CESSNA COMPANY AIRCRAFT DIVISION WICHITA, KANSAS 67277

TKS W/ FAIRING ICA SUPPLEMENT

MODEL NO: 208B

SUPPLEMENT NO: ICA-208-30-00003

SUPPLEMENT 7/8/2010 DATE:

PREPARED BY: T.F.

CHECKED BY: G.A.S.

APPROVED BY: G.B.

APPROVED BY: N.L.C.

ICA Supplement.dot (Rev. 09/26/2008) Form 2261 Cessna Aircraft Company Page i Aircraft Division TKS W/ FAIRING ICA SUPPLEMENT Wichita, Kansas 67277 Supplement No.: ICA-208-30–00003 Rev B

REVISIONS

Rev Date By Approved By - 07/08/2010 See Title Sheet See Title Sheet ECR: 059461 Section Description ALL Initial Release Rev Date By Approved By A 01/02/2010 S.P.W. G.M.B. L.N.C. ECR: 059461 Section Description Contents Updated to reflect changes made by Rev A; Figures Added Figures 2 thru 11; 2.1 Was: Beginning Eff. 002000 3.1 Was: Deviations to the overall aircraft, compared with the 208 TKS W/ Fairing, are limited to the inclusion of VG’s and removal of the 18° travel change. 3.3.4 Was: The Wing VG installation is identical to the Wing VG installation used for the 208B TKS W/ Cargo Pod configuration.; 3.3.5 Was: Elevator travel is NOT modified per the 208 W/ Fairing System requirements. The elevator travel maintains the typical 208B specification of 25° +/- 2°.; 3.3.6 Added section 3.3.6 Boundary Energizers; 3.5.2 Deleted: 23. Install the aft fairing. Refer to Install the Aft Fairing in this section.; 3.8.1 Was: The Wing VG removal is identical to the Wing VG removal used for the 208B TKS W/ Cargo Pod configuration.;

ICA Supplement.dot (Rev. 09/26/2008) Form 2261 Cessna Aircraft Company Page ii Aircraft Division TKS W/ FAIRING ICA SUPPLEMENT Wichita, Kansas 67277 Supplement No.: ICA-208-30–00003 Rev B

3.8.2 Was: The Wing VG installation is identical to the Wing VG installation used for the 208B TKS W/ Cargo Pod configuration.; 3.9 Added section 3.9 Elevator Travel; 3.10 Added section 3.10 Boundary Energizers; Rev Date By Approved By B 12/03/2010 S.P.W. Section Description 3.3.5 Now: reduced Was: set

ICA Supplement.dot (Rev. 09/26/2008) Form 2261 Cessna Aircraft Company Page iii Aircraft Division TKS W/ FAIRING ICA SUPPLEMENT Wichita, Kansas 67277 Supplement No.: ICA-208-30–00003 Rev B

CONTENTS

Section / Title Page

REVISIONS ...... i CONTENTS ...... iii TABLES ...... v Figures ...... v 1. INTRODUCTION HEADING ...... 1 1.1. Purpose ...... 1

2. APPLICABILITY ...... 2 2.1. Effectivity ...... 2 2.2. Complete ICA Documents ...... 2

3. DESCRIPTION AND OPERATION ...... 3 3.1. Description ...... 3 3.2. Operation ...... 3 3.3. System Component(s) ...... 3

3.3.1. External FIller Port ...... 3

3.3.2. Fluid Filler Tube ...... 3

3.3.3. Vent Tube ...... 3

3.3.4. Wing VG’s ...... 4

3.3.5. Elevator Travel ...... 4

3.3.6. Boundary Energizers ...... 4 3.4. Aircraft Wiring ...... 4

REMOVAL AND INSTALLATION ...... 4 3.5. Filler Tube ...... 4

3.5.1. Remove the Filler tube...... 4

3.5.2. Install the Filler Tube...... 5 3.6. Filler Port Assembly ...... 7

3.6.1. Remove the Filler Port Assembly...... 7

3.6.2. Install the Filler Port Assembly...... 8 3.7. Vent Tube ...... 8

3.7.1. Remove the Vent Tube...... 8

ICA Supplement.dot (Rev. 09/26/2008) Form 2261 Cessna Aircraft Company Page iv Aircraft Division TKS W/ FAIRING ICA SUPPLEMENT Wichita, Kansas 67277 Supplement No.: ICA-208-30–00003 Rev B

