None None
MN101-20 7 Sleeve None None
MN101-32 16 Sleeve None None
MN4855 7 Nut None None
MN4856 3 Nut None None
MN6079 1 Backnut 1/8 BSP None None
MN6201 16 Nut None None
MN6211 2 Backnut None None
MN6216 1 Tee, Bulkhead Unequal None None
MN6235 1 Bulkhead Short Connector Same Discard
MN6782 1 5/16 Blanking Cap
Assembly None None
MN6838 2 Elbow Assembly None None
MS20470A4-6N 22 Rivet None None
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SERVICE KIT
SK208-179B
MS20470A5-4A 2 Rivet None None
MS20426AD3-4A 34 Rivet None None
MS20470AD3-3A 126 Rivet None None
MS20470AD3-4A 32 Rivet None None
MS20470AD4-3A5 12 Rivet Various Discard
MS20470AD4-4A 290 Rivet None None
MS20470AD4-4A5 184 Rivet None None
MS20470AD4-6A 8 Rivet
MS20470AD5-8A 3 Rivet
MS20470AD5-9A 2 Rivet
MS21042-3 2 Nut None None
MS21044N3 15 Nut None None
MS21047L3 1 Nutplate
MS21047L08 14 Nutplate None None
MS21059L3 67 Nutplate None None
MS21073L3 1 Nutplate
MS21073L08 2 Nutplate None None
MS21075L3N 1 Nutplate
MS21083C3 8 Nut None None
MS21919WDG13 2 Clamp
MS21919WDG20 2 Clamp
MS21919WDG22 6 Clamp
MS21919WDG24 1Clamp
MS21919WDG26 2Clamp
MS21919WDG3 3Clamp None None
MS21919WDG4 3Clamp
MS24524-23 1Switch
MS24524-27 1 Switch
MS24694-C53 8 Screw None None
MS25036-102 14 Terminal
MS25083-2BB16 1 Bond Jumper
MS27039-1-07 2 Screw
MS27039-1-08 8 Screw
MS27407-1 1 Switch
MS35206-215 4 Screw
MS35206-228 4Screw
SK208-179B
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SERVICE KIT
SK208-179B
MS35206-229 4Screw
MS35207-258 12 Screw None None
MS35207-273 1Screw
MS35489-6 1 Grommet
NAS1033A3 4 Nutplate
NAS1149C0363R 8 Washer None None
NAS1149D1290K 1 Washer None None
NAS1149F0316P 26 Washer None None
NAS1149F0332P 31 Washer None None
NAS1149FN832P 16 Washer None None
NAS43DD3-109FC 1Spacer
NAS43DD3-18FC 1Spacer
NAS6203-4 14 Bolt None None
MS21071L3 1 Nutplate
P440032 9 square feet Damping Tape
S1495-6 (R221249) 12 feet Tubing
S1050-1 2 Grommet None None
S1050-1-1.40 1 Grommet
S1050-3-3.70 1 Grommet
S1050-1-4.50 1 Grommet
S1050-1-5.50 1 Grommet None None
S1053K10W 1 Duct None None
S1212-66 1Control
S1232-502 1Circuit Breaker
S1232-505 2Circuit Breaker
S1367-1-6 3 Terminal
S1741-1 2 Anchor
S1891-20S 2 Clamp None None
S1979-1 1 Knob Assembly
S2034-1 54 Mount None None
S2099-4 20 Contact
S2099-7 1 Contact
S2209-1 100 Tie None None
S2209-5 1 Tie
S2319-30 2 Receptacle
S2357-1 6Clamp None None
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SERVICE KIT
SK208-179B
S2357-2 2Clamp
S2456-4-2 50 Rivet
S2548-4-6.00 2 Hose None None
S2548-10 (R221240) 1 Tubing
S2562-3 (P610099) 1 Tubing
S2562-5 (P610022) 1 Tubing
S2800-942 18 Sealing Ring Same Discard
S2800-943 9 Sealing Ring Same Discard
S2906-4-2 14 Rivet None None
S2974-8 1 Solder Sleeve None None
S3001-13 2Bracket
S3017-6-6-6 1 Tee None None
ZCT-TS-080 1Tubing, Convoluted
ZN101-12 1 Olive for 3/16 Nylon
ZN101-20 1 Sleeve
ZN4855 1 Nut
ZN4856 1 Nut
ZN6079 1 Nut
ZN6261 1 Fitting
ZN6756 1 Backnut
ZN6829 1 Fitting
0823337-2 1 Grommet None None
100-013-8810 18 Sealing Ring Same Discard
13122-08 2 8-Bolt Gasket Filler None None
13122-09 1 Filler Cap Flange None None
13122-10 1 Filler Cap None None
13146-05 1 Wire Harness, LP Tank
13146-06 1 Wire harness, LP Pallet
180C4 1 Valve Assembly None None
2105015-7 1 Placard, Operational
