Model 550 Maintenance Manual (Rev 34)

56-00-00 (Rev 28)

WINDOWS - GENERAL
1. Scope
A. This chapter gives a general description of the fuselage and crew compartment windows. This includes the windshield,
cabin windows, and door windows.
2. Definition
A. Damage areas are shown below:
(1) Delamination - Separation of the acrylic sheet from the vinyl layer. Bubbles are a type of delamination and all bubbles
are thought to be delamination. These small bubbles will not significantly cause an effect on the structural integrity of
the windows.
(2) Pits, chips, gouges, and scratches – Removal of material from a window.
(3) Cracks – A small separation of material.
(4) Crazing - A group of fine cracks on or under the surface of a material. Crazing is caused by cleaning material, paint
stripper, solvents, heat, ultraviolet rays and other materials that are not approved for use, which cause surface stress
in the acrylic.
(5) Distortion - Distortion of objects when seen through the window.
(6) Banding - An area of distortion that extends across the window.
(7) Wedge - A difference in the thickness that results in a difference of how light absorbs from one side to the another.
Wedging will cause multiple images or distorted images.
3. Tools and Equipment
NOTE: Equivalent substitutes may be used for the following items except for the CJMD156-101 calibration
standard:
NAME NUMBER MANUFACTURER USE
Aliphatic Naphtha, Type To clean windows and
TT-N-95 Commercially Available
II windshield.
Buffing Compound 765 or 881 Lea Manufacturing Company To buff out abrasive paper
(Learock) 237 E. Aurora St. marks.
Waterbury, CT 06720
Buffing Wheel Unstitched cotton Commercially available To buff out abrasive paper
flannel, 6-inch marks.
diameter × 20 ply
Calibration Standard CJMD156-101 Cessna Aircraft Company Calibrate ultrasonic thickness
Citation Marketing Division gage.
Department 579
P.O. Box 7706
Wichita, KS 67277
Cement PS30 Caseway Industrial Products To repair chips around spacer
1050 Green Pine Circle hole.
Orange Park, FL 32065
Cleaning Solvent (Refer
Aliphatic Naphtha To clean windows.
to NOTE 1)
Contact Adhesive,
National Sealants and Lubricants, Inc.
Class VA Adhesive, and
AS-157 33210 Old Hempstead Rd. To bond window seal.
Solvent Bonding (Refer
Magnolia, TX 77355
to NOTE 1)
Cork Wheel, 0.50 Inch To remove sealant from
Commercially Available
Stock Cork windows and metal surfaces.

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 Model 550 Maintenance Manual (Rev 34)
56-00-00 (Rev 28)

Couplant Chogel-20 Echo Labratories Couple transducer to window.

R.D. #1
Box 297
Titusville, PA 16354
Die (0.250 Inch
ZT2963-1/4-28 Commercially Available
Diameter Hole)
Hand Tool Kit (Refer to SB550-56-01-1 or Cessna Aircraft Co. Removal/Installation of
Note 2) SB500-56-06-1 Citation Marketing Div. windshield.
Hot dimple rivet and screw
Hot Dimple Equipment 41-CP450EA-36
holes.
VWR Scientific, Inc.
Immersion Oil, Couplant between prism and
JTE395-7 P.O. Box 13320
Cedarwood Oil window.
St. Louis, MO 63157
Aircraft Window Repairs Company
2207 Border Ave. To do optical inspection of
Inspection Prism Kit AWR P-17
Torrance, CA 90501-3612 windows. (NOTE 3)
Web: www.aircraftwindowrepairs.com
Isopropyl Alcohol/Water 50/50 mixture Commercially Available To clean windows and
windshield.
Ivory Liquid Soap Commercially Available To clean windows.
Loctite Corp. Applied to threads of latch
Loctite 222
Newington, CT 06111 screw.
Methyl N-Propyl Ketone
Clean metal prior to installing
(cleaning Solvents, CAS 107-87-9 Commercially available
seal.
Refer to NOTE 1)
Mirror Bright Polish Co. Reduce static electricity buildup
Mirror Glaze MGH-10
Pasadena, CA 91107 with a conductive coating.
Mirror Glaze MGH-17 Mirror Bright Polish Co. Polish windshield
Optical Depth Model 966 (100 DFW Aerospace Measure damage depth.
Micrometer Power) 5100 Airport Fwy
West Irving, TX 75602
Petrolatum Parting
Agents (Refer to NOTE VV-P-236 Commercially available. Check fit of upper hinge half.
1)
Cessna Aircraft Co. To do optical inspection of
Optical Prism 6580000-1
Citation Marketing Division windows.
Portable Control Panel ZT2409E
Del Amo Chemical Co
535 W 152 St Couplant between prism and
Propylene Glycol PR130USP
Gardena, CA 90248 window.
Phone: 310 532 9214
Scotch Brand No-
Protective Coating To protect window panes.
mar Protective Tape
Protect the window during
Protective Coating Masking Tape Commercially available.
removal/installation.
Protective Coating Spraylat A To protect window panes.

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 Model 550 Maintenance Manual (Rev 34)
56-00-00 (Rev 28)

Spraylat (Black) SC-

Protective Coating To protect window panes.
1072
Spraylat (White) SC-
Protective Coating To protect window panes.
1058
Punch (0.250 Inch
ZT1865-1/4-28 Commercially Available
Diameter Hole)
International Paper Company
Veratec Division To clean window and metal
Rymplecloth
100 Elm Street surfaces.
Walpole, MA 02081
Kendall Co.
Rymplecloth Number 301 One Federal Street Clean windows and metal parts.
Boston, MA 02110
Sandpaper or Sandcloth 400A/600A grit (wet Commercially available Initial scratch removal.
or dry)
3M Company
Scotch Brand No-Mar
3M Center To protect window panes.
Protective Tape
St. Paul, MN 55144
ScotchBrite General 61-8614-5506-3 3M Co. To remove sealant from window
Purpose Wheel and metal surfaces.
Scratch Removal Kit AC74 Micro-Surface Finishing Products To remove scratches, gouges
P.O. Box 456 and nicks from acrylic windows.
Wilton, IA 52778
PRC-DeSoto International
Sealant, Type 1, Class 5454 San Fernando Rd. Dip fastener in prior to
Pro-Seal 890
A P.O. Box 1800 installation.
Glendale, CA 91203
Sealant, Type I, Class B- Seal between window, frame
PR1440 PRC-DeSoto International
2 and retainer.
Type I, Class B-2
Applied to threads of lock
Sealant (Weather, and High PRC-DeSoto International
mounting screw.
Temperature)
Fill gap between windshield and
Sealant Type I, Class B-1/2 Refer to Chapter 20 retainers for static discharge
tape.
Seal between window and
Sealant Type I, Class B-4 Refer to Chapter 20
retainers.
Sonotech Inc.
774 Marine Drive
Couplant between prism and
Sonotech UltraGel II Bellingham, WA 98225
window.
Phone: 800 458 4254
Web: www.sonotech-inc.com
Spraylat Corporation
Spraylat (Black) SC-1072 730 S. Columbus Ave. To protect window panes.
Mount Vernon, NY 10550
Spraylat A (White) SC-1058 Spraylat Corporation To protect window panes.
Hot dimple rivet and screw
Squeeze and Heater ZT2012DH
holes.

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 Model 550 Maintenance Manual (Rev 34)
56-00-00 (Rev 28)

Stoddard Super Solvent Anderson Prichard Oil Co. To clean windows and
Oklahoma City, OK windshield.
Toluene, Technical A-A-59107 Commercially available To clean metal areas at
windows.
Transfer Tape Y9473 Clear; 3M Company To bond spacer to foul weather
Double-Backed; window and frost pane.
0.01 x 1.00 inch;
Purchased in 60
yard roll.
Trichloroethane 1-1-1
Clean retainers and window
Technical Inhibited O-T-361 Commercially Available
frame.
(Methyl Chloroform)
Ultrasonic Thickness Model 5222 Panametrics Measure window thickness.
Gage 221 Crescent St.
Waltham, MA 02254
White Light Source
Commercially Available To illuminate inspection area.
(Flashlight or Penlight)
NOTE 1:
Refer to Chapter 20, Adhesive and Solvent Bonding - Maintenance Practices.
NOTE 2:
SB550-56-01-1 or SB500-56-06-1 Hand Tool Kit, both consist of the following part numbers:
NOTE 3:
You can use this prism to inspect the windshield without removal of the shroud.
NOTE 4:
Equivalent couplants may be used. However, the operator/inspector will make sure that the material will not be
invasive or damaging to the window surface, painted surfaces, or airplane structure.
PART NUMBER QTY. NOMENCLATURE
170-10 2 Torque Set - Apex Bit
5591043-9 10 Alignment Guide Tool
5591043-8 50 Temporary Hold-Down Screws
MS20002L6 50 Washers
5591043-5 1 Slip Removable Drill Guide
0.257 OD x 0.156 ID x 1.00 inch
1 Slip Removable Drill Bushing
long

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 Model 550 Maintenance Manual (Rev 34)
56-10-00 (Rev 30)

WINDSHIELDS/WINDOWS - DESCRIPTION AND OPERATION

1. General
A. This section gives a general description of the windows.
B. The windows include the windshield, pilot's and copilot's side windows, foul weather window and cabin windows (refer to
Figure 1).
2. Description
A. Windshield.
(1) The windshield is laminated with an outer pane of stretched acrylic 0.414 inch (10.52 mm) thick, a vinyl layer of 0.050
inch (1.27 mm) thick and an inner pane of stretched acrylic 0.414 inch (10.52 mm) thick.
B. Windows.
(1) The pilot's side windows are found aft of the windshield on each side of the fuselage. The windows are not laminated
and the panes are separated by airspaces. Each window has a 0.460-inch (11.68 mm) thick stretched acrylic outer
pane, an airspace, and a 0.250-inch (6.35 mm)-thick stretched acrylic inner pane, and airspace, and a 0.060 inch
(1.52 mm) thick acrylic frost pane.
(2) The foul weather window is found on the left side between the windshield and the pilot's side window. The window is a
laminated construction with an outer panel of stretched acrylic 0.276 inch (7.01 mm) thick, a vinyl layer 0.050 inch
(1.27 mm) thick, and an inner pane of stretched acrylic 0.092 inch (2.34 mm) thick. A 0.060-inch (1.52 mm)-thick
acrylic frost pane has a separation from the window laminate by airspace. The window has a hinge at the bottom with
the latch assembly at the top.
(a) The latch assembly has a ball detent locking mechanism to prevent accidental opening of the window. To
operate the latch, push the spring-loaded button on the latch to release the lock and turn the handle from the
hook.
(b) The hook is attached on the structure adjacent to the window and gives the mating surface of the window. A seal
is bonded to the perimeter of the window and gives an airtight installation when the foul weather window is
closed and latched.
(3) The cabin windows, which include the cabin door and the emergency exit door, are typical in construction. These are
plug-type windows, with no fastener holes through the transparent part of the window.
(a) The window is a laminated construction with an outer panel of stretched acrylic 0.250 inch (6.35 mm) thick, a
vinyl layer 0.050 inch (1.27 mm) thick, and an inner pane of stretched acrylic 0.094 inch (2.39 mm) thick. A
0.060-inch (1.52 mm)-thick acrylic frost pane has a separation from the laminate by an airspace.

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 Model 550 Maintenance Manual (Rev 34)
56-10-00 (Rev 30)

Figure 1 : Sheet 1 : Windows

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 Model 550 Maintenance Manual (Rev 34)
56-10-00 (Rev 30)

WINDSHIELDS/WINDOWS - ADJUSTMENT/TEST
1. Description
A. This optical inspection procedure will help find voids and cracks in the area of the fastener holes on acrylic windows
without the removal of the edge retainers or their associated fasteners.
B. Look for cracks that start at the fastener hole(s) and extend to adjacent fastener holes, into the viewable area, or to the
edge of the window.
NOTE: The optical prism is purchased or locally fabricated. Refer to Figure 501 for information on how to
make the optical prism.
2. Tools and Equipment
A. For information on tools and equipment, refer to Windows - General.
3. Preparation
A. Remove the windshield deicing ducts.
NOTE: If the AWR P-17 prism is used, the windshield deicing ducts do not need to be removed.
CAUTION: Do not use cleaning materials that are not approved. Crazing of the acrylic windows will occur if an
incorrect cleaner is used.
B. Use aliphatic naphtha followed by a solution of liquid soap and water to thoroughly clean dust and material from the
window, 6 to 8 inches (150 to 200 mm) from the fastener holes that are to be inspected.
4. Inspection
A. Use the 70-degree Prism to complete an inspection of the window. Refer to Figure 502.
(1) Apply couplant to the 70-degree face of the prism and area of the window to be inspected.
NOTE: Inspections are done from the outside surface of the windows. The pilot and copilot side
windows are constructed with an inner and an outer window ply separated by an air gap. It is
only necessary to do an inspection of the outer window ply.
(2) Put the prism on the window as shown in Figure 502.
(3) Use the light source at an angle of 30 to 60 degrees from the vertical of the prism to examine the fastener holes.
NOTE: To see the top and bottom of the fastener hole clearly, it can be necessary to move the prism
toward and away from the fastener that is to be viewed.
(a) An undamaged hole will look like a frosty cylinder.
(b) A fastener hole that has a crack that extends from one surface of the material under inspection into the hole will
look like a frosty or reflective ear or projection that extends from the fastener hole as shown in View A-A of
Figure 502.
(c) A crack that extends from one fastener hole to another will look like a frosty irregular surface as shown in View
B-B of Figure 502.
B. Use the 6580000-1 or AWR P-17 Prism to complete an inspection of the window. Refer to Figure 503.
(1) Apply couplant to the face of the prism and area of the window to be inspected as shown in Figure 503.
NOTE: Inspections are done from the outside surface of the windows.
(2) Put the prism on the window as shown in Figure 503.
C. When the inspection is completed, use aliphatic naphtha followed by a solution of soap and water to remove the couplant
from the window.