3.7.2. Install THE Vent Tube...... 8 3.8. Wing VG’s ...... 8

3.8.1. Remove the Wing VG’s ...... 8

3.8.2. Install the Wing VG’s ...... 12 3.9. Elevator Travel ...... 17

3.9.1. ELEVATOR - MAINTENANCE PRACTICES ...... 17

3.9.2. Elevator system rigging ...... 17 3.10. Boundary Energizers ...... 17

3.10.1. landing and taxi recongition lights – maintenance practices ...... 17

3.10.2. Waxing and polishing Windshield and windows ...... 17

4. MAINTENANCE AND SPECIAL TOOLS ...... 18 4.1. Maintenance – Line Replaceable Units (LRU) ...... 18 4.2. System Wiring ...... 18

5. TESTING, RETURN TO SERVICE AND TROUBLESHOOTING ...... 18 5.1. Adjustment/Test ...... 18 5.2. Inspection/Check ...... 18 5.3. Troubleshooting ...... 18

6. AIRWORTHINESS LIMITATIONS ...... 18 6.1. Limitations and Replacement Intervals ...... 18

6.1.1. Mandatory replacement times...... 19

6.1.2. Mandatory inspection intervals...... 19

6.1.3. Mandatory inspection procedures...... 19

ICA Supplement.dot (Rev. 09/26/2008) Form 2261 Cessna Aircraft Company Page v Aircraft Division TKS W/ FAIRING ICA SUPPLEMENT Wichita, Kansas 67277 Supplement No.: ICA-208-30–00003 Rev B

TABLES

Table / Title Page Table 1 Installation ICA Effectivity ...... 2

FIGURES

Figure / Title Page Figure 1: Convolute Tubing Location on Filler Tube ...... 6 Figure 2 Vortex Generator ...... 9 Figure 3 View A-A ...... 9 Figure 4 Detail A ...... 10 Figure 5 Detail B ...... 11 Figure 6 Detail C ...... 11 Figure 7 Vortex Generator ...... 13 Figure 8 View A-A ...... 13 Figure 9 Detail A ...... 14 Figure 10 Detail B ...... 15 Figure 11 Detail C ...... 15

ICA Supplement.dot (Rev. 09/26/2008) Form 2261 Cessna Aircraft Company Page 1 Aircraft Division TKS W/ FAIRING ICA SUPPLEMENT Wichita, Kansas 67277 Supplement No.: ICA-208-30-00003 Rev A

1. INTRODUCTION HEADING 1.1. Purpose

1.1.1. The purpose of this Instructions for Continued Airworthiness Supplement is to provide the maintenance technician with the information necessary to ensure the correct functionality and performance of the TKS W/ Fairing system on the Cessna Model 208B. 1.1.2. This supplemental document is designed to satisfy the required 14 CFR 23.1529 “Instructions for Continued Airworthiness” requirements associated with this installation. This document is a supplement to the Model 208B Maintenance Manual and may or may not be incorporated. 1.1.3. If this information is incorporated into the Model 208B Maintenance Manual, the maintenance manual shall take precedence over this supplemental document. Refer to the application ATA chapter and section of the respective Maintenance Manual for the status of all ICA Supplements applicable to your model. NOTE: This document must be placed with the aircraft operator’s Technical Library CD- ROM or Maintenance Manual and incorporated into the operator’s scheduled maintenance program.

ICA Supplement.dot (Rev. 09/26/2008) Form 2261 Cessna Aircraft Company Page 2 Aircraft Division TKS W/ FAIRING ICA SUPPLEMENT Wichita, Kansas 67277 Supplement No.: ICA-208-30-00003 Rev A

2. APPLICABILITY 2.1. Effectivity

This Instructions for Continued Airworthiness (ICA) supplement is effective for the following aircraft model(s) and serialization where the TKS W/ Fairing System is installed:

Beginning Ending Model Effectivity Effectivity 208B 002256 and ON

Table 1 Installation ICA Effectivity

2.2. Complete ICA Documents

2.2.1. The following document(s), in conjunction with this supplement, constitute the Instructions for Continued Airworthiness for the TKS W/ FAIRING system. All items must be available to the operator at initial delivery. • Model 208B Wiring Diagram Manual • Model 208B Wiring Diagram Manual CD-ROM. • Model 208B Maintenance Manual • Model 208B Illustrated Parts Catalog

Note: Except as noted in this document, maintenance procedures for the Model 208 TKS W/ Fairing system are applicable to the Model 208B TKS W/ Fairing system.