Limitations None None
2601212-5 1 TKS Fairing Cover None None
2601548-1 1 Strap Assembly, Forward
Left None None
2601548-2 1 Strap Assembly, Forward
Right None None
2601548-3 1 Strap Assembly, Aft Left None None
2601548-4 1 Strap Assembly, Aft Right None None
SK208-179B
February 7, 2013 Page 5

SERVICE KIT
SK208-179B
2601552-1 1 TKS Tank Vent Weldment None None
2601552-7 1 Filler Port Weldment None None
2601552-10 1 Doubler, Filler Port, 208B None None
2601553-12 1 Aft Drain Tube Assembly None None
2601553-14 1 TKS Accessory Pallet None None
2601553-3 1 TKS Filler Pallet None None
2601554-1 1 Tank and Equipment
Assembly None None
2601558-1 1 Pump 1 Outlet Hose None None
2601558-2 1 Pump 2 Outlet Hose None None
2605070-10 1 Placard, Icing Conditions None None
2605076-14 1 Placard, TKS Filler Cap None None
2605076-4 1 Placard, Operational Limit None None
2605076-5 1 Placard, TKS Operational
Limit None None
2613466-200 2 Strip
2613466-7 1 Fairing Assembly None None
2613495-1 1 Doubler, TKS Left External None None
2613495-10 1 Doubler, TKS Connectors None None
2613495-11 1 Stiffener None None
2613495-2 1 Doubler, TKS Right
External None None
2613495-3 1 Doubler, TKS Left Forward None None
2613495-4 1 Doubler, TKS Right
Forward None None
2613495-5 1 Doubler, TKS Left Aft None None
2613495-6 1 Doubler, TKS Right Aft None None
2613495-7 2 Strap Angle, TKS Forward None None
2613495-8 2 Strap Angle, TKS Aft None None
2613495-9 1 Doubler, TKS Cutouts None None
2613498-1 1 Forward Fairing Assembly None None
2613498-2 1 Aft Fairing Assembly None None
2616033-3 1 Skin Panel, Removable None None
2616033-5 1 Drain Tube Assembly,
Welded
2616033-8 1 Tube Assy, Sump, 208B None None
2620028-1 1 BLE Lens Assembly, Left
2620028-2 1 BLE Lens Assembly, Right
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SK208-179B
2625027-1 2 Gurney Flap
2677123-3* 1 Wiring Assembly,
Windshield Ice
Detec-LSWPNL
2677124-1* 1 Wiring Assembly, TKS,
ELEFUS 2677122-1 Discard
2677124-2* 1 Wiring Assembly, TKS -
LSWPNL
2680003-3 1 TKS Fairing MTG, Left None None
2680003-4 1 TKS Fairing MTG, Right None None
3D5304 71 Vortex Generator
336-00021-00 1 Contact
7000-03 4 Placard, Solvent Caution
7000-26 1 Placard, Windshield
Anti-Ice None None
*These wire bundles are included in this kit as part of the wire bundle assembly.
The handbooks below will also be necessary:
NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION
208BPHBUS-S30-00 1TKS Pilot's Operating
Handbook Supplement None None
208BPHBUS-02 1Pilot's Operating Handbook
and FAA Approved Airplane
Flight Manual
The following material, or equivalent, is necessary.
NAME NUMBER MANUFACTURER USE
Tape P840154 Cessna Aircraft Company
Cessna Service Parts and
Programs
5800 East Pawnee
PO Box 1521
Wichita, KS 67218
To use in the installation of
the duct at the filler port.
Tape P840294 Cessna Aircraft Company
Cessna Service Parts and
Programs
5800 East Pawnee
PO Box 1521
Wichita, KS 67218
To hold porous panels tightly
to leading edge
SK208-179B
February 7, 2013 Page 7

SERVICE KIT
SK208-179B
NAME NUMBER MANUFACTURER USE
Epoxy Adhesive U000978S Cessna Aircraft Company
Cessna Service Parts and
Programs
5800 East Pawnee
PO Box 1521
Wichita, KS 67218
To install grommets and to
install vortex generators to
the wings.