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 Model 550 Maintenance Manual (Rev 34)
56-10-00 (Rev 30)

Figure 501 : Sheet 1 : Optical Prism Fabrication

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 Model 550 Maintenance Manual (Rev 34)
56-10-00 (Rev 30)

Figure 502 : Sheet 1 : Optical Inspection Using A 70-Degree Prism

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 Model 550 Maintenance Manual (Rev 34)
56-10-00 (Rev 30)

Figure 502 : Sheet 2 : Optical Inspection Using A 70-Degree Prism

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 Model 550 Maintenance Manual (Rev 34)
56-10-00 (Rev 30)

Figure 503 : Sheet 1 : Optical Inspection Using A 6580000-1 or APR P-17 Prism

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 Model 550 Maintenance Manual (Rev 34)
56-10-00 (Rev 30)

Figure 503 : Sheet 2 : Optical Inspection Using A 6580000-1 or APR P-17 Prism

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 Model 550 Maintenance Manual (Rev 34)
56-10-00 (Rev 30)

WINDSHIELDS/WINDOWS - INSPECTION/CHECK
1. General
A. This section gives the procedures to complete the inspections and checks on the airplane windows and windshields.
TASK 56-10-00-210
2. Airplane Windows Inspection
NOTE: If problems are found while you do the inspections, refer to Chapter 56, Windshields/Windows -
Approved Repairs for the specified criteria that give the types of damage and approved repair practices.
A. Do a windshield, cockpit side window, and cabin window inspection (refer to Figure 601).
(1) Visually examine the windows for cracks, scratches, discoloration, crazing, or other damage.
(2) Use the optical prism method to examine any cockpit window that has contained cracks or other defects in the past.
(Refer to Windshields/Windows - Adjustment/Test).
B. Do a Foul Weather Window Inspection (refer to Figure 601).
(1) Visually examine the window for cracks, scratches, discoloration, crazing, or other damage.
(2) Operate the window to the closed and open position and examine the seal mating surface and latch operation.
(3) Examine the seal for rips, tears or other indication of damage.
END OF TASK
TASK 56-10-00-280
3. Windshield and Flight Compartment Side Windows Prism Inspection
NOTE: If problems are found while you do the inspections, refer to Windshields/Windows - Approved Repairs
for the specified criteria that give the types of damage and approved repair practices.
A. Do a windshield and flight compartment side windows inspection and prism test (refer to Figure 601).
(1) Use the optical prism method to examine the windshields and flight compartment side windows for cracks. (Refer to
Windshield/Windows - Adjustment/Test).
END OF TASK
TASK 56-10-00-281
4. Copilot's Side Window Inspection
A. Use the Optical Prism Method to Inspect the Copilot's Side Window (refer to Figure 602).
(1) Visually inspect the copilot's (right) side window at attachment holes number 3 through 8 (at the forward retainer) for
cracks and other anomalies using the optical prism method. Use the applicable test procedure shown in
Windshields/Windows - Adjustment/Test and in the inspection criteria listed below.
(2) If a crack or any other anomaly is found, determine its orientation relative to quadrant information found on Figure
602, Sheet 2.
(a) If the anomaly is in either attachment hole number 5 or 6, contact Cessna Customer Service for disposition.
(b) If the anomaly is in hole number 3, 4, 7 or 8 and is in the Northwest quadrant, but can be verified to extend into
the adjacent fastener hole, the acceptance criteria is as specified in Task 56-10-00-280.
(c) If the anomaly is found in any other quadrant (than Northwest) of holes number 3, 4, 7 or 8, the acceptance
criteria is as specified in Task 56-10-00-280.
(d) If the anomaly appears to be in the Northwest quadrant of attachment hole number 3, 4, 7 or 8 and does not
extend to the adjacent hole, contact Cessna Customer Service for disposition.
(e) Report all anomalies from the inspected holes to Cessna Customer Service for record.
END OF TASK

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 Model 550 Maintenance Manual (Rev 34)
56-10-00 (Rev 30)

Figure 601 : Sheet 1 : Airplane Windows Inspection

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 Model 550 Maintenance Manual (Rev 34)
56-10-00 (Rev 30)

Figure 602 : Sheet 1 : Copilot's Side Window Inspection

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 Model 550 Maintenance Manual (Rev 34)
56-10-00 (Rev 30)

Figure 602 : Sheet 2 : Copilot's Side Window Inspection

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 Model 550 Maintenance Manual (Rev 34)
56-10-00 (Rev 30)

WINDSHIELDS/WINDOWS - APPROVED REPAIRS

1. General
A. This section gives the information to examine and repair window damage.
2. Tools and Equipment
A. For a list of required tools and equipment, refer to Windows - General.
3. Damage Evaluation and Rework Criteria
A. Damage Analysis
(1) Measure the window ply(s) thicknesses in at least three areas within 0.5 inch (12.70 mm) of the damage with
ultrasonic test equipment.
(2) Find the maximum depth of the damage with an optical depth micrometer.
(3) Subtract the measured depth of the damage from the measured ply(s) thickness to find the remaining window ply(s)
thickness. If the values are less than the minimum window thickness as shown in Table 801, replace the window.
(4) You must do the "key" inspection points that follow to make sure the inspection agrees from one thickness
measurement to another or if there is a change in test equipment or test equipment operator.
(a) Calibrate the test equipment on material with the same sound velocity as that of the material in the windshields
to be examined.
NOTE: The CJMD156-101 calibration standard is made from the same type of acrylic as the
Cessna Citation airplane acrylic windshield and cabin windows.
(b) The CJMD156-101 calibration standard is to be put on or adjacent to the windshield or windows to be inspected
for 30 minutes prior to calibration of the thickness gage. This will let the reference standard and airplane
windshield or window temperature be the same.
(c) The thinnest point of the inner ply will usually not be at the same location or area as the thinnest point of the outer
ply.
Total Thickness
Type Nominal Thickness Minimum Thickness
Required
Windshield
0.414 inch (10.52 mm) 0.3726 inch (9.46 mm)
Outer Ply
0.050 inch (1.27 mm) 0.050 inch (1.27 mm) 0.813 inch (20.65 mm)
PVB Layer
0.414 inch (10.52 mm) 0.3726 inch (9.46 mm)
Inner Ply
Pilot/Copilot Window
0.460 inch (11.68 mm) 0.410 inch (10.41 mm)
Outer Pane
0.250 inch (6.35 mm) 0.225 inch (5.72 mm)
Inner Pane
Foul Weather Window
0.276 inch (7.01 mm) 0.249 inch (6.32 mm)
Outer Ply
0.050 inch (1.27 mm) 0.050 inch (1.27 mm) 0.382 inch (9.70 mm)
PVB Layer
0.092 inch (2.34 mm) 0.083 inch (2.11 mm)
Inner Ply
Cabin Window
0.250 inch (6.35 mm) 0.200 inch (5.08 mm)
Outer Ply
0.050 inch (1.27 mm) 0.050 inch (1.27 mm) 0.324 inch (8.23 mm)
PVB Layer
0.094 inch (2.39 mm) 0.074 inch (1.88 mm)
Inner Ply
Cabin Window
Outer Ply
PVB Layer 0.187 inch (4.75 mm) 0.150 inch (3.81 mm)
Inner Ply 0.050 inch (1.27 mm) 0.050 inch (1.27 mm) 0.274 inch (6.96 mm)
Airplanes -0001 thru -0213 0.094 inch (2.39 mm) 0.074 inch (1.88 mm)
with SB56-5 or SB21-9
completed.
B. Windshield Rework Standard

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 Model 550 Maintenance Manual (Rev 34)
56-10-00 (Rev 30)

Problem Repair or Replacement Disposition

Replace windshield(s) if:
1. Cracks extend beyond the retainer into vision area.
2. Cracks in three or more adjacent attachment holes.
Crack NOTE:
If windshield replacement is not required, but lesser cracks are in the windshield,
the windshield inspection intervals must be changed to every 300 hours or 24
months, whichever occurs first.
Cracks cannot be repaired.
Replace windshield(s) if:
1. Pit/Chip/Gouge occurs at the attachment holes of the windshield and causes a
depth of more than 0.080 inches after repair of the area.
NOTE:
Pit, Chip, or Gouge If windshield replacement is not required, but lesser pits/chips/gouges are
repaired the windshield inspection intervals must be changed to every 300 hours
or 24 months, whichever occurs first.
You must repair any other damage (scratch/crazing) in the windshield that is greater than
0.010 inch in depth or replace the windshield.
Replace windshield(s) if:
1. Delamination of windshield is in the critical vision area, except for small bubbles
which do not affect the structural integrity or the visibility.
Delamination
2. Delamination of windshield outside the critical vision area exceeds 0.75 inch in
diameter (0.442 square inches) at any one location.
Delamination cannot be repaired.
Minor optical distortion outside the critical viewing area is permitted.
Distortion
It is necessary to repair distortion in the critical viewing area.
This condition will not change the strength of the windshield. If vision is decreased, replace
Discoloration the windshield.
Discoloration cannot be repaired.
C. Flight Compartment Side Windows Rework Criteria
Discrepancy Disposition
Outer Pane
Replace flight compartment side window outer pane(s) if:
1. Cracks occur in the attachment holes at number five or number six of the copilot's
side window. This is for Model 550, Bravo, and 560 only.
2. Cracks that extend beyond the retainer into the vision area.
3. Any combination of cracks or Pit/Chip/Gouge at three or more adjacent attachment
holes.
Crack Inner Pane
Replace flight compartment side window inner pane(s) if:
1. Any crack is found.
NOTE:
If windshield replacement is not required, but lesser cracks are in the windshield,
the windshield inspection intervals must be changed to every 300 hours or 24
months, whichever occurs first.
Cracks cannot be repaired.

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 Model 550 Maintenance Manual (Rev 34)
56-10-00 (Rev 30)

Outer Pane
Replace flight compartment side window outer pane(s) if:
1. A pit, chip, or gouge is deeper than 0.050 inches (1.27 mm) after a repair, in three
or more adjacent attachment holes.
2. Any combination of cracks or a pit, chip, or gouge at three or more adjacent
attachment holes.
3. A pit, chip, or gouge occurs in the attachment holes number five or number six of
the copilot's side window. This is for the Model 550, Bravo, and 560 only.
NOTE:
If windshield replacement is not required, but lesser pits/chips/gouges are
Pit, Chip, Gouge, Scratch, or repaired the windshield inspection intervals must be changed to every 300 hours
Crazing or 24 months, whichever occurs first.
Inner Pane
Replace flight compartment side window inner pane(s) if:
1. A pit, chip, or gouge that is deeper than 0.050 inches (1.27 mm) after repair.
2. A pit, chip, or gouge in three or more adjacent attachment holes.
NOTE:
If windshield replacement is not required, but lesser pits/chips/gouges are
repaired the windshield inspection intervals must be changed to every 300 hours
or 24 months, whichever occurs first.
Any other damage (scratch/crazing) in the window panes greater than 0.010 inch in depth
must be repaired or the window pane replaced.
Delamination Not Applicable
Distortion Minor optical distortion is permitted.
This condition will not affect the strength of the windshield. If vision is decreased, replace
Discoloration the windshield.
Discoloration cannot be repaired.
D. Foul Weather Window Rework Criteria
Discrepancy Disposition
Crack Replace the window if a crack is present.
Pit, Chip, Gouge, Scratch, or You must repair or replace window pane with any damage greater than 0.010 inch in
Crazing depth.
Delamination in a foul weather window that is in more than 10 percent of the window area
Delamination
requires replacement of the window.
Distortion Minor optical distortion is permitted.
This condition will not affect to the strength of the windshield. If vision is decreased, replace
Discoloration the windshield.
Discoloration cannot be repaired.
E. Cabin Window Rework Criteria
Discrepancy Disposition
Crack Replace window if a crack is present.
Any damage in the window panes that is greater than 0.015 inch in depth must be repaired
Pit, Chip, Gouge, Scratch, or
or the window pane must be replaced.
Crazing
Model 500-0001 thru - 0213 applicable only if SB56-5 or SB21-9 has been complied with.
Delamination in the cabin windows that is in more than 10 percent of the window area
Delamination
requires replacement of the window.
Distortion Minor optical distortion is permitted.

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 Model 550 Maintenance Manual (Rev 34)
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This condition will not affect the strength of the windshield. If vision is decreased, replace
Discoloration the windshield.
Discoloration cannot be repaired.
F. Description and disposition of deformities.
(1) Delamination - Separation of acrylic sheet from vinyl layer. Delamination may take the form of bubbles and all
bubbles must be considered to be delamination. These small bubbles will not significantly affect the structural integrity
of the windshield.
(a) (Refer to Figure 801) Any delamination of windshields that is in the critical vision area requires replacement of
the windshield.
(b) Delamination in windshield areas outside the critical vision area, which connect and exceed 0.75 inch in
diameter, requires replacement of the windshield. Relaminating the windshield or window is not an approved
procedure.
(c) Delamination in cabin windows involving more than 10 percent of the window area requires replacement of the
window. It is permissible to postpone replacement to the next Phase 5 inspection.
(2) Discoloration.
(a) Strength of the windshield or window is not affected. If vision is impaired, replace windshield or window. No
repair is allowed.
(3) Pits, chips, gouges and scratches - Marks on the surface of the windshield, flight compartment or cabin window,
including entry door and escape hatch windows.
(a) Pits, chips, gouges and scratches must be removed by polishing and/or buffing or other procedures which
locally remove material to the depth of the damage. Refer to Table 801, Rework Limits.
(4) Cracks - Breaks that extend more than 0.015 inch in any plane of the acrylic.
(a) Cracks which extend beyond the retainer will affect the strength of the windshield, flight compartment or cabin
windows, including entry door and escape hatch windows. No repair is allowed.
(b) Cracks under retainers which connect three or more attachment holes, or which do not connect but cause three
adjacent fasteners to be ineffective, or cracks which extend into the visibility area, require window replacement.
Window replacement is not required for lesser cracks under retainers; however, refer to Task 56-10-00-280 for
reduced inspection interval.
(c) Crack repair is not permitted.
(5) Distortion - Waviness or distortion of objects when looking through the window. Refer to Distortion Evaluation.
(6) Crazing - Fine hairline cracks on surface or within acrylic sheet.
(a) Crazing may be caused by nonapproved cleaning material, paint stripper, solvents, heat, ultraviolet rays and
other materials which set up surface stress in the acrylic. For crazing in windshields, flight compartment windows
or cabin windows, refer to Windshield Surface Damage Criteria and Evaluation or Cabin, Passenger/Crew
Entry Door and Emergency Exit Door Window Surface Damage Criteria and Evaluation.
G. Windshield Surface Damage (includes scratches, pits, chips, gouges and crazing) Criteria and Evaluation.
(1) Damage Evaluation
(a) Measure the windshield’s ply thicknesses in at least three areas within 0.5 inch of the damage.
NOTE: The thickness of an individual ply of a windshield or the total thickness of the windshield
is determined with an ultrasonic thickness gage.
(b) Determine maximum depth of damage using an optical depth micrometer.
(c) Determine the remaining windshield ply thickness by subtracting the measured depth of damage from the
measured ply thickness.
(d) Determine the overall remaining windshield thickness in the area of the damage by subtracting the measured
damage depth from the overall thickness at that point.
(2) Damage Disposition
(a) If the values determined in Damage Evaluation are less than the minimum windshield thickness as specified in
Table 801, replace the windshield.