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3. DESCRIPTION AND OPERATION 3.1. Description

The 208B TKS W/ Fairing installation is similar to the 208 TKS W/ Fairing installation. The porous panels, propeller slinger, spraybar, wing and tube routings, tank, and fairing installations are all identical to the 208 configuration. TKS System deviations from the 208 configuration are limited to the filler port, filler tube, and vent tube installations. In all three cases, the installations are similar to the 208 configuration, but require differences due to the longer on the 208B. Deviations to the overall aircraft, compared with the 208 TKS W/ Fairing, are limited to the inclusion of Wing VG’s, landing light boundary energizers, longer span gurney and elevator up travel change to 22 degrees from 18 degrees.

3.2. Operation

System operation is the same as the 208 TKS W/ Fairing configuration.

3.3. System Component(s)

System Components are the same as the 208 TKS W/ Fairing configuration, except as noted below. 3.3.1. EXTERNAL FILLER PORT

The external filler port for the tank is on the left airplane fuselage at FS 196.18, WL 94.73. 3.3.2. FLUID FILLER TUBE

The Fluid Filler Tube routing is revised to accommodate the longer run between the filler port and tank attachment and changes in the fuselage between the Model 208 and Model 208B. Additional chafing protection for the Fluid Filler Tube is also provided. The material for the filler tube is the same as on the 208 W/ Fairing System. The convolute tubing used for additional chafing protection is P/N ZCT-TS-080. 3.3.3. VENT TUBE

The Fluid Filler Tube routing is revised to accommodate the longer run between the filler port and tank attachment and changes in the fuselage between the Model 208 and Model 208B. The material for the vent tube is the same as on the 208 W/ Fairing System.

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3.3.4. WING VG’S

The Model 208B airplane with the TKS Fairing anti-ice system installed, uses vortex generators (VG's) to improve air flow on control surfaces. There are 37 VG’s equally spaced at 6 inches on the surface of each wing, 24 VG’s from the fairing to the landing light and 13 after the landing light. There are no VG’s installed on or behind the . On aircraft equipped with radar, the three VG’s that would be located directly behind the radar fairing are removed. 3.3.5. ELEVATOR TRAVEL

The elevator control system is the same as current 208B Non TKS and TKS aircraft except for the Model 208B airplanes with the TKS Fairing anti-ice system installed have the elevator up rigging reduced to 22 to 23 degrees. 3.3.6. BOUNDARY ENERGIZERS

The Model 208B airplane with the TKS Fairing anti-ice system installed uses landing light cover assemblies with boundary energizers installed on the lens. They are the same cover assemblies as Model 208 and 208B Non TKS and TKS aircraft except the lenses contain two boundary energizers.

3.4. Aircraft Wiring

Except for wire length, wiring is the same as the 208 W/ Fairing System.

REMOVAL AND INSTALLATION NOTE: If applicable, make sure that the aircraft is configured for maintenance as defined by the associated system in the maintenance manual or in this document, including the removal of electrical power, avionics power, hydraulic power, etc., prior to removal or installation of aircraft components.

If maintenance configuration is not available in the maintenance manual, add procedures prior to the removal and installation procedures.