Detergent, Mild Purchase Locally To clean wing panels
Alodine U074093 Cessna Aircraft Company
Cessna Service Parts and
Programs
5800 East Pawnee
PO Box 1521
Wichita, KS 67218
To apply to bare metal
Corrosion
Resistant Primer K000912 Cessna Aircraft Company Cessna Service Parts and
Programs
5800 East Pawnee
PO Box 1521
Wichita, KS 67218
For corrosion protection
Sealant Tape U554426 Cessna Aircraft Company
Cessna Service Parts and
Programs
5800 East Pawnee
PO Box 1521
Wichita, KS 67218
To adhere the TKS fairing to
the structure
Sealant U470642 Cessna Aircraft Company
Cessna Service Parts and
Programs
5800 East Pawnee
PO Box 1521
Wichita, KS 67218
To fay seal doublers
Sealant U470644 Cessna Aircraft Company
Cessna Service Parts and
Programs
5800 East Pawnee
PO Box 1521
Wichita, KS 67218
To shank seal rivets and fillet
seal around flange of fairing
and fillet seal tube to fairing
assembly
Sealant U544055S Cessna Aircraft Company
Cessna Service Parts and
Programs
5800 East Pawnee
PO Box 1521
Wichita, KS 67218
To do a fay surface seal
between grommets and
structure and to fay and fillet
seal between fairing cover
and structure
Sealant U470638 Cessna Aircraft Company
Cessna Service Parts and
Programs
5800 East Pawnee
PO Box 1521
Wichita, KS 67218
To brush coat rivets
Scotch Brite Pad Purchase locally To abrade the leading edges
SK208-179B
Page 8 February 7, 2013

SERVICE KIT
SK208-179B
NAME NUMBER MANUFACTURER USE
Sealant U470637 Cessna Aircraft Company
Cessna Service Parts and
Programs
5800 East Pawnee
PO Box 1521
Wichita, KS 67218
To use as a fillet seal from
pitot tube to lens retainer
Denatured
Alcohol Purchase locally To clean the leading edge
Sealant U000701S Cessna Aircraft Company
Cessna Service Parts and
Programs
5800 East Pawnee
PO Box 1521
Wichita, KS 67218
To attach gurney flaps to
wing flaps
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)
TKS Anti-ice Fluid
IF-406B-KF-
250M (250 gallon)
Cessna Aircraft Company
Cessna Service Parts and
Programs
5800 East Pawnee
PO Box 1521
Wichita, KS 67218
TKS Anti-ice fluid for TKS
system
The equipment below, or equivalent, will also be necessary:
Name Number Manufacturer Use
TKS System Test Cart 09301-01 CAV Aerospace, Inc.
2734 Arnold Court
Salina, KS 67401
Phone: [phone]
Fax: [phone]
To do the TKS porous
panel purge and test
procedures
Plastic Guttering Commercially Available To catch anti-ice fluid
from the TKS panel
purge procedure
Clenching Tool, with
Mandrel (3/16 Inch) T300-112A CAV Aerospace Inc. To fabricate TKS tubing
Clenching Tool Body
(3/16 Inch) T300-112-01 CAV Aerospace Inc. To fabricate TKS tubing
Clenching Tool Mandrel
(3/16 Inch) T300-112-02 CAV Aerospace Inc. To fabricate TKS tubing
Clenching Tool Body
(5/16 Inch) T300-120-01 CAV Aerospace Inc. To fabricate TKS tubing
SK208-179B
February 7, 2013 Page 9

SERVICE KIT
SK208-179B
Name Number Manufacturer Use
Clenching Tool Mandrel
(5/16 Inch) T300-120-02 CAV Aerospace Inc. To fabricate TKS tubing
Clenching Tool (5/16
Inch) T300-120A CAV Aerospace Inc. To fabricate TKS tubing
Clenching Tool (1/2 Inch) T300-144 CAV Aerospace Inc. To fabricate TKS tubing
Clenching Tool (3/8 Inch) T300-145 CAV Aerospace Inc. To fabricate TKS tubing
Blank Olive with MN4856
Nut (3/16- Inch Tube) P075 CAV Aerospace Inc. To cap the TKS tubing during tests
Nylon Ball with MN4855
Nut (5/16- Inch Tube) 03-151-07 CAV Aerospace Inc. To cap the TKS tubing
during tests
Nylon Ball with MN6201
Nut (1/2-Inch Tube) 03-151-10 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
0-200 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
ACCOMPLISHMENT INSTRUCTIONS
NOTE: Upon delivery to the customer after the installation of this Service Kit, the TKS system in the airplane
should contain only new and not refiltered TKS fluid.
NOTE: As applicable, you must accomplish Service Kit SK208-180, Low Airspeed Awareness System
Installation for Airplanes with TKS (or latest revision) or SK208-175B Low Airspeed Awareness System
Installation for Airplanes with TKS (or latest revision) in conjunction with this Service Kit.
1. Prepare the airplane for maintenance as follows:
A. Electrically ground the airplane.
B. Make sure that all switches are in the OFF/NORM position.
C. Disconnect electrical power from the airplane.
(1) Disconnect the airplane battery.
(2) Disconnect external electrical power.
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Page 10 February 7, 2013

SERVICE KIT
SK208-179B
D. Attach maintenance warning tags to the battery and external power receptacle that have "DO NOT
CONNECT ELECTRICAL POWER - MAINTENANCE IN PROGRESS" writtenonthem.
E. 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: For health 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.
WARNING: 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.
WARNING: 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.
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.
SK208-179B
February 7, 2013 Page 11

SERVICE KIT
SK208-179B
CAUTION: Do not do damage to the ice protection system with solvents or paints. 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 P840294 Tape or equivalent low-residue masking material to protect the porous
panels from unapproved materials.
(8) (Refer to Figure 7.) Use these instructions when you do the assembly and the installation of
the tubing and the lines:
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.
(a) Cut and install the nylon tubing in lengths that take into consideration the effects of
tension and strain.
(b) 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.