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(b) If the values determined in Damage Evaluation are greater than the minimum windshield thickness as specified
in Table 801, repair the windshield per the following paragraphs.
(c) Any damage in the windshield, that is less than or equal to 0.005 inch in depth is acceptable for further flight
operations with no repairs, provided
1 The windshield damage is measured during the required windshield phase inspection and reevaluated
according to the limitations in Table 801 (Refer to Chapter 5 for applicable inspection time limits).
NOTE: Leaving damage in either ply of windshield, may reduce the windshield’s ultimate
service life. Therefore, it is recommended, but not required, that any damage to the
windshield be repaired as soon as possible.
(d) Any damage in the windshield that is greater than 0.005 inch in depth must be repaired or the windshield must
be replaced.
1 If the windshield is repaired, the rework limits outlined in Table 801 must be maintained. Refer to Approved
Repair NOTE 3.
2 If the minimum thickness cannot be met, the windshield must be replaced.
(e) Any damage inside the critical vision area or repair of damage in critical vision area must maintain the limits
outlined in Table 801 and Distortion Evaluation Criteria.
H. Cabin, Passenger/Crew Entry Door and Emergency Exit Door Window Surface Damage (includes scratches, pits, chips,
gouges and crazing) Criteria and Evaluation (Part Numbers 9912207-1, -8 only)
(1) Determine the maximum depth of the window damage using an optical depth micrometer, the thickness of the outer
ply and categorize the depth of the damage as light, moderate or heavy.
NOTE: The thickness of an individual ply of a window or the total thickness of the window is
determined with an ultrasonic thickness gage.
(a) Light damage - If the depth of the window damage is less than or equal to 0.005 inch, it is defined as light.
(b) Moderate damage - If the depth of the window damage is greater than 0.005 inch, but less than 0.015 inch, it is
defined as moderate.
(c) Heavy damage - If the depth of the window damage is greater than or equal to 0.015 inch, it is defined as heavy.
(2) If the window outer ply thickness is greater than or equal to 0.225 inch, the following options are available.
(a) Light damage (Two Options)
1 Continue to fly if the damage is optically measured during each required window phase inspection.
NOTE: Leaving damage in the outer ply of the window can reduce the window’s ultimate
service life. Therefore, it is recommended, but not required, that any damage to the
window be repaired as soon as possible.
2 Repair window by removing all damage while maintaining a minimum outer ply thickness of 0.200 inch.
(b) Moderate damage (Two Options)
1 Continue to fly if the damage is optically measured during each required window phase inspection.
NOTE: Leaving damage in the outer ply of the window can reduce the window’s ultimate
service life. Therefore, it is recommended, but not required, that any damage to the
window be repaired as soon as possible.
2 Repair window by removing all damage while maintaining a minimum outer ply thickness of 0.200 inch.
(c) Heavy damage - Repair by removing all damage maintaining a minimum outer ply thickness of 0.200 inch.
(3) Window outer ply thickness is less than 0.200 inch, replace window.
I. Pilot’s Left/Right side windows are multiple ply but are not laminated. If damage is discovered, window must be repaired
or replaced. Repairs can be performed as long as minimum ply thicknesses are maintained per Table 801.
J. Foul weather windows must be evaluated for damage and repaired or replaced.
(1) Any damage in the foul weather window, that is less than or equal to 0.005 inch in depth is acceptable for further flight
operations with no repairs, provided
(a) The foul weather window damage is measured during the required window phase inspection and reevaluated
according to the limitations in Table 801.

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 Model 550 Maintenance Manual (Rev 34)
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NOTE: Leaving damage in either ply of foul weather window, may reduce the windows’s ultimate
service life. Therefore, it is recommended, but not required, that any damage to the
windshield be repaired as soon as practical.
(2) Any damage in foul weather window greater than 0.005 inch in depth must be repaired or the foul weather window
replaced.
(a) If the foul weather window is repaired, the rework limits outlined in Table 801 must be maintained.
(b) If the minimum thickness cannot be met, replace the foul weather window.
Table 801. Rework Limits except as noted in Approved Repair
WINDSHIELD
Outer Ply Core Inner Ply Total of All Plies
Maximum Thickness 0.4710 0.050 0.471 0.992
With Minimum Outer Ply 0.3726 0.050 0.3904 0.813
With Minimum Inner Ply 0.3904 0.050 0.3726 0.813

PILOT/COPILOT SIDE WINDOWS

Outer Ply Inner Ply
Maximum Thickness 0.506 0.275
Nominal Thickness 0.460 0.250
Minimum Thickness 0.410 0.225

FOUL WEATHER WINDOWS

Outer Ply Core Inner Ply Total of All
Plies
Maximum Thickness 0.303 0.050 0.101 0.454
With Minimum Outer Ply 0.249 0.050 0.083 0.382
With Minimum Inner Ply 0.249 0.050 0.083 0.382

CABIN WINDOWS
Outer Ply Core Inner Ply Total of All
Plies
Maximum Thickness 0.275 0.050 0.114 0.439
Minimum Thickness 0.200 0.050 0.074 0.324
4. Approved Repair
A. Notes:
(1) Approved repairs for acrylic windows are those permitted for the purpose of the removal of small damage in order to
make visibility or appearance better and to remove stress concentration points. When you do the repairs, remove
only the minimum material necessary to remove the damage. This will make sure there is a maximum number of
repairs.
(2) Before you start the repair, always find if you can meet the criteria of Table 801.
NOTE: It is recommend to contract a company that repairs acrylic windows to do the repair
procedures.
(3) If a scratch repair kit is available with instructions, use the repair kit instructions. If a repair kit is not available, use the
procedure that follow.
(4) If the foul weather window is damaged, with a frost pane bonded to the inner surface, it is necessary to remove the
frost pane to measure total thickness. The frost pane is bonded with clear RTV adhesive.

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 Model 550 Maintenance Manual (Rev 34)
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B. Repair Procedure.
(1) Clean the windshield or window. Refer to Chapter 12, Window - Servicing.
(2) Pits, chips, gouges, scratches and crazing removal.
(a) Apply a buffing compound to the repair area of the acrylic or to the buffing wheel.
(b) Set the buffer to a speed of 1300 RPM or less, move the buffing wheel across the damaged area with light
pressure and change the direction frequently.
(c) Buff an area larger than the area with the damage. Buff the area until the area surface is back to its original
condition.
1 If the repair is in the critical vision area, the final result must meet the criteria of the Distortion Evaluation.
(d) It is necessary to buff out all repairs with a smooth radius in a ratio of 30:1 repaired area to depth of removed
material.
(3) Windshield and Pilot's/Copilot's Side Window Outer Pane Attachment Hole Chip Repair.
(a) Get access to the windshield or pilot's/copilot's side window outer pane. Refer to Chapter 25, Flight
Compartment Side Panels and Trim - Maintenance Practices.
(b) Remove the nut, washer, spacer, (rubber grommet if applicable), and bolt from the windshield or pilot's/copilot's
side window outer pane attachment hole. Refer to Chapter 56, Windshield - Maintenance Practices.
(c) Polish the chipped area until all damage is smooth. Chamfer the sharp edges 0.03 inch (0.76 mm) x 45
degrees.
(d) Clean the area to be repaired with aliphatic naptha type II and dry with a lint-free rymple cloth #301. Refer to
Chapter 56, Windows - General.
(e) Install bolt, spacer, washer (rubber grommet, if applicable), and nut into the windshield/side window attachment
hole. Refer to Chapter 56, Windshield - Maintenance Practices.
(f) Install the trim for the windshield or pilot's/copilot's side window access. Refer to Chapter 25, Flight
Compartment Side Windows and Trim - Maintenance Practices.
C. Distortion Evaluation.
(1) Use a grid board to examine the window for distortion.
(2) A grid board can be made, and the airplane put in position as shown in Figure 802.
(3) With your eyes centered at FS 136.17, WL 142.50, BL 13.50 (eye-point) look at the grid board, look for lines, which
are not parallel or perpendicular.
(4) Any line that is not in its correct point by more than three degrees shows an unacceptable amount of distortion in the
windshield. If more than five adjacent lines show distortion to a lesser degree, the windshield distortion is
unserviceable. If there is enough thickness at the spot that shows the distortion, the windshield must be repaired or
replaced per Table 801.
NOTE: It can be necessary to photograph the grid board with the camera lens set up at the eye point.
This will let you examine an photographic print of the image and measure the lines with a
protractor for an angle of distortion.

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 Model 550 Maintenance Manual (Rev 34)
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Figure 801 : Sheet 1 : Windshield Viewing Area Definition

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 Model 550 Maintenance Manual (Rev 34)
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Figure 801 : Sheet 2 : Windshield Viewing Area Definition

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 Model 550 Maintenance Manual (Rev 34)
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WINDSHIELD - MAINTENANCE PRACTICES

1. General
A. Maintenance practices or procedures are the same for the left or right windshield panel. The windshield is removed from
outside the flight compartment.
B. When a windshield is changed because of an overheated condition, it is essential that the windshield anti-ice system be
functionally checked. Refer to Chapter 30, Windshield Bleed Air Anti-Ice - Maintenance Practices.
C. Polish windshield with MGH-10 to reduce static discharge each time the windshield is cleaned.
2. Tools and Equipment
A. For a list of required tools and equipment, refer to Windows - General.
3. Removal/Installation of Windshield
A. Prepare the Airplane for Windshield Removal.
NOTE: Careful inspection should be given to check all systems and items (which are exposed during the
installation of the windshield) to ensure that they will function properly.
(1) Disconnect electrical power (optional equipment unit, auxiliary power unit and battery) on airplane and attach the
following maintenance tag at these locations.
WARNING: Do not connect electrical power - maintenance in progress.
(2) If existing windshields are to be reinstalled, place a protective covering over the windshield panel.
(3) Place a protective covering over the adjacent side windows and tape in position.
(4) Remove the windshield anti-ice nozzle. Refer to Chapter 30, Windshield Anti-Ice Nozzle - Removal/Installation.
(5) Remove magnetic compass. Refer to Chapter 34, Magnetic Compass - Maintenance Practices.
(6) Remove crew seats from cockpit. Refer to Chapter 25, Flight Crew Seats - Maintenance Practices.
(7) Remove the sunvisors. Refer to Chapter 25, Sunvisor - Maintenance Practices.
(8) Remove the glareshield. Refer to Chapter 25, Glareshield - Maintenance Practices.
(9) Remove Royalite trim from around windshield. Refer to Chapter 25, Flight Compartment Side Panels and Trim -
Maintenance Practices.
(10) Remove overhead upholstery panel. Refer to Chapter 25, Flight Compartment Overhead Panel - Maintenance
Practices.
CAUTION: Use care to cover and protect circuit breaker wiring and components from inadvertent damage or
sheet metal shavings which could cause short circuits in electrical equipment.
(11) Remove the circuit breaker panels. Refer to Chapter 39, Main Circuit Breaker Panel Components - Maintenance
Practices.
CAUTION: Cover and protect all carpet, upholstery, exposed wire bundles and equipment inside the cockpit.
Carefully move wire bundles that are located near the windshield attach holes.
CAUTION: Cap and plug all disturbed plumbing to keep them free of metal shavings and other foreign objects.
(12) Remove the center instrument panel and the instrument panels beneath the windshields. Refer to Chapter 39, Center
Panel - Maintenance Practices.
B. Removal of Windshield (Refer to Figure 201).
CAUTION: If windshield being removed is to be reinstalled, use extreme care to avoid damage to windshield.
(1) Remove all fasteners from the windshield retainers. Airplanes -0372 and On, and Airplanes -0002 thru -0371
incorporating SB550-56-01, require torque set apex bit Part Number 170-10 to remove all NAS1581A4T17 bolts.
CAUTION: Use extreme care to avoid damaging adjacent side windows and structure (windshield frame)
while removing retainers. Under no circumstances are gouges and scratches allowed in
windshield frame.
CAUTION: Do not damage side windows while removing side retainers. Where the retainer is being
removed adjacent to a side window, work the scraper from the side of the retainer that is
adjacent to the side window. Use only the special retainer removal tool, if the tool is needed,
between the retainer and side windows. Work the special retainer removal tool at a low angle
to avoid scratching or gouging the side windows.

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 Model 550 Maintenance Manual (Rev 34)
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NOTE: When removing fasteners from retainers, note the location of the different length screws for
reinstallation.
NOTE: In order to remove Hi-Lok fasteners from the forward edge of side windows, use the short end
of an Allen wrench and pliers in areas where fasteners fit down into a recess.
(2) Use retainer removal tool (Refer to Figure 201) to separate the sealant beneath the retainers and remove the upper,
lower, center and side retainers as follows:
CAUTION: Do not cut or scratch windshield frame while removing windshield.
NOTE: The retainer removal tool shown in Figure 201 will work much better than a scraper in
removing the retainers. Use of the retainer removal tool will help prevent damage to adjacent
side windows.
(a) On the upper retainer, work the removal tool from the outboard edges toward the center.
(b) On the lower retainer, work the removal tool from the outboard end of the retainer toward the inboard end.
(c) On the center retainer, work the removal tool from the top and bottom. Work from the sides only, if necessary.
(d) On the side retainer, work the removal tool from the top and bottom of the retainer toward the center.
NOTE: As the side retainers are removed from the airplane, temporary hold-down fasteners
should be progressively installed through the side windows (which will not be removed)
to ensure that side windows are held down and will not separate from the sealant.
(3) Working from inside the cockpit, use the removal tool to separate the sealant between the windshield and frame.
NOTE: Work from inside the cockpit as little as possible to avoid damage to the structure.
(4) Scrape or cut bulk sealant from around windshield frame, then use a ScotchBrite wheel on a drill motor to remove
remaining sealant. Remove all existing sealant that directly contacts the windshield.
NOTE: All existing sealant need not be removed in areas that do not directly contact the windshield.
Large bulky areas of existing sealant may be left intact to act as filler when installing new
sealant. Remove the glaze from this existing sealant to provide good adhesion to new sealant.
(5) Remove the windshield using care to prevent bending or damaging the windshield frame.
NOTE: Ensure that temporary hold-down fasteners are installed through the side windows prior to
windshield removal to keep the side windows from separating from the sealant.
(6) After removal of the windshields, clean out all existing sealant that will come in direct contact with the windshields.
C. Install Windshield.
(1) If new retainers are being installed, refer to procedure, Drill and Fit - New Windshield Retainers.
(2) Use the following procedure to remove grease, dirt, oils, etc., from the windshield frame prior to surface finishing:
(a) Mask adjacent surfaces of windows and protect all exposed areas and equipment inside the cockpit.
(b) Using isopropyl alcohol or aliphatic naphtha, Type II, clean an area approximately 1.5 inches wide completely
around the windshield frame.
(c) Alternately during the cleaning process, use a ScotchBrite pad or 320 grit sandpaper as necessary to lightly
abrade the surface.
(d) Clean the area until there is no discoloration on the drying cloth.
(3) Prime and paint the windshield frame as follows:
(a) Apply one coat of (Ameron Enpox #5400 or equivalent) fuel and corrosion resistant epoxy primer and allow a
curing time (at room temperature) of at least one hour.
(b) Apply one coat of dull black (Sherwin-Williams #561550 or equivalent) epoxy enamel and allow a curing time (at
room temperature) for at least eight hours.
(4) Seal and install windshield as follows (Refer to Figure 202):
(a) Clean the windshield frame with a clean cheesecloth, moistened with isopropyl alcohol or aliphatic naphtha,
Type II.
(b) Apply sealant to the windshield frame as follows:
1 Apply a zigzag bead of AMS-S-8802, Type I, Class B4 sealant along both rows of fastener holes as shown
in Figure 202. For sealant information, refer to Chapter 20, Fuel, Weather, Pressure and High Temperature

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 Model 550 Maintenance Manual (Rev 34)
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Sealing - Maintenance Practices.