3.5. Filler Tube

3.5.1. Remove the FILLER TUBE.

1. Remove external electrical power from the airplane.

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2. Set the BATTERY switch (SC005) on the circuit breaker switch panel, to the OFF position. 3. Disengage the circuit breakers on the left circuit breaker panel that follow: a. PRIMARY ANTI-ICE b. W/S ANTI-ICE c. BACKUP ANTI-ICE. 4. Remove the floor coverings necessary to get access to the filler tube. Refer to Floor Covering/Column Cover - Maintenance Practices. 5. Remove floor panels (251AL), (251BL), (251EL), (251FL), (251HL), (251JL), and (232BC), to get access to the filler tube. Refer to Chapter 6, Access Plates and Panels Identification - Description and Operation. 6. At the left side of the cabin interior at FS 196.18, WL 94.73 remove airplane side wall. 7. Loosen, but do not remove the hose clamp at the fluid tank filler neck. 8. Remove the filler tube from the filler neck. 9. At the left side of the cabin interior at FS 196.18, WL 94.73 loosen the filler tube clamp on the filler port sleeve. 10. Remove the filler tube from the filler port sleeve. 11. Cut the tie wraps or loosen the p-clamps at the tube mounts and remove the tie wraps from the airplane. 12. Make sure that you remove the cut tie wraps from the airplane. 13. Carefully remove the filler tube from the airplane floor structure. 14. Put caps on all openings to keep FOD out of the fluid system. 3.5.2. Install the FILLER TUBE.

1. Remove the caps from the openings. 2. Prepare the end of the hose to fit on the filler port sleeve: a. Unwrap the string from the hose that will go over the filler port sleeve. b. Use pliers to pull the wire so that on the part of the hose that will go over the filler port sleeve, the wire is straight. c. Make sure that you do not make a tight bend in the wire. d. Make sure that you do not damage the tube wall. e. Cut off the part of the string and wire that go past the end of the tube. 3. Prepare the end of the hose to fit on the filler neck: a. Unwrap the string from the hose that will go over the filler neck.

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b. Use pliers to pull the wire so that on the part of the hose that will go over the filler neck, the wire is straight. 4. Make sure that you do not make a tight bend in the wire. 5. Make sure that you do not damage the tube wall. a. Cut off the part of the string and wire that go past the end of the tube. 6. Install the filler tube through the correct openings in the floor structure. NOTE: The correct routing of the filler tube has openings with grommets or mounts installed to prevent damage to the tube. 7. Install the corrugated tubing in the correct locations on the filler tube as shown in Figure 1.

Figure 1: Convolute Tubing Location on Filler Tube

8. Put the filler tube in its position on the filler port sleeve.

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9. Wrap silicone tape around tube where clamp is installed. 10. Put the tube clamp in its correct position on the tube where the tape is wrapped. 11. Tighten the tube clamp at the filler port sleeve. 12. Make sure that the clamp is positioned on the filler tube tape before you tighten the clamp. 13. Make sure that the clamp tightening screw is not positioned over the wire. 14. Put the filler tube in its position on the fluid tank filler neck. 15. Wrap silicone tape around tube where clamp is installed. 16. Put the tube clamp in its correct position on the tube where the tape is wrapped. 17. Tighten the hose clamp on the fluid tank filler neck. a. Make sure that the clamp is positioned on the filler tube tape before you tighten the clamp. b. Make sure that the clamp tightening screw is not positioned over the wire. 18. Install tie wraps or p-clamps at the tube mounts. 19. Engage the circuit breakers on the left circuit breaker panel that follow: a. PRIMARY ANTI-ICE b. W/S ANTI-ICE c. BACKUP ANTI-ICE 20. Do the fluid tank servicing if necessary. Refer to Chapter 12, TKS Anti-Ice System - Servicing. 21. Install the floor panels (251AL), (251BL), (251EL), (251FL), (251HL), (251JL), and (232BC). Refer to Chapter 6, Access Plates and Panels Identification - Description and Operation. 22. Install the floor coverings. Refer to Floor Covering/Column Cover - Maintenance Practices.

3.6. Filler Port Assembly

3.6.1. Remove the FILLER PORT ASSEMBLY.

1. The procedure to remove the Filler Port Assembly is the same as the procedure for the 208 TKS W/ Fairing system except the Filler Port Assembly is located at FS 196.18, WL 94.73.

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3.6.2. Install the FILLER PORT ASSEMBLY.