(c) Do not use components of dissimilar metals unless the instructions specify components
that have dissimilar metals.
(d) Use only the specified nylon tubing, coupling bodies, olives, rubber sealing rings, and
nuts in accordance with these instructions to make compression fitting connections.
(e) 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.
(f) Use only the specified clenching tools in accordance with these instructions to make
compression fitting connections.
(g) 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.)
(h) 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.)
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SERVICE KIT
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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.
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
clench and the sealing ring will be unserviceable.
(i) Put the end of the nylon tubing into the correctly-sized clenching tool as far as it will go.
(j) Make sure that the outer end of the olive is in the correct position in the bore of the nut.
(k) Turn the nut onto the clenching tool until it is finger tight plus 315° (five and one quarter
flats).
1Make sure that the nylon tubing stays bottomed out in the clenching tool until the
clenching operation is completed.
2Make 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.
3The tubing, olive, and mandrel can turn during the clenching operation, and that
is permitted.
(l) 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.
(m) 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.
(n) Put a sealing ring of the correct dimension over the end of the tubing.
(o) Put the tubing into the coupling body and move the sealing ring into the recess at the
end of the coupling body.
(p) Push the tubing toward the coupling body to make the olive hold the sealing ring in
position.
(q) Engage and finger tighten the nut.
(r) Tighten the nut until the torque starts to increase quickly (to approximately 180° from
finger tight).
(s) 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.
(9) (Refer to Figure 7.) 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 7.) Assemble the nylon tubing and the couplings in accordance with approved
maintenance practices.
SK208-179B
February 7, 2013 Page 13

SERVICE KIT
SK208-179B
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.
2. 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 SK208-180 or latest revision) or SK208-175B (or latest revision) as applicable
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 fuselage wing and wing strut fairings. (Refer to the 208 Maintenance Manual, Chapter
57 - Wings - Removal/Installation.)
C. Remove the pilot's and the copilot's seats. (Refer to the 208 Maintenance Manual, Chapter 25,
Flight Compartment - Maintenance Practices.)
D. 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.)
E. Remove the floor covers in the area between FS 118.00 and FS 214.00 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.)
F. Remove the aft cabin bulkhead cover.
G. Remove Panel 320A from the lower tailcone area. (Refer to the 208 Maintenance Manual, Chapter
6, Access Plates and Panels Identification - Description and Operation.)
H. Remove the access panel over the fuel reservoir tank.
I. Remove the 503HB, 503DB, 503BB, 503AB, and 501BB Access Plates from the left wing and
remove the 603HB, 603DB, 603BB, 603AB, and 601BB Access Plates from the right wing. (Refer
to the Model 208 Maintenance Manual, Chapter 6, Access Plates and Panels Identification -
Description and Operation.)
J. Remove the 373BL Access Plate form the left horizontal stabilizer and the 374BR Access Plate
from the right horizontal stabilizer. (Refer to the Model 208 Maintenance Manual, Chapter 6, Access
Plates and Panels Identification - Description and Operation.)
K. Remove the 341C and the 341B Access Plates and the 341A Access Plate (if installed) from the
vertical stabilizer. (Refer to the Model 208 Maintenance Manual, Chapter 6, Access Plates and
Panels Identification - Description and Operation.)
L. Remove and keep the radome, radar, and pod assembly. (Refer to the Model 208 Maintenance
Manual, Chapter 34, Garmin GWX-68 Weather Radar - Maintenance Practices.)
3. Make changes to the structure of the airplane for the ice protection system installation as follows:
A. (Refer to Figure 6, View A-A and View B-B.) If not installed already, drill three drain holes in the
tailcone at FS 284.00 and install six grommets as follows:
(1) Drill three 0.25-inch diameter holes through the airplane skin 2.40 inches aft of FS 284.00. Put
one hole at RBL 1.75, one hole at RBL 9.00 and one hole at LBL 9.00.
(2) Deburr and apply Alodine and epoxy primer to bare metal.
(3) Install 0823337-2 Grommets in the six holes as follows:
(a) Make marks at the 12 positions on the tailcone where you will install the rivets that attach
the 0823337-2 Grommets.
(b) Match drill 12 Number 40 (0.098-inch diameter) holes in the tailcone.
(c) Deburr and apply Alodine to bare metal.
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(d) With U544055S Sealant, do a fay surface seal between the 0823337-2 Grommets and
the structure. (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather, and
High-Temperature Sealing - Maintenance Practices.)
(e) With 12 MS20470AD3-3A Rivets, attach the six 0823337-2 Grommets to the structure.
B. (Refer to Figure 5, View A-A.) On the bottom of the airplane, install doublers for the support of the
TKS tank as follows:
(1) From the right side of the airplane, remove the XPDR1 transponder antenna. (Refer to the
Model 208 Maintenance Manual, Chapter 34.)
(2) (For airplanes with a XPDR2 transponder antenna) Remove the XPDR2 transponder antenna
from the left side of the airplane. (Refer to the Model 208 Maintenance Manual, Chapter 34.)