2 Use a cutoff tongue depressor or other suitable tool to spread the sealant evenly.
3 Apply a bead of sealant along the edge of adjacent window retainers and skin.
4 Apply an extra bead of sealant around the inner row of fastener holes.
5 Apply an extra bead of sealant just inside the outer row of fastener holes.
(c) Wipe both sides of the windshield around the edge with a clean cheesecloth, moistened with isopropyl alcohol
or aliphatic naphtha, Type II.
(d) Lay the windshield in the frame and insert alignment guide tools through the windshield attach holes and into the
frame at the top and bottom rows to align and hold the windshield temporarily in place.
(5) Apply sealant to the windshield as follows:
(a) Apply a zigzag bead of AMS-S-8802, Type I, Class B4 sealant along the row of fastener holes in the windshield.
For sealant information, refer to Chapter 20, Fuel, Weather, Pressure and High Temperature Sealing -
Maintenance Practices.
(b) Use a cutoff tongue depressor or other suitable tool to spread the sealant evenly.
(c) Apply an extra bead of sealant around the inner row of fastener holes.
(d) Fill the gap between the windshields with sealant.
(e) Apply a thick bead of sealant along the lower edge of the windshield next to the frame and all around the
windshield and frame.
(6) Install windshield retainer as follows (Refer to Figure 203):
NOTE: Airplanes -0372 and On, and Airplanes -0002 thru -0371 incorporating SB550-56-01, require
torque set apex bit part number 170-10 to install all NAS1581A4T bolts.
NOTE: To prevent water leaks in the nose cone area, ensure that sealant is applied around the attach
screws and rivets of the windshield retainer.
(a) Apply some sealant to cover the bottom two holes on the center retainer.
(b) Lay the center retainer on the windshield and insert bolts through the fastener holes.
(c) Lay the upper retainer on the windshield and fasten the retainer to the fuselage structure with four temporary
fasteners along the top row of fastener holes.
(d) Insert bolts through the windshield fastener holes and upper retainer.
(e) Lay the side retainer on the windshield and fasten with two temporary holddown screws on top and two on
bottom.
(f) Insert bolts through the windshield fastener holes and side retainer.
(g) Insert other fasteners in the side retainer as called out.
(h) Install the lower retainer and cover and fasten to the structure using five temporary fasteners per retainer, evenly
spaced. Fasten the cover to the retainers with screws as illustrated in Figure 203.
(i) Insert bolts through the windshield fastener holes and lower retainer.
(j) Insert screws in the lower retainer and structure.
(k) Insert screws in the upper retainer and structure.
(l) Apply two-inch wide masking tape to cover the fasteners just inserted in the upper and lower retainer to hold the
fasteners in place during installation of the washer and nuts.
(7) Install washers and nuts on all the windshield attach bolts.
(8) Install washers and nuts on the screws that attach the upper and lower retainers to the fuselage structure.
(9) Install washers and nuts on remaining fasteners as called out.
(10) Torque fasteners according to the following procedure:
(a) Tighten the outer row of retainer fasteners all the way around.
CAUTION: Do not torque fasteners in a way that will cause retainers to wrinkle.
NOTE: This is a special torque and must not be exceeded under any circumstances.
(b) On Airplanes -0002 thru -0371, except airplanes incorporating SB550-56-01, tighten the windshield fasteners to

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 Model 550 Maintenance Manual (Rev 34)
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10 to 12 inch-pounds. Refer to Chapter 20, Torque Data - Maintenance Practices, Free Running Torque Value.
(c) (Airplanes -0372 and On, and Airplanes -0002 thru -0371 incorporating SB550-56-01) Tighten the windshield
fasteners 30 to 40 inch-pounds. Refer to Chapter 20, Torque Data - Maintenance Practices, Free Running
Torque Value.
(d) Install required rivets (Refer to Figure 203).
(11) Remove all extruded sealant around edges of the retainers and windshield using cheesecloth moistened with
isopropyl alcohol or aliphatic naphtha, Type II.
(a) Mask the windshield as shown in Figure 204 to provide a reference guide to fair the sealant.
(b) Make a fillet seal using AMS-S-8802, Type I, Class B4 sealant according to the dimensions shown in Figure
204. For sealant information, refer to Chapter 20, Fuel, Weather, Pressure and High Temperature Sealing -
Maintenance Practices.
(c) Remove masking tape and clean excess sealant from the windshield and airplane skin.
(12) Allow sealant to cure a minimum of 72 hours before pressurizing the airplane.
(13) Perform the final assembly and cleanup as follows:
(a) Perform a cabin leak test on the airplane. Refer to Chapter 21, Cabin Pressure Control - Adjustment/Test.
(b) Reinstall all equipment and items required to remove the windshield. For equipment and items reference
chapter, refer to paragraph 3.A., Prepare the Airplane for Windshield Removal.
(c) Perform a leak test of the pitot and static systems. Refer to Chapter 34, Pitot Static System - Adjustment/Test.
(d) Perform an operational check on all removed or disturbed equipment.
(e) Remove protective covering from windshield.
4. Replacement of Windshield
NOTE: This procedure provides instructions for replacement of old windshields with new windshields
(Airplanes -0372 and On, and Airplanes -0002 thru -0371 Incorporating SB550-56-01).
NOTE: Hand Tool Kit SB550-56-01-1 must be available before replacement of windshield can be accomplished.
A. Replace Windshield.
(1) Remove the old windshield. Refer to Removal/Installation of Windshield.
(2) Align the windshield in the frame as follows:
(a) Pull the protective covering back from edges of new windshields approximately one inch.
(b) Position the new windshields in frame opening and align holes as follows:
NOTE: To align the windshields in the frame, special 5591043-9 alignment guide tools are
required. Refer to SB550-56-01-1 Hand Tool Kit in Tools and Equipment list.
CAUTION: Do not use any other tools to align the new windshields in the frame other than the alignment
guide tools provided in the SB550-56-01-1 hand tool kit.
CAUTION: Do not apply excessive side loads on the windshield spacers when using the alignment guide
tools. Use only small movements, allowing the taper on the tools to align the holes and
preventing the possibility of chipping the plexiglas around the spacers in the new windshield.
(c) Starting at the inboard lower corner, insert one 5591043-9 alignment guide tool every three or four holes working
outboard or up along the center. Try to obtain as many aligned holes as possible.
(d) If holes do not match, remove the guide tool and start at another position, such as lower outboard, upper inboard
or upper outboard.
(e) Insert the alignment guide tool every three or four holes to obtain the best possible hole alignment.
NOTE: Chips in the Plexiglas, that may have occurred around the windshield spacers during the
alignment process, must be repaired using the procedure outlined in step (5), provided
that the chipped out portion does not exceed a diameter of 0.650 inch and/or a depth of
0.080 inch around any particular spacer. Windshields that have chips greater than
described around any particular spacer cannot be repaired and must be replaced.
(3) If a gap exists between the windshield frame and the inside surface of the windshield, position the windshield to
equalize the gap around the windshield periphery. Maximum allowable gap is 0.500 inch. If the gap exceeds the

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 Model 550 Maintenance Manual (Rev 34)
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maximum allowable gap, a different windshield must be obtained and fitted to the frame.
(4) After the best overall hole alignment has been obtained, measure each hole that is out of align (if any exists) using a
ball gage and micrometer to determine that it is within the maximum out-of-alignment tolerance of 0.020 inch.
(a) If holes are determined to be out-of-tolerance (out-of-alignment more than 0.020 inch), refer to Figure 205 for the
maximum number of out-of-tolerance holes which are allowed per area.
(b) If more than the maximum number of out of tolerance holes exists per area, refer to the repair instructions
outlined in Structural Repair Manual, Chapter 53, Windshield Frame Repair - Out-of-Tolerance Holes.
(5) The following procedure outlines the use of PS-30 cement to repair inadvertent chips (in the Plexiglas) around the
spacers in the new windshields.
NOTE: This Plexiglas repair procedure may be used only when chips DO NOT EXCEED a diameter of
0.650 inch and/or a depth of 0.080 inch.
(a) The following materials and equipment must be available for use before the repairs can be accomplished:
1 PS-30 cement.
2 One polyethylene container for mixing.
3 Surgeons gloves or equivalent.
4 Tool to apply cement (spatula, brush and/or hypodermic syringe).
(b) Prepare the area to be repaired as follows:
1 Mask off the area around the repair.
2 Polish the chipped out area(s) until all imperfections are smooth. (Use standard Plexiglas procedures.)
NOTE: Remove the spacer(s) from the new windshield attach holes before attempting to
polish the damaged area(s).
3 Clean the areas to be repaired using aliphatic naphtha, Type II.
NOTE: The area to be repaired must be free of chips, powder, grease and other foreign
matter before applying cement.
(c) Prepare the PS-30 cement for use by mixing the components as follows:
NOTE: All cement applications shall be accomplished in a temperature controlled area between
65°F and 80°F.
NOTE: Both base cement (Component A) and catalyst (Component B) should be at room
temperature at the time of mixing.
1Using a clean polyethylene container, combine Components A and B in the ratio of 95 parts of Component
A to five parts of Component B, either by weight or by volume.
2 When Components A and B are combined, stir continuously to ensure that they are completely mixed. Let
the air bubbles rise to the surface before using the cement.
(d) Apply the PS-30 cement to the prepared area as follows:
CAUTION: Ensure there is adequate protection for surrounding areas to prevent the cement from
contacting other than the repair area.
1Insert a bolt through the windshield attach holes such that the shank fits the hole and extends at least 0.500
inch on each side of the windshield.
2 Fill the area with cement using a spatula, brush and/or hypodermic syringe.
3 Allow the cement to cure at least eight hours.
4 Turn the bolt and remove it from the windshield.
5 Polish the repaired area to the windshield contour.
6 Install original spacer(s) removed and seal with RTV sealer.
(6) Install the new windshields. Refer to step 3., Removal/Installation of Windshield.
5. Drill and Fit New Windshield Retainer
A. Drill and fit retainers as follows: (Refer to Figure 206 or Figure 207).
NOTE: The following instructions apply to a left or right windshield as required.

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NOTE: Special 5591043-8 temporary hold down screws and MS20002C6 washers are required to fit the
new retainers. Refer to SB550-56-01-1 Hand Tool Kit.
(1) Position windshield in windshield frame in exact position as aligned.
CAUTION: Do not tighten screws at this time as it may cause windshield to crack.
(2) Insert 5591043-8 temporary hold down screws and MS20002C6 washers through windshield attach holes where
holes align and snug windshield down using original nuts.
(3) Insert a 5591043-5 slip removable drill guide in each hole in windshield that does not have an attach screw.
CAUTION: Do not drill through windshield spacers (if installed) without having a slip removable drill guide
inserted.
(4) Drill 0.156 inch diameter holes through drill guide and into reinforcement strap and/or doubler(s) (that were attached
previously).
(a) Repeat the above step for each hole to be drilled through repaired areas.
(5) Remove original nuts, 5591043-9 temporary hold down screws and MS20002C6 washers, and carefully remove
windshield.
(6) Enlarge the 0.156 inch diameter holes just drilled to 0.257 inch diameter and deburr all holes on both ends.
(7) Reposition windshield, align and temporarily secure again using temporary hold-down screws, special washers and
original nuts in every third or forth windshield attach hole.
(8) Position the side, upper, lower and center retainers (respectively) around windshield and temporarily hold in place
using additional personnel.
(9) Working from inside airplane, insert a 5591043-5 slip removal drill guide in the top outboard corner and drill 0.156
inch diameter pilot holes through the drill guide and into the retainer working top down. Locate a double row of
fasteners alternating diagonally across the retainer. Insert a temporary fastener after each hole is drilled.
(10) Using a hole finder, locate and drill (0.156 inch) diameter holes in retainers to match existing holes in adjacent
structure.
NOTE: Hole finder used should have a peg diameter to fit a 0.156 inch hole.
NOTE: On left side retainer only, some holes are smaller than 0.156 inch diameter. These may be back
drilled at a later time.
(11) Remove retainers, enlarge 0.156 inch diameter holes to 0.257 inch diameter (only holes directly above windshield)
and deburr all holes.
(12) Trim new retainers to approximate size and shape of corresponding old retainers. The maximum gap at intersection
of all retainers is 0.030 inch, except at the intersection of the lower retainers at center of windshield; at this location
maximum gap is 0.060 inch. Grind or file edges of new retainers to make an exact fit with adjacent skins and
structure.
NOTE: New windshield may have an area around the edge that is milled down (thinner) to maintain a
required edge thickness. New retainers must be trimmed to fit within this cutout area, if it
exists.
NOTE: New retainers may require hand forming to provide an adequate fit to the windshield and
windshield frame. Ensure windshield is in frame properly prior to any hand forming of
retainers to ensure retainer will fit on installation.
(13) Ensure lower retainers are trimmed to match existing holes for windshield anti-ice nozzles.
6. Inspection/Check
A. Windshield.
(1) Visually inspect the retainers for loose fasteners. Chipped, cracked or loose paint around the fasteners is cause for
additional fastener attention.
(2) Visually check the windshield for delaminations, discoloration, scratches, gouges and cracks. If any irregularities or
deformities occur, refer to Windshields/Windows - Approved Repairs, for explanation and description.
B. Checking for cracks that may occur between or adjacent to the windshield installation holes but remain out of the viewing
area is performed by an optical prism inspection. Refer to Windshield/Windows - Adjustment/Test.
7. Window Storage

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 Model 550 Maintenance Manual (Rev 34)
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A. Windows shall be stored in a cool dry room away from heating coils, radiators, hot water pipes and away from solvent
fumes (such as may exist near paint storage areas).
B. Windshield must be stored with adequate supports to prevent warpage.

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 Model 550 Maintenance Manual (Rev 34)
56-10-01 (Rev 30)

Figure 201 : Sheet 1 : Windshield Removal

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 Model 550 Maintenance Manual (Rev 34)
56-10-01 (Rev 30)

Figure 202 : Sheet 1 : Windshield Sealing

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 Model 550 Maintenance Manual (Rev 34)
56-10-01 (Rev 30)

Figure 203 : Sheet 1 : Windshield Installation

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 Model 550 Maintenance Manual (Rev 34)
56-10-01 (Rev 30)

Figure 203 : Sheet 2 : Windshield Installation

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 Model 550 Maintenance Manual (Rev 34)
56-10-01 (Rev 30)

Figure 204 : Sheet 1 : Fillet Seal Windshield Retainers

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 Model 550 Maintenance Manual (Rev 34)
56-10-01 (Rev 30)

Figure 205 : Sheet 1 : Windshield Hole Out of Tolerance

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 Model 550 Maintenance Manual (Rev 34)
56-10-01 (Rev 30)

Figure 206 : Sheet 1 : Drilling and Fitting Windshield Retainers

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 Model 550 Maintenance Manual (Rev 34)
56-10-01 (Rev 30)

Figure 206 : Sheet 2 : Drilling and Fitting Windshield Retainers

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 Model 550 Maintenance Manual (Rev 34)
56-10-01 (Rev 30)

Figure 206 : Sheet 3 : Drilling and Fitting Windshield Retainers

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 Model 550 Maintenance Manual (Rev 34)
56-10-01 (Rev 30)

Figure 207 : Sheet 1 : Drilling and Fitting Windshield Retainers

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 Model 550 Maintenance Manual (Rev 34)
56-10-01 (Rev 30)

Figure 207 : Sheet 2 : Drilling and Fitting Windshield Retainers

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 Model 550 Maintenance Manual (Rev 34)
56-10-01 (Rev 30)

Figure 207 : Sheet 3 : Drilling and Fitting Windshield Retainers

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 Model 550 Maintenance Manual (Rev 34)
56-10-02 (Rev 30)

SIDE WINDOWS - MAINTENANCE PRACTICES

1. General
A. The removal and installation procedures for the left and right side window inner and outer panes are typical. The forward
retainer on the left side window has a different shape than the right side window forward retainer. The difference in shape
is because of the foul weather window installation on the pilot side.
NOTE: The inner pane side window can be removed with the outer pane side window installed.
NOTE: Airplanes serial numbers, 550-0001 through 550-0681, do not have a frost pane. Airplanes serial
numbers, 550-0682 through 550-0733, do have a frost pane.
2. Tools and Equipment
A. For the necessary tools and equipment, refer to Window - General.
3. Inner Pane Removal/Installation
A. Remove the Inner Pane (Refer to Figure 201).
(1) Remove the related flight crew seat. Refer to Chapter 25, Flight Crew Seats - Maintenance Practices.
(2) Remove the related cockpit circuit breaker panel. Refer to Chapter 39, Main Circuit Breaker Panel Components -
Maintenance Practices.
(3) Remove the related pilot or copilot trim. Refer to Chapter 25, Flight Compartment Side Panels and Trim -
Maintenance Practices.
(4) Remove the related sunvisor. Refer to Chapter 25, Sunvisor - Maintenance Practices.
(5) Remove the flight compartment headliner and forward trim panel. Refer to Chapter 25, Flight Compartment Overhead
Panel - Maintenance Practices.
(6) Remove the glareshield. Refer to Chapter 25, Glare Shield - Maintenance Practices.
CAUTION: Be careful to prevent damage to the seal or frost pane during their removal.
(7) Remove the frost pane and seal.
(8) Put a protective cover on the inboard side of the inner pane.
(9) Remove the nuts and washers that attach the screen assembly to the inner ring.
(a) Hold the Hi-Lok fasteners at the threaded end.
(10) Remove the screen assembly.
NOTE: Sealant is applied between the screen assembly and the window frame. Refer to Chapter 20,
Fuel, Weather, Pressure and High Temperature Sealing - Maintenance Practices.
(11) Remove the air outlet and remove the hose from the air outlet assembly.
NOTE: Adhesive is applied between the air outlet and the window frame. Refer to Chapter 20,
Adhesive and Solvent Bonding - Maintenance Practices.
(12) Remove the inner ring.
(13) Remove the inner pane and shims.
NOTE: Tape is applied between the inner pane and shims.
NOTE: Sealant is applied between the shims and the window frame doubler. Refer to Chapter 20,
Fuel, Weather, Pressure and High Temperature Sealing - Maintenance Practices.
(a) Identify and record the location of the shims.
NOTE: It is necessary for the shims to be installed in their same locations during the installation
procedure because the shims have different shapes and thicknesses.
CAUTION: Be careful to prevent damage to the inner pane during the removal procedure.
(b) Use a blunt tool if necessary to remove the inner pane.
(c) Remove the shims from the window frame doubler.
(14) Remove the inner pane and shims from the airplane.
(15) Put a protective cover on the inner and outer surfaces of the inner pane for temporary storage.
B. Install the Inner Pane (Refer to Figure 201).