1. The procedure to remove the Filler Port Assembly is the same as the procedure for the 208 TKS W/ Fairing system except the Filler Port Assembly is located at FS 196.18, WL 94.73. 3.7. Vent Tube

3.7.1. REMOVE THE VENT TUBE.

1. The procedure to remove the vent tube is the same as the procedure for the 208 TKS W/ Fairing system, except the following floor panels must be removed for access: Remove the floor panels (251AL), (251BL), (251EL), (251FL), (251HL), (251JL), (232BC), (232AC), (231DL), and (232BR). Refer to Chapter 6, Access Plates and Panels Identification - Description and Operation.

3.7.2. INSTALL THE VENT TUBE.

1. The procedure to remove the vent tube is the same as the procedure for the 208 TKS W/ Fairing system, except the following floor panels must be installed after the vent tube is installed: Install the floor panels (251AL), (251BL), (251EL), (251FL), (251HL), (251JL), (232BC), (232AC), (231DL), and (232BR). Refer to Chapter 6, Access Plates and Panels Identification - Description and Operation. 3.8. Wing VG’s

3.8.1. REMOVE THE WING VG’S

1. General A. The Model 208B airplane with the TKS Fairing anti-ice system installed uses vortex generators (VG's) to improve air flow on control surfaces. There are 37 VG’s equally spaced at 6 inches on the leading edge surface of each wing, 24 VG’s from the wing root fairing to the landing light and 13 after the landing light. There are no VG’s installed on or behind the landing lights. On aircraft equipped with radar, the three VG’s that would be located directly behind the radar fairing are removed. 2. Tools and Equipment

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A. For a list of tools and equipment, refer to - General 3 Vortex Generator Removal NOTE: Removal of the VG'is typical for the left and right wing leading edges

A. Remove the Vortex Generator (Refer to Figure 2 thru figure 6).

Figure 2 Vortex Generator

C B A

Figure 3 View A-A

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Figure 4 Detail A

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Figure 5 Detail B

Figure 6 Detail C

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B. Use a toluene solvent cleaning compound to lift the edge of the VG, and remove the VG. C. When a sufficient piece of the VG is lifted, use hands or pliers and more removal solvent to pull the VG off the wing surface. D. Discard the used VG. E. Clean the remaining adhesive from the wing surface with a toluene solvent cleaning compound. F. Use a cloth in one hand wetted with the toluene solvent and a clean dry cloth in the other hand. G. Wipe the solvent immediately from the cleaned surface before it evaporates. Note: Cloth should be folded each time surfaced is wiped to present a clean area and avoid redepositing of grease. H. Visually inspect the wing for corrosion where the VG was installed. I. If you find corrosion it must be repaired. Refer to Model 208, Structural Repair Manual, Corrosion - Repair, 51-11-00.

3.8.2. INSTALL THE WING VG’S

1. General B. The Model 208B airplane with the TKS Fairing anti-ice system installed uses vortex generators (VG's) to improve air flow on control surfaces. There are 37 VG’s equally spaced at 6 inches on the leading edge surface of each wing, 24 VG’s from the wing root fairing to the landing light and 13 after the landing light. There are no VG’s installed on or behind the landing lights. On aircraft equipped with radar, the three VG’s that would be located directly behind the radar fairing are removed. 2. Tools and Equipment A. For a list of tools and equipment, refer to Wings- General 3 Vortex Generator Installation NOTE: Installation of the VG's is typical for the left and right wing leading edges

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NOTE: It is recommended that you replace all used VGs with new VGs when you complete this VG removal/installation procedure. B. Remove the Vortex Generator (Refer to Figure 7 thru Figure 11).

Figure 7 Vortex Generator

C B A

Figure 8 View A-A

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Figure 9 Detail A

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Figure 10 Detail B

Figure 11 Detail C

B. Find the location on the wing where the VG is to be installed.

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Note: The VG (with the paper backing intact) can be used to outline the area to be prepared.