(3) Remove and keep the doubler for the XPDR1 antenna and the doubler for the XPDR2 antenna
(if installed).
(4) (Refer to Figure 5, View A-A.) Use six MS20470AD4-3A5 Rivets as plugs and install them in
the holes (through the skin only) that you made when you removed the rivets that attached the
doubler for the XPDR1 transponder antenna.
(5) Use six MS20470AD4-3A5 Rivets as plugs and install them (through the skin only) in the
holes that you made when you removed the rivets that attached the doubler for the XPDR2
transponder antenna (if installed).
(6) Install the 2613495-1 TKS Left External Doubler and the 2613495-2 TKS Right External
Doubler on the bottom of the airplane as follows:
(a) Carefully remove the two 3.00-inch orange ducts below the floorboards that connect to
the heater control valve wye and the left and right side forward plenums. (Refer to the
Model 208 Maintenance Manual, Chapter 21, Heating and Defrosting Air Distribution -
Maintenance Practices.)
(b) Remove the power converter assembly under the copilot's seat floorboard. Remove
mounting brackets as necessary. (Refer to the Model 208 Maintenance Manual, Chapter
24, 12-Volt Direct Current Power Outlet System - Maintenance Practices.)
(c) Remove the sound dampening material between FS 128.00 and FS158.00 and between
RBL8.00 and RBL19.00. (Refer to the Model 208 Maintenance Manual, Chapter 25,
Soundproofing - Maintenance Practices.)
(d) (Refer to Figure 5, View A-A, Detail B, and Detail G.) From the structure, remove the 89
rivets shown on the right side and the 93 rivets shown on the left side.
(e) Put the 2613495-1 TKS Left External Doubler and the 2613495-2 TKS Right External
Doubler in position on the structure.
(f) Between FS128.00 and FS143.00, make marks to show the outline of the doublers to the
skin and remove the five existing nutplates on the left that are under the doubler and the
five existing nutplates on the right that are under the doubler.
(g) Match drill one 0.81-inch diameter hole in the skin to the 2613495-2 TKS Right External
Doubler for the XPDR1 transponder antenna.
(h) Match drill one 0.81-inch diameter hole in the skin to the 2613495-1 TKS Left External
Doubler for the XPDR2 transponder antenna, if installed.
(i) Match drill two 0.812-inch diameter holes in the 2613495-1 TKS Left External Doubler.
(j) Match drill 89 Number 30 (0.128-inch diameter) holes in the 2613495-2 TKS Right
External Doubler.
(k) Match drill 93 Number 30 (0.128-inch diameter) holes in the 2613495-1 TKS Left External
Doubler.
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(l) Match drill the five nutplate holes and the 10 Number 40 (0.098-inch diameter) holes in
the 2613495-1 TKS Left External Doubler.
(m) Match drill the five nutplate holes and the 10 Number 40 (0.098-inch diameter) holes in
the 2613495-2 TKS Right External Doubler.
(n) Match drill one 0.75-inch diameter hole in the 2613495-1 TKS Left External Doubler and
airplane skin and one 0.75-inch diameter hole in the 2613495-2 TKS Right External
Doubler and airplane skin for drain holes
(o) Make marks for and drill 54 Number 30 (0.128-inch diameter) holes in the 2613495-2
TKS Right External Doubler.
(p) Make marks for and drill 51 Number 30 (0.128-inch diameter) holes in the 2613495-1
TKS Left External Doubler.
(q) Deburr and apply Alodine to bare metal.
(r) Fay seal the 2613495-1 TKS Left External Doubler and the 2613495-2 TKS Right
External Doubler with U470642 Sealant.
(s) Put the 2613495-1 TKS Left External Doubler and the 2613495-2 TKS Right External
Doubler in position on the structure.
(t) Attach the 2613495-1 TKS Left External Doubler and the 2613495-2 TKS Right External
Doubler to the structure with the 182 MS20470AD4-4A5 Rivets.
(u) Attach the 2613495-1 TKS Left External Doubler and the 2613495-2 TKS Right External
Doubler to the structure with the 97 MS20470AD4-4A Rivets.
(v) Install the eight S2906-4-2 Rivets (heads on the near side) that attach the 2613495-2
TKS Right External Doubler to the structure.
(w) With the 20 MS20470AD3-4A5 Rivets, install the five MS21059L3 Nutplates in the drilled
holes in the 2613495-1 TKS Left External Doubler and the five MS21059L3 Nutplates in
the drilled holes in the 2613495-2 TKS Right External Doubler.
(7) (Refer to Figure 5.) Install the 2613495-11 Stiffener, 2613495-10 TKS Connectors Doubler,
and 2613495-9 TKS Cutouts Doubler on the bottom of the airplane as follows:
(a) (Refer to Figure 5, View A-A and Detail E.) Put the 2613495-11 Stiffener in position on the
structure and make marks for and then match drill 13 Number 30 (0.128-inch diameter)
holes in the 2613495-11 Stiffener and the structure.
(b) Deburr and apply Alodine to bare metal.