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(1) Clean the bond area of the shims with isopropyl alcohol, where the tape is to be applied. Refer to Chapter 20,
General Solvents - Maintenance Practices.
(2) Apply 4508 or 4718 tape 0.125 inch (3.175 mm) to the inside surface of the shims.
CAUTION: Make sure if new sealer has been applied to the outer pane fasteners, that the necessary cure time
of the sealer has expired.
(3) If temporary fasteners were installed in the outer pane, make sure they are removed.
(4) Remove the protective cover on the inner pane.
(5) Clean the inner pane with Aliphatic Naphtha or an equivalent cleaner. Refer to Chapter 12, Window - Servicing.
CAUTION: Make sure there has been a sufficient amount of cure time for the adhesive on the shims before the
fay seal is applied.
(6) Put the inner pane in the correct position.
(a) The nuts must align with the cutouts in the inner pane.
(b) Install MS21042L3 nuts as required where the inner pane touches the outer pane fastener nuts.
(c) If a Hi-Lok (long) fastener is moved during the inner pane installation, seal the fastener again. Refer to Chapter
20, Fuel, Weather, Pressure and High Temperature Sealing - Maintenance Practices.
(7) Put the inner ring, air outlet, and screen assembly in the correct position.
(8) Install the washers and nuts on the Hi-Lok (long) fasteners, do not tighten the nuts.
(9) Connect the hose to the air outlet.
CAUTION: The Hi-Lok nuts must be torqued in the torque pattern shown in Figure 201. Damage can occur to
the inner pane if the correct torque pattern is not done.
(10) Tighten the Hi-Lok nuts.
(a) Hold the Hi-Lok (long) fasteners with an Allen wrench at the threaded end.
(b) Begin with the fastener labeled number one in the torque pattern, torque the nut 10 to 12 inch-pounds (1.13 to
1.36 N.m)
(c) Tighten the nuts to approximately 2 to 3 inch-pounds (0.23 to 0.34 N.m) above the running torque.
(d) Continue to tighten the nuts and use the torque pattern in Figure 201.
(e) After the torque pattern is completed, do a torque check of the nuts again.
(11) Apply a fillet seal of Class VC solvent bonding and adhesive around the opening of the air outlet. Refer to Chapter 20,
Adhesive and Solvent Bonding - Maintenance Practices.
NOTE: The fillet seal will prevent air leaks from the defog air system.
(12) Apply a filler seal of Type I, Class B, sealant around the edge of the screen assembly. Refer to Chapter 20, Fuel,
Weather, Pressure and High Temperature Sealing - Maintenance Practices.
(13) Allow sealant to cure a minimum of 72 hours before pressurizing the airplane.
(14) Perform a cabin leak test on the airplane. Refer to Chapter 21, Cabin Pressure Control - Adjustment/Test.
(15) Clean the bonding surface of the seal. Refer to Chapter 20, General Solvents - Maintenance Practices.
(16) Apply RTV103 to the seal. Refer to Chapter 20, Adhesive and Solvent Bonding - Maintenance Practices.
(17) Put the frost pane and seal in the correct position.
(a) Make sure the seal is installed approximately 0.05 inch (1.27 mm) out of the critical vision area of the window.
(18) Install the glareshield. Refer to Chapter 25, Glare Shield - Maintenance Practices.
(19) Install the flight compartment headliner and forward trim panel. Refer to Chapter 25, Flight Compartment Overhead
Panel - Maintenance Practices.
(20) Install the sunvisor. Refer to Chapter 25, Sunvisor - Maintenance Practices.
(21) Install the pilot or copilot trim. Refer to Chapter 25, Flight Compartment Side Panels and Trim - Maintenance
Practices.
(22) Install the cockpit circuit breaker panel. Refer to Chapter 39, Main Circuit Breaker Panel Components - Maintenance
Practices.

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 Model 550 Maintenance Manual (Rev 34)
56-10-02 (Rev 30)

(23) Install the flight crew seat. Refer to Chapter 25, Flight Crew Seats - Maintenance Practices.
4. Outer Pane Removal/Installation
A. Remove the Outer Pane (Refer to Figure 201 and Figure 202).
(1) Remove the inner pane, refer to Inner Pane Removal/Installation.
(2) Identify the size of the Hi-Lok fasteners that are used to attach the outer pane to the window frame.
NOTE: The same size Hi-Lok fasteners will be used for the outer pane installation.
(3) Remove the nuts and washers that attach the outer pane to the window frame.
(a) Hold the Hi-Lok fasteners at the threaded end.
(4) Remove the Hi-Lok fasteners that attach the forward and aft retainers to the window frame.
(5) Remove the nuts, washers, screws, and rivets, that attach the forward and aft retainers to the window frame.
(6) Remove the forward and aft retainers from the airplane.
(7) Remove the tubing from the outer pane.
(8) Remove the outer pane.
NOTE: Sealant is applied between the outer pane and the window frame doubler. Refer to Chapter 20,
Fuel, Weather, Pressure and High Temperature Sealing - Maintenance Practices.
CAUTION: Be careful to prevent damage to the outer pane during the removal procedure.
(a) Use a blunt tool if necessary to remove the outer pane.
(9) Remove the outer pane from the airplane.
(10) Put a protective cover on the inner and outer surfaces of the outer pane for temporary storage.
B. Install the Outer Pane (Refer to Figure 201 and Figure 202).
NOTE: Align the outer pane to the best position possible. Double drilled holes in the window frame are
permitted.
NOTE: Some new outer pane kits have tubing and spacers. These can be installed in the outer pane
fastener holes during the Hi-Lok fasteners installation.
(1) Remove the unwanted sealant from the window frame doubler. Refer to Chapter 20, Fuel, Weather, Pressure and
High Temperature Sealing - Maintenance Practices.
CAUTION: Make sure that you use the correct solvent for the nylon shims, damage can occur to the shims.
(2) Clean the window frame doubler. Refer to Chapter 20, Fuel, Weather, Pressure and High Temperature Sealing -
Maintenance Practices.
(3) Remove a sufficient amount of the protective cover on the edge of the outer pane to get access to the attachment
holes.
(4) Remove all the sealer from the outer pane.
NOTE: A cork wheel can be used to remove the sealant from the outer pane.
(5) Put the correct tubing/spacers in the outer pane and align the tubing/spacers with the window frame doubler.
(6) Put the outer pane in the correct position in the window frame.
(7) Install Hi-Lok pins in some locations to hold the outer pane in position.
(8) Examine the outer pane position.
(a) Look at the contour fit of the outer pane compared to the window frame and fuselage.
(b) Look for voids between the window and the window frame doubler.
CAUTION: The maximum permitted void without sealant is 0.25 Inch (6.35 mm).
(c) Do a check to see if the outer pane moves inboard and outboard or forward and aft.
(9) Remove the outer pane.
(10) Clean the outer pane. Refer to Chapter 12, Window - Servicing.
(11) With a roller, apply a constant layer of Type I, Class B, sealant to fay seal the outboard side of the window frame
doubler. Refer to Chapter 20, Fuel, Weather, Pressure and High Temperature Sealing - Maintenance Practices.
(12) Put the outer pane in the correct position in the window frame.

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 Model 550 Maintenance Manual (Rev 34)
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(13) Make sure the correct tubing/spacers that are installed in the outer pane are not damaged.
(a) If necessary replace the damaged tubing/spacers.
(14) Apply Type I, Class B sealant to the ends of the shims (butt joint). Refer to Chapter 20, Fuel, Weather, Pressure and
High Temperature Sealing - Maintenance Practices.
(15) Identify the shim location and put the shims in the correct positions in the inboard side of the window frame doubler.
(16) Fay seal the forward and aft retainers with Type I, Class B sealant. Refer to Chapter 20, Fuel, Weather, Pressure and
High Temperature Sealing - Maintenance Practices.
(a) Make sure there are no voids in the seal.
(17) Install the rivets, screws, washers and nuts that attach the forward and aft retainers to the window frame.
(18) Install the Hi-Lok fasteners (short) that attach the retainers, bushings, and shims to the window frame.
NOTE:Screws, washers, and nuts can be used as temporary fasteners in the Hi-Lok holes if
necessary.
CAUTION: The Hi-Lok fasteners must be installed in the correct hole locations to correctly install the inner
pane, refer to Figure 201.
(19) Install the washers and nuts on the Hi-Lok (short) fasteners, do not tighten the nuts.
CAUTION: The Hi-Lok nuts and temporary fasteners must be torqued in the torque pattern shown in Figure
201. Damage can occur to the outer pane.
(20) Tighten the Hi-Lok nuts.
(a) Hold the Hi-Lok (short) fasteners with an Allen wrench at the threaded end.
(b) Begin with the fastener labeled number one in the torque pattern, torque the nut 10 to 12 inch-pounds (1.13 to
1.36 N.m)
(c) Tighten the nuts to approximately 2 to 3 inch-pounds (0.23 to 0.34 N.m) above the running torque.
(d) Continue to tighten the nuts and use the torque pattern in Figure 201.
(e) After the torque pattern is completed, do a torque check of the nuts again.
(21) The fasteners installed between the side window and the windshield are not shown in this procedure. Refer to
Windshield - Maintenance Practices.
(22) Remove the protective coverings from the outer pane if they are installed.
(23) Clean the outer pane with Aliphatic Naphtha or an equivalent cleaner. Refer to Chapter 12, Window - Servicing.
(24) Install the inner pane, refer to Inner Pane Removal/Installation.
(25) Allow sealant to cure a minimum of 72 hours before pressurizing the airplane.
(26) Perform a cabin leak test on the airplane. Refer to Chapter 21, Cabin Pressure Control - Adjustment/Test.
(27) Do a side window prism inspection. Refer to Windshield/Windows - Inspection Check.
(28) If the copilot's side window was replaced, schedule a Phase 57 inspection.
5. Inspection/Check
A. Do an inspection of the Side Windows
(1) Examine the retainers for loose fasteners, or loose paint around the fasteners.
NOTE: Damaged paint around the fasteners is a possible indication of a loose bolt.
(2) Examine the inner pane, outer pane, and the frost pane for scratches, gouges and cracks. If necessary, refer to
Windshields/Windows - Approved Repairs.
6. Window Storage
A. The windows and frost panes must be stored in a cool, dry room away from heating coils, radiators, hot water pipes and
away from paint storage area solvent fumes.
B. The windows must be stored with sufficient supports, to not let the windows to become warped.

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 Model 550 Maintenance Manual (Rev 34)
56-10-02 (Rev 30)

Figure 201 : Sheet 1 : Side Window Installation

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 Model 550 Maintenance Manual (Rev 34)
56-10-02 (Rev 30)

Figure 201 : Sheet 2 : Side Window Installation

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 Model 550 Maintenance Manual (Rev 34)
56-10-02 (Rev 30)

Figure 201 : Sheet 3 : Side Window Installation

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 Model 550 Maintenance Manual (Rev 34)
56-10-02 (Rev 30)

Figure 201 : Sheet 4 : Side Window Installation

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 Model 550 Maintenance Manual (Rev 34)
56-10-02 (Rev 30)

Figure 202 : Sheet 1 : Retainer Installation

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 Model 550 Maintenance Manual (Rev 34)
56-10-03 (Rev 28)

FOUL WEATHER WINDOW - MAINTENANCE PRACTICES

1. General
A. The foul weather window is installed on the left side between the windshield and the pilot's side window. The window is
hinged at the bottom and may be opened by the pilot. A seal is bonded to the window frame which mates with the parting
surface of the window when the window is in the closed position.
2. Tools and Equipment
A. For a list of required tools and equipment, refer to Windows - General.
3. Latch Assembly Removal/Installation
A. Removal of the Handle and Hook (Refer to Figure 201).
(1) Remove mounting screw to remove the handle.
NOTE: The handle screw and handle are installed with adhesive sealant and will require additional
effort to remove.
(2) Remove the mounting screw to remove the hook.
NOTE: The hook mounting screw is found in the windshield retainer. Therefore, the foul weather
window hook will be removed when the retainer is removed.
B. Installation of Handle Assembly and Hook (Refer to Figure 201).
(1) Install Handle Assembly.
(a) Position handle assembly to the foul weather window and install mounting screw.
(b) Close and latch the foul weather window and check the seal. To check the seal, place thin strips of paper
between the foul weather window and the seal. If the strips of paper can be easily pulled from between the
window and the seal with the foul weather window closed and latched, adjust the handle.
1 Adjust the foul weather window latch by removing the handle assembly and adding shim(s), washer(s) and
reinstall handle assembly.
2 Check the seal between foul weather window and the seal with thin paper strips.
3 Do the foul weather window handle adjustment again to get a satisfactory seal.
(c) Remove handle assembly mounting screw, apply Loctite 222 to the screw threads and reinstall handle mounting
screw. Refer to Chapter 20, Fuel, Weather, Pressure, and High-Temperature Sealing - Maintenance Practices.
(2) Install Hook.
(a) Apply Type I, Class B-2 Weather, Pressure and High Temperature sealant to the threads of the hook mounting
screw. Refer to Chapter 20, Fuel, Weather, Pressure, and High-Temperature Sealing - Maintenance Practices
for sealant information.
(b) Position hook to the window frame and secure with the lock mounting screw.
4. Foul Weather Window Removal/Installation
NOTE: The following procedure may be used when binding or misalignment does not exist. If binding or
misalignment is experienced, refer to Foul Weather Window Replacement.
NOTE: Removal of the foul weather window will depend on the maintenance required. The hinge pins may be
removed or the hinge half mounting screws may be removed.
A. Remove Foul Weather Window (Refer to Figure 202).
(1) Place protective tape on both sides of window.
(2) Remove screws from window hinge half. Remove the window.
B. Install Foul Weather Window (Refer to Figure 202).
CAUTION: Do not exceed 5 inch-pounds of torque or window may crack.
(1) Assemble window to the hinge half by installing hinge screws. Torque screws to 4 inch-pounds, +1 or -1 inch-pounds.
(2) Remove the protective tape covering window.
5. Foul Weather Window Seal Removal/Installation
A. Remove Foul Weather Seal (Refer to Figure 201).
(1) Mask or tape the frames and adjoining areas outside of the foul weather seal contact area.

