Date: 201407
Local time of day: 1801-2400
Location: ZZZ.Airport, US
Flight conditions: VMC
Light: Daylight
Aircraft: Caravan 208B
Operator: Air Taxi
Operating under: Part 135
Flight plan: IFR
Flight phase: Initial Approach
Airspace: Class B ZZZ
ATC / advisory: TRACON ZZZ
Aircraft component: Ice/Rain Protection System
Component problem: Design
Reporter organization: Air Taxi
Reporter function: Pilot Flying; Captain
Reporter qualification: Flight Crew Air Transport Pilot (ATP)
Human factors: Physiological - Other; Situational Awareness; Time Pressure
Anomaly: Aircraft Equipment Problem Less Severe; Flight Deck / Cabin / Aircraft Event Illness / Injury; Flight Deck / Cabin / Aircraft Event Smoke / Fire / Fumes / Odor
Detector: Person Flight Crew
When detected: In-flight
Result: General Physical Injury / Incapacitation
Contributing factors: Procedure; Human Factors; Environment - Non Weather Related; Aircraft
Primary problem: Aircraft

Narrative: I was complying with my airline's requirement to test the TKS System. Previous experience has taught that using it at the end of the flight reduces my exposure to the fumes sucked into the aircraft ventilation system. I turned the system ON for a timed 2 minutes prior to landing. I experienced several of the symptoms listed in the Kilfrost TKS 406B Safety Data Sheet. There was an immediate respiratory irritation which felt like a mild burning in my chest or upper respiratory tract and which continued while the system was operating. The system was turned OFF after 2 minutes of use. I landed within 3 minutes and then experienced additional symptoms to include mild headache and nausea; and dizziness that left me feeling unable to drive home for about 20 minutes. The nausea; headache and general fatigue continued for about 90 minutes. The only solution I have found acceptable is to don the oxygen mask set to 100% prior to starting the TKS flow and leaving the mask on for the duration of the flight.

Callback: The reporter is a former air carrier pilot; has been flying the C208B for several years and had three TKS episodes. In each event the physical effects have been very similar and persist two to three hours. The reporter personally believes pilots are reluctant to discuss their own experiences for fear of losing their job. Because the reporter is concerned for personal health; speaking out can also protect younger pilots from the long term MSDS listed hazards. Reporter has personally flown only one aircraft which had noticeable TKS fluid residue on cockpit surfaces. After flying that aircraft mild; but noticeable after effects were noted. Reporter feels that a pilot can only safely fly this aircraft with TKS ON and using 100% oxygen. When conditions warrant; reporter intends to begin using oxygen when the system is active and remain on oxygen until landing. The prop slinger fluid is also designed to deice the cargo box front. That fluid slinging also exposes the engine intake and windshield. The cockpit can then be exposed through engine heated air or fluid leaking around the windshield.



Synopsis: A C208B pilot delayed the TKS System two minute functional checks until on approach and experienced immediate respiratory irritation. After landing additional symptoms included mild headache; nausea; and dizziness.