(c) With two MS20470AD4-4A5 Rivets and 11 MS20470AD4-4A Rivets, install the
2613495-11 Stiffener to the structure.
(d) (Refer to Figure 5, View A-A and Detail F.) Put the 2613495-10 TKS Connectors Doubler
in position inside the airplane on the lower skin between the pilot's and the copilot's seats.
(e) Make marks on the 2613495-10 TKS Connectors Doubler for the 35 rivet holes to attach
the 2613495-10 TKS Connectors Doubler to the structure.
(f) Make marks on the 2613495-10 TKS Connectors Doubler for the 0.87-inch diameter hole,
0.44-inch diameter hole, 0.69-inch diameter hole, and 1.00-inch diameter hole.
(g) Use the MS3472L10-6S Connector and the MS3472L16-26S Connector to drill in the
2613495-10 TKS Connectors Doubler for the eight 0.15-inch diameter holes.
(h) Match drill the 35 Number 30 (0.128-inch diameter) rivet holes, 0.87-inch diameter hole,
0.44-inch diameter hole, 0.68-inch diameter hole, 1.00-inch diameter hole, and eight
0.15-inch diameter holes in the structure and in the 2613495-10 TKS Connectors Doubler.
(i) Deburr and apply Alodine to bare metal.
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(j) (Refer to Figure 5, View A-A and Detail A.) Put the 2613495-9 TKS Cutouts Doubler in
position on the structure and make marks on the 2613495-9 TKS Cutouts Doubler for
the 3.34-inch diameter hole, 1.75-inch diameter hole, and 52 rivet holes to attach the
2613495-9 TKS Cutouts Doubler to the structure.
(k) Match drill the 3.34-inch diameter hole and the 1.75-inch diameter hole in the 2613495-9
TKS Cutouts Doubler and the structure.
(l) Match drill the 52 Number 30 (0.128-inch diameter) holes in the 2613495-9 TKS Cutouts
Doubler and the structure.
(m) Deburr and apply Alodine to bare metal.
(n) Fay seal the 2613495-9 TKS Cutouts Doubler and the 2613495-10 TKS Connectors
Doubler with U470642 Sealant.
(o) With the 52 MS20470AD4-4A Rivets, attach the 2613495-9 TKS Cutouts Doubler to
the structure.
(p) With 35 MS20470AD4-4A Rivets, attach the 2613495-10 TKS Connectors Doubler to
the structure.
(q) With U000978S Adhesive, install an S1050-1-5.50 Grommet in the rear half only of the
3.34-inch diameter hole.
(8) (Refer to Figure 5, View A-A, Detail C, and Detail D.) Make a 6.23-inch slot and a 4.07-inch slot
at the four positions shown.
(9) Deburr and apply Alodine to bare metal.
C. (Refer to Figure 5, View A-A and View B-B.) Install doublers on the longeron for the tank straps
as follows:
(1) Install the 2613495-3 TKS Left Forward Doubler and the 2613495-5 TKS Left Aft Doubler:
(a) Remove the two rivets that you will replace to install the 2613495-3 TKS Left Forward
Doubler.
(b) Put the 2613495-3 TKS Left Forward Doubler in position and match drill 19 Number 30
(0.128-inch diameter) holes in the 2613495-3 TKS Left Forward Doubler and 17 Number
30 (0.128-inch diameter) holes in the structure.
(c) Put the 2613495-5 TKS Left Aft Doubler in position and match drill 17 Number 30
(0.128-inch diameter) holes in the 2613495-5 TKS Left Aft Doubler and the structure.
(d) Deburr and apply Alodine to bare metal.
(e) With the 19 MS20470AD4-4A Rivets, install the 2613495-3 TKS Left Forward Doubler to
the structure.
(f) With the 17 MS20470AD4-4A Rivets, install the 2613495-5 TKS Left Aft Doubler to
the structure.
(2) (Refer to Figure 5, View A-A and View C-C.) Install the 2613495-6 TKS Right Aft Doubler and
the 2613495-4 TKS Right Forward Doubler.
(a) Remove the four rivets that you will replace to install the 2613495-6 TKS Right Aft Doubler.
(b) Put the 2613495-6 TKS Right Aft Doubler in position and match drill four Number 30
(0.128-inch diameter) holes in the 2613495-6 TKS Right Aft Doubler and four Number 30
(0.128-inch diameter) holes in the structure.
(c) Put the 2613495-4 TKS Right Forward Doubler in position and match drill 19 Number
30 (0.128-inch diameter) holes in the 2613495-4 TKS Right Forward Doubler and the
structure.
(d) Deburr and apply Alodine to bare metal.
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(e) With the two S2906-4-2 Rivets, five MS20470AD4-4A Rivets, and one CM3827AD4-4A
Rivet, install the 2613495-6 TKS Right Aft Doubler to the structure.
(f) With the 19 MS20470AD4-4A Rivets, install the 2613495-4 TKS Right Forward Doubler
to the structure.