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(2) Remove the seal using a plastic scraper.

(3) Clean all traces of silicone adhesive from the frame and surrounding area and wipe with Methyl n-Propyl Ketone.
Refer to Chapter 20, Fuel, Weather Pressure and High-Temperature Sealing - Maintenance Practices.
(4) Color-chem treat all bare aluminum and apply corrosion resistant primer. Ensure that the primer is fully cured before
applying solvents or sealer. Refer to Chapter 20, Exterior Finish - Cleaning/Painting.
B. Install Foul Weather Window Seal Using Liquid Shim (Preferred Method) (Refer to Figure 202).
(1) Apply 2-inch Teflon tape around periphery of outer surface of foul weather window, but do not allow tape to overlap.
Cover the remaining outer surface and entire inner surface of the window with Teflon tape or masking tape. Refer to
Chapter 56, Windows - General.
(2) Apply Type 1, Class B-2 (AMS-S-8802) sealant to the inner side of the foul weather window frame. Refer to Chapter
20, Adhesive and Solvent Bonding - Maintenance Practices.
(3) Position the lower part of the foul weather window with the hinges installed into the window opening and temporarily
attach to the intercostal with screws. Close the window forcing the sealer to flow until the upper hook can be engaged.
Place a 0.100 inch spacer (wood, rubber or equivalent) between the hook and the latch. Allow the sealant to cure.
NOTE: Some sealant will extrude out between the window and skin or window and frame.
(4) Remove the foul weather window and remove protective tape from the window.
(5) Inspect and fill any voids, as required. Allow sealant to cure and trim liquid shim.
(6) Clean seal contact surface of liquid shim with Methyl n-Propyl Ketone.
(7) Install seal on the liquid shim.
(a) For airplanes that use seal 5511279-1, bond seal with an approved Class VA adhesive. Refer to Chapter 20,
Adhesive and Solvent Bonding - Maintenance Practices.
(b) For airplanes that use seal 5511275-20, bond seal with an approved Class II adhesive (EC1300L). Seal the
joint with an approved Class VA adhesive. Refer to Chapter 20, Adhesive and Solvent Bonding - Maintenance
Practices.
C. Install Foul Weather Window Seal (Optional Method) (Refer to Figure 201).
NOTE: Two types of window seals may be installed, Styguard 187, identified by Part Number 5511279 or
an alternate seal identified as RTV 93-072, manufactured by Dow Corning Corp., Midland, MI.
(1) Place protective tape on the windows to prevent cleaning solvent from damaging the Plexiglas panes.
(2) Clean the surface and metal window frame where the seal is to be installed. Refer to Chapter 20, Adhesive and
Solvent Bonding - Maintenance Practices.
(3) Install the seal on the window frame.
(a) For airplanes that use seal 5511279-1, bond seal with an approved Class VA adhesive. Refer to Chapter 20,
Adhesive and Solvent Bonding - Maintenance Practices.
(b) For airplanes that use seal 5511275-20, bond seal with an approved Class II adhesive (EC1300L). Seal the
joint with an approved Class VA adhesive. Refer to Chapter 20, Adhesive and Solvent Bonding - Maintenance
Practices.
6. Foul Weather Window Replacement
A. Preliminary Preparation (Refer to Figure 202).
(1) Foul weather window contour varies. Therefore, when replacing the window, it is important to order a spare window
having a contour similar to the window being removed. To check foul weather window contour, perform the following
procedures.
NOTE: If a spare window has been installed previously, it is possible to have an installed foul weather
window with a contour that requires lengthy adjustments to provide a satisfactory installation.
A foul weather window having a different contour may reduce adjustments to provide a
satisfactory installation.
(a) Prepare a template to check foul weather window contour. Scribe a 32 inch radius arc approximately 10 inches
in length on suitable material that can be used for a check template or transferred to check template material.
Cut out check template (Refer to Figure 202).
(b) Place the check template to the foul weather window from top to bottom. Verify that the mating surface between

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the template and the window is not resting on a raised area or an indented area. Also, if the contour check is
being performed with the foul weather window installed, verify that the template is not contacting window trim
panel.
NOTE: If the contour check is performed with the foul weather window installed, open foul
weather window and place the check template from top to bottom adjacent to the window
latch assembly.
CAUTION: Exercise care to prevent scratching the window when checking window contour.
(c) For airplanes -0002 thru -0681, order part number 5511275-7 Foul Weather Window as a replacement.
(d) For airplanes -0682 and On, measure the foul weather window contour gap between the template and the
window at the center of the window.
1 If there is no gap, order Part Number 5511275-17 Foul Weather Window as a replacement.
2 If the gap is 0.000 thru 0.059 inch, order Part Number 5511275-201 Foul Weather Window as a
replacement.
3 If the gap is 0.060 inch or greater, order Part Number 5511275-202 Foul Weather Window as a
replacement.
(2) The foul weather window is hinged at the bottom, latched at the top and is sealed when closed.
(a) For alignment of the window, it is recommended that the slotted (adjustable) type hinges be used. The existing
unslotted hinges may be modified when the foul weather window is replaced or the slotted hinges and required
hardware ordered.
B. Modify Existing Foul Weather Window Hardware.
NOTE: To modify the existing unslotted foul weather window hinges, the lower hinge mounting screw
holes are elongated for adjustment of the hinges during installation. The hinge-pin holes of the
upper hinge halves are enlarged to alleviate hinge bind. Window mounting screws are backed up
with dimple washer. Shims are used when required during window-hinge mating. The following
procedure may be utilized for modifying the foul weather window hardware for reinstallation during
window replacement.
(1) Remove the foul weather window. Refer to Foul Weather Window Removal/Installation.
(2) Remove latch from the window. Refer to Latch Assembly Removal/Installation.
(3) Remove hinge assemblies and window trim retainers from the window frame by removing the screws.
(4) Separate the upper and lower hinge halves by removing the hinge pins. Retain hinge pins, if not damaged, for
reinstallation.
(5) Elongate/slot the four lower hinge mounting screw holes as required, without exceeding dimensions illustrated in
Figure 202 (Refer to Figure 202).
(6) Enlarge/drill hinge pin hole in the upper hinge halves to a diameter of 0.098 inch.
CAUTION: Do not enlarge hinge pin holes in the lower hinge halves.
(7) If, during window installation, shims are required to position hinges with window, cut and drill shim stock of thickness
needed to the dimensions illustrated in Figure 202 (Refer to Figure 202).
(8) Replacement hardware required for the modified installation is four screws, Part Number AN 525-832R8, and four
washers, Part Number A3135-017-24A.
NOTE: Utilizing the above modified parts and replacement hardware, install the replacement foul
weather window as outlined in Replace Foul Weather Window. Omit removal steps already
accomplished.
C. Replace Foul Weather Window (Refer to Figure 202 and Figure 203).
NOTE: The following procedures describe the replacement of the foul weather window utilizing the slotted
(adjustable) type hinges. Then installing the adjustable hinges for the first time, the required parts
may be ordered or existing parts modified in accordance with Modifying Existing Foul Weather
Window Hardware.
(1) Remove the foul weather window. Refer to Foul Weather Window Removal/Installation.
(2) Remove latch from the window. Refer to Latch Assembly Removal/Installation.

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(3) Remove hinge assemblies and window trim retainers from the window frame by removing the screws.
(4) Separate the upper and lower hinge halves by removing the hinge pins. If not damaged, retain hinge pins for
reinstallation.
(5) Align retainers and slotted lower hinge halves with nutplates in structure (window ledge). Install four screws, Part
Number AN 525-832R8. Do not tighten screws.
(6) Install handle assembly on the foul weather window. Place the foul weather window to the opening so it is equally
spaced on all sides and temporarily secure the window in the opening with tape and check the latch attachment.
(a) Window closed and latched - maximum latching surface between the handle assembly and the latch hook.
(b) Window unlatched - the window shall not interfere with the latch hook as the window is opened.
(7) Mate the upper and lower hinge halves using a drill bit, stiff wire or section of hinge pin stock that will extend through
the forward and aft hinges (approximately 6.0 inches in length and 0.062 inch in diameter).
NOTE: Verify that the longest upper hinge half is located in the aft hinge position.
(8) Move the upper hinge halves up toward the window and adjust the lower hinges in the slots until the full surface of the
upper hinges contact the window. Tighten lower hinge mounting screws.
(a) The retainers located under the lower hinges are installed to cover the cutouts of the window trim. If the retainers
limit the adjustment of the lower hinges outboard, the outboard edge of the retainer(s) may be trimmed to clear
the shoulder of the window trim.
NOTE: Retainer Part Number 5514651-110 is 0.10 inch longer on each end should retainer
require trimming.
(b) If the upper hinge(s) contacts the window too late (contact made across the top part of the hinge surface), and
the screws are at the slot limits, shims of correct thickness will be required between the upper hinge surface and
the window (Refer to Figure 202).
(c) If the upper hinge(s) contacts the window too soon (contact made across the bottom of the hinge surface), and
the screws are at the slot limits, trim by filing of the upper hinge fay surface until its full surface contacts the
window. Maximum allowable trimming of the hinge surface is 0.08 inch (Refer to Figure 202).
(d) If the upper hinge(s) contact the window too low (hinge surface extended below the bottom edge of the window),
shim(s) will be required under the lower hinge half/retainers to raise the hinge(s) (Refer to Figure 202).
(9) Verify that the upper hinges contact the window flat (full surface) by coating the surface of the upper hinge with
Vaseline or similar material (Refer to Figure 203).
NOTE: Use a thin coat of Vaseline that will not spread out when contact is made with the window.
(a) Press the upper hinges against the window, then release. Check area of window where Vaseline contact was
made to determine if the full surface of the hinges contact the window. If full surface contact was not made, refer
to information on retainers and hinge halves contact (Refer to Figure 203).
(10) Clean Vaseline from the window and upper hinges. Place masking tape on the window where upper hinges make
contact. While holding the upper hinges against the masking tape, mark the outline of the upper hinges on the tape.
(11) Remove the temporary hinge pin (drill bit/wire), upper hinges and the window from the airplane.
(12) Fabricate templates to match the upper hinge surfaces using 0.20 inch aluminum.
(a) Drill two holes in the pieces of aluminum, 0.193 inch diameter and 1.00 inch between hole centers to match
upper hinge screw holes.
(b) Attach aluminum pieces to upper hinge with screws.
(c) Scribe outline of hinge surfaces on aluminum.
(d) Mark (identify) aluminum pieces for position (top, aft, forward).
(e) Remove aluminum and cut templates on scribed marks.
(13) Identify and align templates with applicable hinge position and masking tape outlines on the window. Using the
templates as a guide, drill 0.193 inch diameter hole in the window until point of drill bit is just piercing the opposite
side of the window. Finish drilling hole from the opposite side.
NOTE: It is best to use a dull drill bit with light pressure to drill holes in the window. A sharp bit
penetrates plastic too fast and may chip or crack the window.

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(14) Countersink screw holes 100 degrees x 0.360 inch, +0.010 or -0.010 inch diameter in the window on the outboard
side opposite the hinge.
(15) Clean window and hinges. Refer to Chapter 12, Window - Servicing.
(16) Install latch on window. Refer to Latch Assembly Removal/Installation.
(17) Mate upper and lower hinge halves and install hinge pins. Stake hinge pins in place.
CAUTION: Do not exceed 5 inch pounds of torque.
(18) Align window to upper hinge halves with shim(s), if any required. Secure window to hinges with screws, Part Number
MS24694S4, and washers, Part Number A3135-017-24A. Torque screws to 4 inch-pounds, +1 or -1 inch-pound.
7. Foul Weather Window Shimming
A. Window Shimming Procedure (Airplanes Not Using Liquid Shim) (Refer to Figure 204).
(1) Determine areas where seal shims are required.
(a) Open the foul weather window.
(b) Apply a thin, even layer of Vaseline to the entire circumference of the window seal.
(c) Close and latch the window.
NOTE: Do not use more force than is required to engage the latch. Excessive pressure will result
in false indications.
(d) Mark the structure with a grease pencil in the areas where there is not uniform contact between the seal and the
window.
(e) Open and remove the foul weather window by removing the hinge pins. Refer to Foul Weather Window
Removal/Installation.
(2) Remove the seal using a wide blade putty knife to work the seal free from the window frame.
(3) Place the 5590032-2 (black) or 5590032-3 (white) shim in the location of the seal and, if required, cut out a piece of
the shim to match the areas previously marked. Leave approximately 0.250 inch clearance between each cut end of
the shim and the index markings on the structure.
NOTE: Use 5590032-2 (black) shim and RTV103 adhesive with black seals and 5590032-3 (white) shim
and RTV102 white adhesive with white seals.
(4) Bond the shim(s) in place. Fill and blend at the cut ends of the shim(s). Refer to Chapter 20, Adhesive and Solvent
Bonding - Maintenance Practices (Refer to Figure 204).
NOTE: No more than two (2) thicknesses of 5590032-2 or 5590032-3 shims are to be used in any area.
(5) Allow the RTV102 or RTV103 bonding and filling agent to cure.
(6) Install 5511279-1 (black) seal or RTV 93-072 (white). Refer to Foul Weather Window Seal Removal/Installation.
NOTE: Complete installation and recheck contact before adhesive has time to set.
(7) Install the foul weather window. Refer to Foul Weather Window Removal/Installation.
(8) Recheck the contact between the seal and window according to Foul Weather Window Shimming.
(9) Wipe the Vaseline from the window and seal.
(10) Remove all index marks from the structure.