Note: The vortex generators are installed 6.00 inches inboard edge to inboard edge, parallel to porous panels, with the peak pointing aft. C. To locate the alignment for the FWD edge of the VG's do the steps that follow: a. At wing root of fairing edge measure from the top of the porious panel to a point on the upper wing surface 0.5 inches (12.7 mm) Along Contour (A.C.). b. At measure from the top of the porious panel to a point on the upper wing surface 0.5 inches (12.7 mm ) Along Contour (A.C.). c. Snap a line between the two points. d. Put the FWD edge of each VG on the line. D. Apply masking tape to the area around the installation surface on the VG. Leave approximately a 0.15 inch, (3.81 mm) distance between the tape and the edges of the VG. Caution: For best results, do not install if temperature is below 50 °F (10 °C). The vortex generators are temperature sensitive and will bond best when then temperature is 50 °F (10 °C) or above. E. Apply EC-1300L adhesive to the wing surface where the VG will be installed, and to the VG bond surface. Refer to Chapter 20, Adhesive and Solvent Bonding - Maintenance Practices. F. Put the VG in the correct position on the wing surface. G. Mask the VG before painting or sealing. H. Use the adhesive and apply a fillet seal around the base of the vortex generator. I. Apply primer and paint to agree with the exterior finish of the airplane. Refer to Chapter 20,Interior and Exterior Finish - Cleaning/Painting.

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3.9. Elevator Travel

3.9.1. ELEVATOR - MAINTENANCE PRACTICES

Except for elevator up rigging, elevator maintenance practices is the same as Chapter 27-30-01 ELEVATOR - MAINTENANCE PRACTICES

3.9.2. ELEVATOR SYSTEM RIGGING

Except for setting elevator up travels, elevator system rigging is the same as section 3 ELEVATOR SYSTEM RIGGING in Chapter 27-30-01 ELEVATOR - MAINTENANCE PRACTICES. Replace steps 9) and 10) with the following. 1. For the Model 208B airplanes with the TKS Fairing anti-ice system installed, set the elevator to 22 to 23 degrees on the UP mark on the elevator rigging protractor, then adjust the UP stop bolt if necessary. 3.10. Boundary Energizers

3.10.1. LANDING AND TAXI RECONGITION LIGHTS – MAINTENANCE PRACTICES

No change to Chapter 33-40-10 Landing and Taxi Recognition Lights – Maintenance Practices.

3.10.2. WAXING AND POLISHING WINDSHIELD AND WINDOWS

1.Mask off Boundary Energizers prior to polishing landing and taxi light lens.

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4. MAINTENANCE AND SPECIAL TOOLS 4.1. Maintenance – Line Replaceable Units (LRU)

No LRU’s beyond those defined for the 208 W/ TKS Fairing installation.

4.2. System Wiring

Refer to the Wiring Diagram Manual, Chapter 20, Standard Practices, for wiring maintenance requirements and practices.

5. TESTING, RETURN TO SERVICE AND TROUBLESHOOTING 5.1. Adjustment/Test

Refer to Model 208 Maintenance Manual 30-11-11, TKS ANTI-ICE SYSTEM ADJUSTMENT/TEST - FAIRING INSTALLATION

5.2. Inspection/Check

Refer to Model 208 Maintenance Manual 30-11-11, TKS ANTI-ICE SYSTEM - MAINTENANCE PRACTICES.

5.3. Troubleshooting

Refer to Model 208 Maintenance Manual 30-11-11, TKS ANTI-ICE SYSTEM - MAINTENANCE PRACTICES.

6. AIRWORTHINESS LIMITATIONS 6.1. Limitations and Replacement Intervals

Cessna Aircraft Company Model 208B Maintenance Manual, Chapter 4, Airworthiness Limitations for Model 208 airplanes, contains the system and limitations for the Model 208B.

NOTE: The Airworthiness Limitations section is FAA-approved and specifies maintenance required under Section 43.16 and 91.403 of Title 14 Code of Federal Regulations, unless an alternative program has been FAA approved.

This system is has no mandatory replacement time, inspection interval, or structural inspection procedures, and has no impact on Cessna Aircraft Company Model 208B Maintenance Manual, Chapter 4 Airworthiness Limitations for Model 208 airplanes.

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However, airframe inspection times, intervals, and procedures for Model 208B aircraft with TKS installed must be adhered to.

6.1.1. Mandatory replacement times.

None 6.1.2. Mandatory inspection intervals.

None 6.1.3. Mandatory inspection procedures.

None

ICA Supplement.dot (Rev. 09/26/2008) Form 2261