D. (Refer to Figure 5, View D-D, Detail H, and Detail J.) Do the modification of the 2611127-22
Floorboard Assembly as follows:
(1) Remove the 2611058-22 Access Cover from the 2611127-22 Floorboard Assembly. Keep
the attachment hardware.
(2) Make marks for the hole that you will make in the 2611058-22 Access Cover.
(3) With a permanent marker, draw a line through the 2611058-22 part number on the 2611058-22
Access Cover.
(4) With the permanent marker, write the new part number of 2611058-26 on the access cover.
(5) Install the 2611058-26 Access Cover with the kept attachment hardware.
(6) Deburr and apply Alodine to bare metal.
(7) With U000978S Adhesive, install the S1050-3-3.70 Grommet and the S1050-1-1.40 Grommet
in the new hole.
E. (Refer to Figure 8, View J-J.) With U000978S Adhesive, install one S1050-1 Grommet of the correct
length on the flanges of the tank.
F. (Refer to Figure 8.) Install the nutplates for the tank as follows:
(1) Put the tank in position on the belly of the airplane.
(2) (Refer to Figure 8, View C-C, View D-D, and View E-E.) In the airplane belly, match drill 16
holes that are from 0.167-inch to 0.171-inch in diameter.
(3) (Refer to Figure 8, Detail C.) On the left and the right side of the belly at the locations shown
near FS 128.00 and LBL 8.00 and RBL 8.00, drill one 0.25-inch diameter hole in each of the
two tank forward brackets for clearance of the rivet heads at this location.
(4) (Refer to Figure 8, View F-F and View G-G.) Drill 24 Number 40 (0.098-inch diameter) holes
through the doubler and the skin only for the rivet holes to attach the nutplates.
(5) (Refer to Figure 8, View H-H.) Drill eight Number 40 (0.098-inch diameter) holes through the
doubler, skin, and bulkhead segment for the rivet holes to attach the nutplates.
(6) Countersink the 32 rivet holes and apply Alodine to bare metal.
(7) With the 32 MS20426AD3-4A Rivets, install the 14 MS21047L08 Nutplates and the two
MS21073L08 Nutplates to the structure.
G. (Refer to Figure 11.) Install the tank straps as follows:
(1) Use the tank to help find the correct installation position for the tank straps.
(2) (Refer to Figure 11, View A-A and View B-B.) Make marks for and match drill four Number
30 (0.128-inch diameter) holes in each of the two 2613495-7 TKS Forward Strap Angles
and the structure.
(3) Make marks for and match drill five Number 30 (0.128-inch diameter) holes in each of the two
2613495-8 TKS Aft Strap Angles and the structure.
(4) (Refer to Figure 11, Detail A.) On the right side, remove the rivet in the 2613499 Longeron
Assembly at RBL 19.00.
(5) (Refer to Figure 11, View C-C and View E-E.) Align the 2601548-1 Forward Left Strap
Assembly and the 2601548-2 Forward Right Strap Assembly with the 2613495-7 TKS Forward
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Strap Angles and the structure and match drill to enlarge the three holes through each of the
two 2613495-7 TKS Forward Strap Angles to 0.193-inch in diameter.
(6) (Refer to Figure 11, View D-D and View F-F.) Align the 2601548-3 Aft Left Strap Assembly and
the 2601548-4 Aft Right Strap Assembly with the 2613495-8 TKS Aft Strap Angles and the
structure and match drill to enlarge the four holes through each of the two 2613495-8 TKS
Forward Strap Angles to 0.193-inch in diameter.
(7) Apply Alodine to bare metal.
(8) (Refer to Figure 11, View B-B.) Put the two 2613495-7 TKS Forward Strap Angles in position
and install them to the structure with the eight MS20470AD4-4A Rivets.
(9) Put the two 2613497-8 TKS Aft Strap Angles in position and install them to the structure with
the ten MS20470AD4-4A Rivets.
(10) (Refer to Figure 11, View E-E.) Put the 2601548-1 Forward Left Strap Assembly and the
2601548-2 Forward Right Strap Assembly in position and attach them to the structure
and to the strap angles with the six MS21044N3 Nuts and NAS6203-4 Bolts and the 12
NAS1149F0332P Washers. Do not tighten the nuts at this time.
(11) (Refer to Figure 11, View F-F.) Put the 2601548-3 Aft Left Strap Assembly and the 2601548-4
Aft Right Strap Assembly in position and attach them to the structure and to the strap angles
with the eight MS21044N3 Nuts and NAS6203-4 Bolts and the 16 NAS1149F0332P Washers.
Do not tighten the nuts at this time.
H. Install the structure for the filler port and the tank vent outlet as follows:
(1) Install the 2601552-10 Filler Port Doubler and the cutout for the filler port on the left side
of the airplane:
(a) (Refer to Figure 20, View F-F.) Remove the sound dampening and clean the area.
(b) Put the 2601552-10 Filler Port Doubler in position on the left side of the airplane and
make a mark for one 0.193-inch diameter hole to match the one in the 2611000 Skin.
(c) Remove the 22 rivets in the 2611000 Skin.