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Figure 201 : Sheet 1 : Foul Weather Window Handle and Hook Installation

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Figure 202 : Sheet 1 : Foul Weather Window Replacement and Modification

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 Model 550 Maintenance Manual (Rev 34)
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Figure 202 : Sheet 2 : Foul Weather Window Replacement and Modification

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 Model 550 Maintenance Manual (Rev 34)
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Figure 202 : Sheet 3 : Foul Weather Window Replacement and Modification

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 Model 550 Maintenance Manual (Rev 34)
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Figure 202 : Sheet 4 : Foul Weather Window Replacement and Modification

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 Model 550 Maintenance Manual (Rev 34)
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Figure 202 : Sheet 5 : Foul Weather Window Replacement and Modification

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 Model 550 Maintenance Manual (Rev 34)
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Figure 203 : Sheet 1 : Alignment of Foul Weather Window/Hinges

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 Model 550 Maintenance Manual (Rev 34)
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Figure 203 : Sheet 2 : Alignment of Foul Weather Window/Hinges

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 Model 550 Maintenance Manual (Rev 34)
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Figure 204 : Sheet 1 : Foul Weather Window Seal Shim Installation

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 Model 550 Maintenance Manual (Rev 34)
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CABIN WINDOWS - MAINTENANCE PRACTICES

1. General
A. For inspecting, cleaning, and approved repairs on window panes, refer to Windshields/Windows - Approved Repairs.
B. Windows are removed and installed from within cabin. For removal and installation procedures, all cabin windows,
including emergency exit door window, are typical.
2. Tools and Equipment
A. For a list of required tools and equipment, refer to Windows - General.
3. Cabin Windows Removal/Installation
NOTE: Alternate window assembly may be used as a replacement. Window assembly consists of window,
retainer, seal and frost pane as one unit. Complete ship set replacement is recommended upon initial
installation. Refer to Removal/Installation of Alternate Cabin Window Assembly, located in this section.
NOTE: Retain all attaching hardware for reinstallation.
A. Remove Window (Airplanes -0002 thru -0420) (Refer to Figure 201).
(1) Remove headliner. Refer to Chapter 25, Sidewall and Headliner Panels - Maintenance Practices.
(2) Remove window shade and window shade tracks. Refer to Chapter 25, Sidewall and Headliner Panels- Maintenance
Practices.
(3) Remove screws holding the inner window and window shade guard; remove inner window and guard.
(4) Remove nuts, washers, brackets, screws and window assembly.
(5) Clean old sealant from skin and doubler with cork wheel. Refer to Chapter 20, Fuel, Weather, Pressure and High-
Pressure Sealing - Maintenance Practices.
B. Remove Window (Airplanes -0421 and On) (Refer to Figure 201).
(1) Remove inner window by affixing two pieces of good grade masking tape to inner window and pulling inboard until
free from outer window trim, window shade and window trim.
(2) Remove headliner. Refer to Chapter 25, Sidewall and Headliner Panels - Maintenance Practices.
(3) Remove window shade and window shade track. Refer to Chapter 25, Sidewall and Headliner Panels- Maintenance
Practices.
(4) Remove nuts, washers, brackets, screws and window assembly.
(5) Clean old sealant from skin and doubler with cork wheel. Refer to Chapter 20, Fuel, Weather, Pressure and High-
Pressure Sealing - Maintenance Practices.
C. Install Window (Airplanes -0002 thru -0420) (Refer to Figure 201).
(1) Temporarily locate and center window assembly in window opening and drill two pilot holes in retainer. Secure
window in place with temporary fasteners.
NOTE: Retainer is metal portion of window assembly.
(2) Drill holes in window assembly for mounting screws; then, remove window assembly.
NOTE: To avoid a mismatch when installing the window assembly, insure that window assembly is
held securely while drilling mounting holes.
(3) Clean window frame and retainer using Methyl n-Propyl Ketone, and mating surface of window using a 1:1 solution of
Isopropyl Alcohol and water.
(4) Apply Type I, Class B-2 sealant to skin and retainer. Once window assembly is positioned, add additional sealant to
retainer to fill all voids between skin and retainer. Refer to Chapter 20, Fuel, Weather, Pressure and High-
Temperature Sealing - Maintenance Practices.
(5) Install new window assembly, screws, brackets (4), washers and nuts. Finger tighten nuts.
NOTE: All nuts must be installed prior to torquing.
CAUTION: Over torquing will result in damage to skin and seal.
(6) Torque nuts 10 to 12 inch-pounds, beginning at top center and bottom center, alternately working clockwise.
(7) Apply Type I, Class B-2 sealant around outside of retainer and skin. Refer to Chapter 20, Fuel, Weather, Pressure
and High-Temperature Sealing - Maintenance Practices.

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(8) Allow sealant to cure a minimum of 72 hours before pressurizing the airplane.
(9) Perform a cabin leak test on the airplane. Refer to Chapter 21, Cabin Pressure Control - Adjustment/Test.
(10) Install guard, window shade tracks and window shade. Verify window shade operates smoothly. Refer to Chapter 25,
Headliner and Sidewall - Maintenance Practices.
NOTE: Elongate inner window attach holes to ensure window fits flat and does not interfere with
operation of window shade. Elongate hole wherever interference occurs.
(11) Install window shade track and window shade. Refer to Chapter 25,Sidewall and Headliner Panels- Maintenance
Practices.
(12) Install headliner. Refer to Chapter 25, Sidewall and Headliner Panels - Maintenance Practices.
(13) Paint outer surface around window at screw head locations. Refer to Chapter 20, Exterior Finish - Cleaning/Painting.
(14) Remove protective cover and clean window.
D. Install Window (Airplanes -0421 and On) (Refer to Figure 201).
(1) Temporarily locate and center window assembly in window opening and drill two pilot holes in retainer. Secure
window assembly in place with temporary fasteners.
NOTE: Retainer is metal portion of window assembly.
(2) Drill holes in window assembly for mounting screws; then, remove window assembly.
NOTE: To avoid a mismatch when installing the window assembly, ensure that window assembly is
held securely while drilling mounting holes.
(3) Clean window frame and retainer using Methyl n-Propyl Ketone, and mating surface of window assembly using a 1:1
solution of Isopropyl Alcohol and water.
(4) Apply Type 1, Class B-2 sealant to skin and retainer. With window assembly in position, add additional sealant to
retainer to fill all voids between skin and retainer. Refer to Chapter 20, Fuel, Weather, Pressure and High-
Temperature Sealing - Maintenance Practices.
(5) Install new window assembly, screws, brackets, washers and nuts. Finger tighten nuts.
NOTE: All nuts must be installed prior to torquing.
CAUTION: Over torquing will result in damage to skin.
(6) Torque nuts 10 to 12 inch-pounds, beginning at top center and bottom center, alternately working clockwise.
(7) Remove interior protective covering and clean window.
(8) Apply Type 1, Class B-2 sealant around the outside of retainer and skin. Refer to Chapter 20, Fuel, Weather,
Pressure and High-Temperature Sealing - Maintenance Practices.
(9) Allow sealant to cure a minimum of 72 hours before pressurizing the airplane.
(10) Perform a cabin leak test on the airplane. Refer to Chapter 21, Cabin Pressure Control - Adjustment/Test.
(11) Install window shade track, window shade guard and window shade. Refer to Chapter 25, Sidewall and Headliner
Panels- Maintenance Practices.
(12) Maneuver inner window through window trim and window shade. Position to outer window trim, pressing outboard
until inner window snaps securely into outer window trim recess. Remove previously affixed masking tape.
(13) Install headliner. Refer to Chapter 25, Sidewall and Headliner Panels - Maintenance Practices.
(14) Paint outer surface around window at screw head locations. Refer to Chapter 20, Exterior Finish - Cleaning/Painting.
(15) Remove protective cover and clean window.
4. Emergency Exit Door Window Removal/Installation
NOTE: Alternate window assembly may be used as a replacement. Window assembly consists of window,
retainer, seal and frost pane as one unit. Refer to Removal/Installation of Alternate Emergency Exit Door
Window Assembly.
A. Remove Window (Refer to Figure 202).
(1) Remove emergency exit door. Refer to Chapter 52, Emergency Exit Door - Maintenance Practices.
(2) Remove inner handle and pan. Refer to Chapter 52, Emergency Exit Door - Maintenance Practices.
(3) Remove door trim. Refer to Chapter 25, Sidewall and Headliner Panels - Maintenance Practices.

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 Model 550 Maintenance Manual (Rev 34)
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(4) Remove inner window and window trim. Refer to Chapter 25, Sidewall and Headliner Panels - Maintenance
Practices.
(5) Remove upper and lower brackets.
(6) Remove nuts, washers, screws, brackets and window assembly.
(7) Clean old sealant from skin, doubler and retainer with cork wheel. Refer to Chapter 20, Fuel, Weather, Pressure and
High Temperature Sealing - Maintenance Practices.
B. Install Window (Refer to Figure 202).
(1) Temporarily locate and center window assembly in window opening and drill two pilot holes in retainer. Secure
window in place with temporary fasteners.
NOTE: Retainer is metal portion of window assembly.
(2) Drill holes in window assembly for mounting screws; then, remove window assembly.
NOTE: To avoid a mismatch when installing the window assembly, ensure window assembly is held
securely while drilling mounting holes.
(3) Clean window frame using Methyl n-Propyl Ketone, and mating surface of window assembly using a 1:1 solution of
Isopropyl Alcohol and water.
(4) Apply Type I, Class B-2 sealant to skin and retainer. Once window assembly is positioned, add additional sealant to
retainer to fill all voids between skin and retainer. Refer to Chapter 20, Fuel, Weather, Pressure and High
Temperature Sealing - Maintenance Practices.
(5) Install new window assembly, screws, brackets, washers and nuts. Finger tighten nuts.
NOTE: All nuts must be installed prior to torquing.
CAUTION: Over torquing will result in damage to skin and seal.
(6) Torque nuts 10 to 12 inch-pounds, beginning at top and bottom center, alternately torquing clockwise. Refer to Figure
201, Sheet 4, Torque Pattern.
(7) Allow sealant to cure a minimum of 72 hours before pressurizing the airplane.
(8) Perform a cabin leak test on the airplane. Refer to Chapter 21, Cabin Pressure Control - Adjustment/Test.
(9) Install upper and lower brackets.
(10) Install inner window and door trim. Refer to Chapter 25, Sidewall and Headliner Panels- Maintenance Practices.
(11) Install inner handle and pan. Refer to Chapter 52, Emergency Exit Door - Maintenance Practices.
(12) Install emergency exit door. Refer to Chapter 52, Emergency Exit Door - Maintenance Practices.
5. Alternate Cabin Window Assembly Removal/Installation
NOTE: Alternate window assembly consists of window, retainer, seal and frost pane as one unit. Complete
ship set replacement recommended upon initial installation.
NOTE: Retain all attaching hardware for reinstallation.
A. Remove Alternate Cabin Window Assembly (Refer to Figure 201).
(1) Airplanes -0002 thru -0420, remove window assembly.
(a) Remove headliner. Refer to Chapter 25, Passenger Compartment Trim and Paneling - Maintenance Practices.
(b) Remove window trim, window shade, window shade tracks and guard. Refer to Chapter 25, Headliner and
Sidewall - Maintenance Practices.
(c) Remove screws, inner window, outer window trim and brackets. Refer to Chapter 25, Headliner and Sidewall -
Maintenance Practices.
(d) Remove nuts, washers, brackets, Hi-Lok pins and window assembly.
(e) Clean old sealant from skin and doubler using a cork wheel. Refer to Chapter 20, Fuel, Weather, Pressure and
High Pressure Sealing - Maintenance Practices.
(2) Airplanes -0421 and On, remove window assembly.
(a) Remove inner window by affixing two pieces of good grade masking tape to inner window, pulling inboard until
free from outer window trim, window shade and window trim.
(b) Remove headliner. Refer to Chapter 25, Passenger Compartment Trim and Paneling - Maintenance Practices.

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(c) Remove window trim, window shade, window shade tracks and guard. Refer to Chapter 25, Headliner and
Sidewall - Maintenance Practices.
(d) Remove screws, outer window trim and brackets.
(e) Remove nuts, washers, brackets, Hi-Lok pins and window assembly.
(f) Clean old sealant from skin and doubler using a cork wheel. Refer to Chapter 20, Fuel, Weather, Pressure and
High Pressure Sealing - Maintenance Practices.
B. Install Alternate Cabin Window Assembly (Refer to Figure 201).
(1) Working from inside airplane, temporarily position window assembly in window frame with vent hole down and
forward and aft pilot holes aligned with existing holes in window frame. Secure using temporary fasteners.
(2) Match drill remaining holes from window frame thru window assembly retainer, inserting temporary fasteners
throughout procedure.
NOTE: Installation of temporary fasteners during drilling procedure will aid in maintaining window
assembly alignment.
(3) Remove two temporary fasteners from forward and aft pilot holes and drill holes to match window frame.
(4) Remove temporary fasteners and window assembly.
(5) Deburr holes and ensure window frame is free of debris.
(6) Clean window frame and retainer using Methyl n-Propyl Ketone, and mating surface of window assembly using a 1:1
solution of Isopropyl Alcohol and water.
(7) Remove and discard backing from seal, center seal around interior opening of window frame, and firmly press entire
periphery of seal to airplane.
(8) Locate two holes, one each on forward and aft side of window frame common to retainer, and, using an awl, gently
pierce seal to match holes.
(9) Position window assembly to window frame, with vent hole down, and secure using temporary fasteners.
(10) Pierce seal at remaining hole locations, inserting temporary fasteners throughout the procedure.
(11) One at a time, remove temporary fasteners, and install Hi-Lok pins, wet with Type 1, Class A sealant, brackets,
washers and nuts. Finger tighten nuts. Refer to Chapter 20, Fuel, Weather, Pressure and High Pressure Sealing -
Maintenance Practices.
NOTE: All nuts must be installed prior to torquing.
CAUTION: Over torquing will result in damage to skin and seal.
(12) Torque nuts 20 inch-pounds, +2 or -2 inch-pounds, in displayed pattern. Refer to Figure 201, Sheet 4, Torque Pattern.
(13) Remove protective cover from interior side of window assembly and clean window.
(14) Allow sealant to cure a minimum of 72 hours before pressurizing the airplane.
(15) Perform a cabin leak test on the airplane. Refer to Chapter 21, Cabin Pressure Control - Adjustment/Test.
(16) Airplanes -0002 thru -0420, install window assembly.
(a) Place inner window and guard in position and insert screws in inner window guard.
NOTE: To ensure proper clearance and hole alignment, it may be necessary to elongate inner
window holes. Because inner window is not a structural component, there is no limit to
the number or location of elongated holes if the vision area is not affected.
(b) Install upper and lower brackets, outer window trim, inner window, curtain tracks, and curtain shade using
previously retained hardware. Verify curtain operates smoothly. Refer to Chapter 25, Headliner and Sidewall -
Maintenance Practices.
(c) Install headliner. Refer to Chapter 25, Passenger Compartment Trim and Paneling - Maintenance Practices.
(17) Airplanes -0421 and On, install window (Refer to Figure 201).
(a) Install upper and lower brackets, outer window trim, curtain tracks, and window shade using previously retained
hardware. Verify curtain operates smoothly. Refer to Chapter 25, Headliner and Sidewall - Maintenance
Practices.
(b) Maneuver inner window through window shade assembly, position to outer window and press firmly until inner
window snaps into grooved recess of outer window. Remove previously affixed masking tape.