(d) Drill one 0.193-inch diameter hole and two Number 40 (0.098-inch diameter) holes in the
2601552-10 Filler Port Doubler for the MS21071L3 Nutplate.
(e) Drill one 3.25-inch diameter hole in the 2611000 Skin to match the one in the 2601552-10
Filler Port Doubler.
(f) (Refer to Figure 20, View G-G) Drill one 0.25-inch diameter hole in the 2611000 Skin to
align with the one in the 2601552-10 Filler Port Doubler.
(g) Apply Alodine to bare metal.
(h) Fay seal the doubler to the skin with U470642 Sealant (semkit 6 oz).
(i) Attach the 2601552-10 Filler Port Doubler to the structure with the three MS20470AD5-8A
Rivets, two MS20470AD5-9A Rivets, and 17 MS20470AD4-4A Rivets.
(j) Install one MS21071L3 Nutplate at the 0.193-inch diameter hole with two
MS20470AD3-4A Rivets.
(2) (Refer to Figure 19, View K-K and Figure 20, View F-F.) Install the tank vent outlet and the
0823337-2 Grommet to the 2601552-10 TKS Filler Port Doubler:
(a) Drill four Number 40 (0.098-inch diameter) holes in the 2601552-10 Filler Port Doubler to
install the tank vent outlet.
(b) Match drill two Number 40 (0.098-inch diameter) holes in the 0823337-2 Grommet to
the 2601552-1 TKS Tank Vent Weldment.
(c) Apply Alodine to bare metal.
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(d) With U470642 Sealant , fay seal the 2601552-1 TKS Tank Vent Weldment to the inside
of the airplane and fay seal the 0823337-2 Grommet to the outside of the 2601552-10
Filler Port Doubler.
(e) With four MS20470AD3-4A Rivets, install the 2601552-1 TKS Tank Vent Weldment to
the inside of the airplane and the 0823337-2 Grommet to the outside of the 2601552-10
Filler Port Doubler.
(3) Install the mounts for the filler tube installation and for the vent tube installation as follows:
(a) (Refer to Figure 20, View D-D, View G-G, and View H-H.) Make four Number 30
(0.128-inch diameter) holes in the structure for the rivets that attach the mounts for the
filler tube.
(b) (Refer to Figure 20, View B-B, View C-C, View D-D, and View E-E.) Make eight Number
40 (0.098-inch diameter holes in the structure for the rivets that attach the nutplates for
the filler tube.
(c) (Refer to Figure 19, View A-A, View B-B, View C-C, View D-D, View E-E, View F-F, View
G-G, View H-H, and View J-J.) Make nine Number 30 (0.128-inch diameter) holes in the
structure for the rivets that attach the mounts for the vent tube.
(d) Apply Alodine to bare metal.
(e) (Refer to Figure 20, View D-D, View G-G, and View H-H.) With four MS20470A4-6N
Rivets, install four S2034-1 Mounts on the structure for supports for the routing of the
filler tube.
(f) (Refer to Figure 19, View A-A, View B-B, View C-C, View D-D, View E-E, View F-F, View
G-G, View H-H, and View J-J.) With nine MS20470A4-6N Rivets, install nine S2034-1
Mounts on the structure for supports for the routing of the vent tube.
(g) (Refer to Figure 20, View B-B, View C-C, View D-D, and View E-E.) With eight
CM3827AD3-3A Rivets, attach four NAS1033A3 Nutplates to the structure for supports
for the routing of the filler tube.
(h) With four MS27039-1-08 Screws, attach the filler tube to the structure with the three
MS21919WDG22 Clamps and one MS21919WDG26 Clamp.
(4) Install the filler port as follows:
(a) (Refer to Figure 20, View F-F.) Match drill eight 0.307-inch diameter holes in the 2611000
Skin to match the 2601552-10 Filler Port Doubler.
(b) Apply Alodine to bare metal.
(c) Put the two 13122-08 8-Bolt Gasket Fillers, one 13122-09 Filler Cap Flange, 13122-10
Filler Cap, and 2601552-7 Filler Port Weldment in position and install them with the eight
MS24694-C53 Screws, NAS1149C0363R Washers, and MS21083C3 Nuts.
I. (Refer to Figure 16.) Install the nutplates that will attach the TKS fairing to the structure as follows:
(1) Attach the 2680003-3 and the 2680003-4 TKS Fairing MTG Templates to the outside of the
airplane on the belly.
(2) From outside the airplane, drill 57 Number 40 (0.098-inch diameter) holes in the airplane belly.
(3) Remove and discard the 2680003-3 and the 2680003-4 TKS Fairing MTG Templates.
(4) From outside the airplane open the holes to 0.219-inch diameter in the belly and in the fairing.
(5) From the inside of the airplane, drill 114 Number 40 (0.098-inch diameter) holes in the airplane
belly.
(6) Apply Alodine to bare metal.
(7) Attach 57 MS21059L3 Nutplates to the airplane belly with 114 MS20470AD3-3A Rivets.
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