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 Model 550 Maintenance Manual (Rev 34)
56-20-01 (Rev 30)

(18) Fillet seal, using Type 1, Class B sealant, around outside of retainer and skin. Refer to Chapter 20, Fuel, Weather,
Pressure and High Temperature Sealing - Maintenance Practices.
(19) Allow sealant to cure a minimum of 72 hours before pressurizing the airplane.
(20) Perform a cabin leak test on the airplane. Refer to Chapter 21, Cabin Pressure Control - Adjustment/Test.
(21) Paint exterior surface around window at screw head locations. Refer to Chapter 20, Exterior Finish -
Cleaning/Painting.
(22) Remove exterior protective covering and clean window.
6. Alternate Emergency Exit Door Window Assembly Removal/Installation
NOTE: Alternate window assembly consists of window, retainer, seal and frost pane as one unit.
A. Remove Alternate Emergency Exit Door Window Assembly (Refer to Figure 202).
(1) Remove emergency exit door. Refer to Chapter 52, Emergency Exit Door - Maintenance Practices.
(2) Remove inner handle and pan. Refer to Chapter 52, Emergency Exit Door - Maintenance Practices.
(3) Remove door trim. Refer to Chapter 25, Sidewall and Headliner Panels - Maintenance Practices.
(4) Remove inner window and window trim. Refer to Chapter 25, Sidewall and Headliner Panels - Maintenance
Practices.
(5) Remove upper and lower brackets.
(6) Remove nuts, washers, screws, brackets and window assembly.
(7) Clean old sealant from skin, doubler and retainer with cork wheel. Refer to Chapter 20, Fuel, Weather, Pressure and
High Temperature Sealing - Maintenance Practices.
B. Install Alternate Emergency Exit Door Window Assembly (Refer to Figure 202).
(1) Working from inside airplane, temporarily position window assembly in window frame with vent hole down and
forward and aft pilot holes aligned with existing holes in window frame. Secure using temporary fasteners.
(2) Match drill remaining holes from window frame thru window assembly retainer, inserting temporary fasteners
throughout procedure.
NOTE: Installation of temporary fasteners during drilling procedure will aid in maintaining window
assembly alignment.
(3) Remove two temporary fasteners from forward and aft pilot holes and drill holes to match window frame.
(4) Remove temporary fasteners and window assembly.
(5) Deburr holes and ensure window frame is free of debris.
(6) Clean window frame and retainer using Methyl n-Propyl Ketone, and mating surface of window assembly using a 1:1
solution of Isopropyl Alcohol and water.
(7) Remove and discard backing from seal, center seal around interior opening of window frame, and firmly press entire
periphery of seal to airplane.
(8) Locate two holes, one each on forward and aft side of window frame common to retainer, and, using an awl, gently
pierce seal to match holes.
(9) Position window assembly to window frame, with vent hole down, and secure using temporary fasteners.
(10) Pierce seal at remaining hole locations, inserting temporary fasteners throughout the procedure.
(11) One at a time, remove temporary fasteners, and install Hi-Lok pins, wet with Type 1, Class A sealant, brackets,
washers and nuts. Finger tighten nuts. Refer to Chapter 20, Fuel, Weather, Pressure and High Pressure Sealing -
Maintenance Practices.
NOTE: All nuts must be installed prior to torquing.
CAUTION: Over torquing will result in damage to skin and seal.
(12) Torque nuts 20 inch-pounds, +2 or -2 inch-pounds, in displayed pattern. Refer to Figure 201, Sheet 4, Torque Pattern.
(13) Remove protective cover from interior side of window assembly and clean window.
(14) Allow sealant to cure a minimum of 72 hours before pressurizing the airplane.
(15) Perform a cabin leak test on the airplane. Refer to Chapter 21, Cabin Pressure Control - Adjustment/Test.
(16) Install upper and lower brackets.

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 Model 550 Maintenance Manual (Rev 34)
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(17) Install inner window and door trim. Refer to Chapter 25, Sidewall and Headliner Panels - Maintenance Practices.
(18) Install inner handle and pan. Refer to Chapter 52, Emergency Exit Door - Maintenance Practices.
(19) Install emergency exit door. Refer to Chapter 52, Emergency Exit Door - Maintenance Practices.
(20) Fillet seal, using Type 1, Class B sealant, around outside of retainer and skin. Refer to Chapter 20, Fuel, Weather,
Pressure and High Temperature Sealing - Maintenance Practices.
(21) Paint exterior surface around window at Hi-Lok pin locations. Refer to Chapter 20, Exterior Finish -
Cleaning/Painting.
7. Inspection/Check
A. Cabin Windows.
NOTE: Cabin window inspection includes the passenger/crew entrance door and the emergency exit
door.
(1) Visually inspect for loose fasteners. Chipped, cracked or loose paint around the fasteners is cause for additional
fastener attention.
(2) Visually check the cabin windows for cracks, scratches and gouges. If any irregularities or deformities occur, refer to
Chapter 56, Windshields/Windows - Approved Repairs.
8. Window Storage
A. Windows shall be stored in a cool dry room away from heating coils, radiators, hot water pipes and solvent fumes, which
may exist near paint storage areas.
B. Windows must be stored with adequate supports to prevent warpage.

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 Model 550 Maintenance Manual (Rev 34)
56-20-01 (Rev 30)

Figure 201 : Sheet 1 : Cabin Window Installation

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 Model 550 Maintenance Manual (Rev 34)
56-20-01 (Rev 30)

Figure 201 : Sheet 2 : Cabin Window Installation

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 Model 550 Maintenance Manual (Rev 34)
56-20-01 (Rev 30)

Figure 201 : Sheet 3 : Cabin Window Installation

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 Model 550 Maintenance Manual (Rev 34)
56-20-01 (Rev 30)

Figure 201 : Sheet 4 : Cabin Window Installation

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 Model 550 Maintenance Manual (Rev 34)
56-20-01 (Rev 30)

Figure 202 : Sheet 1 : Emergency Exit Door Window Installation

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 Model 550 Maintenance Manual (Rev 34)
56-20-01 (Rev 30)

Figure 202 : Sheet 2 : Emergency Exit Door Window Installation

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 Model 550 Maintenance Manual (Rev 34)
56-30-01 (Rev 30)

PASSENGER/CREW ENTRANCE DOOR WINDOW - MAINTENANCE PRACTICES

1. General
A. For inspecting, cleaning, and approved repairs on window panes, refer to Windshields/Windows - Approved Repairs.
B. Window is removed and installed from within cabin, except when door is removed from airplane.
C. Removal/Installation procedures for optional wide door window are same as standard passenger/crew entrance door
window, except as noted.
2. Passenger/Crew Entrance Door Window Removal/Installation
NOTE: Alternate window assembly may be used as a replacement. Window assembly consists of window,
retainer, seal and frost pane as one unit. Refer to Removal/Installation of Alternate Passenger/Crew
Entrance Door Window, located in this section.
NOTE: Removal/Installation procedures for the standard door window and optional wide door window are
typical, except as noted.
NOTE: Retain all attaching hardware for reinstallation.
A. Remove Window (Refer to Figure 201).
(1) Airplanes with standard door, remove bearing plates, assist strap lug, safety pin chain and receptacles from upper
trim. Refer to Chapter 52, Passenger/Crew Entry Door (Standard) - Maintenance Practices.
(2) Airplanes with optional wide door, disconnect gas spring from upper door. Refer to Chapter 52, Cargo Entrance
Door (Optional) - Maintenance Practices.
(3) Remove inner control handle from door. Refer to Chapter 52, Handles and Linkage (Standard) - Maintenance
Practices and Cargo Entrance Door (Optional) - Maintenance Practices.
(4) Remove fasteners securing upper trim to door. Remove upper trim. Refer to Chapter 25, Cabin Door Trim -
Maintenance Practices.
(5) Remove two angles by drilling rivets out of side braces.
(6) Remove nuts, washers, screws, angle and shim.
(7) Remove nuts, washers, screws, brackets and window assembly.
(8) Clean old sealant from skin, doubler and retainer with cork wheel. Refer to Chapter 20, Fuel, Weather, Pressure and
High-Pressure Sealing - Maintenance Practices.
B. Install Window.
(1) Temporarily locate and center window assembly in window opening and drill two pilot holes in retainer. Secure
window in place with temporary fasteners.
NOTE: Retainer is metal portion of window assembly.
(2) Drill holes in window assembly for mounting screws; then, remove window assembly.
NOTE: To avoid a mismatch when installing the window assembly, ensure that window assembly is
held securely while drilling mounting holes.
(3) Clean window frame and retainer using Methyl n-Propyl Ketone, and mating surface of window using a 1:1 solution of
Isopropyl Alcohol and water.
(4) Apply Type I, Class B-2 sealant to skin and retainer. Once window assembly is positioned, add additional sealant to
retainer to fill all voids between skin and retainer. Refer to Chapter 20, Fuel, Weather, Pressure and High-
Temperature Sealing - Maintenance Practices.
(5) Install new window assembly, screws, brackets, washers and nuts. Finger tighten nuts.
NOTE: All nuts must be installed prior to torquing.
CAUTION: Over torquing will result in damage to skin.
(6) Torque nuts 10 to 12 inch-pounds, beginning at top center and bottom center, alternately working clockwise.
(7) Apply Type I, Class B-2 sealant around outside of retainer and skin. Refer to Chapter 20, Fuel, Weather, Pressure
and High-Temperature Sealing - Maintenance Practices.
(8) Allow sealant to cure a minimum of 72 hours before pressurizing the airplane.
(9) Perform a cabin leak test on the airplane. Refer to Chapter 21, Cabin Pressure Control - Adjustment/Test.

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 Model 550 Maintenance Manual (Rev 34)
56-30-01 (Rev 30)

(10) Place shim and angle in position; install screws, washers and nuts.
(11) Place angles in position; rivet in place.
(12) Install inner handle assembly on door. Refer to Chapter 52, Door Handles and Linkage (Standard) - Maintenance
Practices and Chapter 52 Cargo Entrance Door (Optional) - Maintenance Practices.
(13) Airplanes with standard door, install bearing plates, assist strap lug, safety pin chain and receptacle on upper trim.
Refer to Chapter 52, Passenger/Crew Entry Door (Standard) - Maintenance Practices.
(14) Airplanes with optional wide door, connect gas spring to upper door. Refer to Chapter 52, Cargo Entrance Door
(Optional) - Maintenance Practices.
(15) Paint outer surface around window at screw head locations. Refer to Chapter 20, Exterior Finish - Cleaning/Painting.
(16) Remove protective cover and clean window.
3. Alternate Passenger/Crew Door Window Assembly Removal/Installation
NOTE: Alternate window assembly consists of window, retainer, seal and frost pane as one unit.
NOTE: Removal/Installation procedures for the standard door window and optional wide door window are
typical, except as noted.
NOTE: Retain all attaching hardware for reinstallation.
A. Remove Window (Refer to Figure 201).
(1) Airplanes with standard door, remove bearing plates, assist strap lug, safety pin chain and receptacles from upper
trim. Refer to Chapter 52, Passenger/Crew Entry Door (Standard) - Maintenance Practices.
(2) Airplanes with optional wide door, disconnect gas spring from upper door. Refer to Chapter 52, Cargo Entrance
Door (Optional) - Maintenance Practices.
(3) Remove inner control handle from door. Refer to Chapter 52, Handles and Linkage (Standard) - Maintenance
Practices and Cargo Entrance Door (Optional) - Maintenance Practices.
(4) Remove fasteners securing upper trim to door. Remove upper trim. Refer to Chapter 25, Cabin Door Trim -
Maintenance Practices.
(5) Remove two angles by drilling rivets out of side braces.
(6) Remove nuts, washers, screws, angle and shim.
(7) Remove nuts, washers, screws, brackets and window assembly.
(8) Clean old sealant from skin, doubler and retainer with cork wheel. Refer to Chapter 20, Fuel, Weather, Pressure and
High-Pressure Sealing - Maintenance Practices.
B. Install Passenger/Crew Door Window Assembly (Refer to Figure 201).
(1) Working from inside airplane, temporarily position window assembly in window frame with vent hole down and
forward and aft pilot holes aligned with existing holes in window frame. Secure using temporary fasteners.
(2) Match drill remaining holes from window frame, thru window assembly retainer, inserting temporary fasteners
throughout procedure
NOTE: Installation of temporary fasteners during drilling procedure will aid in maintaining window
assembly alignment.
(3) Remove two temporary fasteners from forward and aft pilot holes and drill holes to match window frame.
(4) Remove temporary fasteners and window assembly.
(5) Deburr holes and ensure window frame is free of debris.
(6) Clean window frame and retainer using Methyl n-Propyl Ketone, and mating surface of window assembly using a 1:1
solution of Isopropyl Alcohol and water.
(7) Remove and discard backing from seal, center seal around interior opening of window frame, and firmly press entire
periphery of seal to airplane.
(8) Locate two holes, one each on forward and aft side of window frame common to retainer, and, using an awl, gently
pierce seal to match holes.
(9) Position window assembly, with vent hole down, to seal and window frame, and secure using temporary fasteners in
forward and aft holes in window frame common to retainer.

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 Model 550 Maintenance Manual (Rev 34)
56-30-01 (Rev 30)

(10) Pierce seal at remaining hole locations, inserting temporary fasteners throughout the procedure.
(11) One at a time, remove temporary fasteners, and install Hi-Lok pins, wet with Type 1, Class A sealant, brackets,
washers and nuts. Finger tighten nuts. Refer to Chapter 20, Fuel, Weather, Pressure and High Pressure Sealing -
Maintenance Practices.
NOTE: All nuts must be installed prior to torquing.
CAUTION: Over torquing will result in damage to skin and seal.
(12) Torque nuts 20 inch-pounds, +2 or -2 inch-pounds, in displayed pattern. Refer to Figure 201.
(13) Allow sealant to cure a minimum of 72 hours before pressurizing the airplane.
(14) Perform a cabin leak test on the airplane. Refer to Chapter 21, Cabin Pressure Control - Adjustment/Test.
(15) Remove interior protective cover and clean window assembly.
(16) Install shim and angle using screws, washers and nuts.
(17) Install angles to side braces using rivets.
(18) Install upper trim on door and secure with previously removed fasteners.
(19) Install inner handle assembly on door. Refer to Chapter 52, Handles and Linkage (Standard) - Maintenance Practices
also Cargo Entrance Door (Optional) - Maintenance Practices.
(20) Airplanes with optional wide door, connect gas spring to upper door. Refer to Chapter 52, Cargo Entrance Door
(Optional) - Maintenance Practices
(21) Airplanes with standard door, install bearing plates, assist strap lug, safety pin chain and receptacle on upper trim,
using previously removed hardware. Refer to Chapter 52, Passenger/Crew Entry Door - Maintenance Practices.
(22) Fillet seal, using Type 1, Class B sealant, around outside of retainer and skin. Refer to Chapter 20, Fuel, Weather,
Pressure and High Temperature Sealing - Maintenance Practices.
(23) Paint surface around window at Hi-Lok pin locations. Refer to Chapter 20, Exterior Finish - Cleaning/Painting.
(24) Remove exterior protective covering and clean window.
4. Inspection/Check
A. Cabin Windows.
NOTE: Cabin window inspection includes the passenger/crew entrance door and the emergency exit
door.
(1) Visually inspect for loose fasteners. Chipped, cracked or loose paint around the fasteners is cause for additional
fastener attention.
(2) Visually check the cabin windows for cracks, scratches and gouges. If any irregularities or deformities occur, refer to
Chapter 56, Windshields/Windows - Approved Repairs.
5. Window Storage
A. Windows shall be stored in a cool dry room away from heating coils, radiators, hot water pipes and solvent fumes, which
may exist near paint storage areas.
B. Windows must be stored with adequate supports to prevent warpage.

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 Model 550 Maintenance Manual (Rev 34)
56-30-01 (Rev 30)

Figure 201 : Sheet 1 : Passenger/Crew Entrance Door Window Installation

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 Model 550 Maintenance Manual (Rev 34)
56-30-01 (Rev 30)

Figure 201 : Sheet 2 : Passenger/Crew Entrance Door Window Installation

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 Model 550 Maintenance Manual (Rev 34)
56-30-01 (Rev 30)

Figure 201 : Sheet 3 : Passenger/Crew Entrance Door Window Installation

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 Model 550 Maintenance Manual (Rev 34)
56-30-01 (Rev 30)

Figure 201 : Sheet 4 : Passenger/Crew Entrance Door Window Installation

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