Service Manual and Instructions for Continued
Contents
1. 524694 52 MACHINE SCREW FLAT COUNTERSUNK HEAD 100 9 6 NAS1149CO363R WASHER FLAT STAINLESS 10 5 NAS1149FN432P WASHER FLAT Figure 6 1 6 Parts Listing for 10 10010 3 Door Configuration 4 20 06 Incorporated PROS 28 of 28 TITLE Service Manual I C A FILE NO A 10033 REVISION REVISION DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack INSTALL WITH LOCTITE 222 THREAD LOCKER PER MFG RECOMMENDATIONS gt DETAIL A SCALE 1 4 DETAIL B SCALE 1 2 10 10030 2 FORWARD HINGING DOOR ASSEMBLY PART NUMBER DESCRIPTION 10 10031 DOOR PANEL FWD HINGING 10 10032 LATCH HANDLE 10 10034 LATCH BUSHING 10 10035 PANEL LATCH POSITION PLACARD 10 10037 LATCH POST 10 10039 EPDM FOAM RUBBER SEAL 1 2 D PROFILE 7 1 assy 10 10040 2 HINGE ASSEMBLY AEROCET 206 CARGO POD 8 PART 35 80004 NUT HEX NYLON 1 2 20 THREAD EREA HRDWR LOCTITE 222 THREAD LOCKER 10 HRDWR MS16562 240 SPRING PIN 11 5 520426 04 5 RIVET COUNTERSUNK LENGTH A R 12 HRDWR 524694 49 MACHINE SCREW FLAT COUNTERSUNK HEAD 100 13 5 HRDWR NAS1149FN432P_ WASHER FLAT 2 Figure 6 1 7 Parts Listing for 10 10030 2 Forward Hinging Door Assembly End2. Incorporated PROS ISSUE DATE 4 20 06 1 of 28 FILE NO TITLE Service Manual and I C A A 10033 REVISION REVISION DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack 2 SERVICE MANUAL AND INSTRUCTIONS FOR CONTINUED AIRWORTHINESS FOR AEROCET 206 CARGO PACK This ICA must be followed when the Cargo Pack is installed in accordance with Supplemental Type Certificate STC No SAO096SE dated June 7 1994 4 The information contained in this document supplements or supercedes the basic manual only in those areas listed herein For limitations procedures and performance information not contained in this manual consult the basic aircraft ICA or Maintenance Manual Aerocet Inc P O Box 2119 265 Shannon Lane Priest River Idaho 83856 Phone 208 448 0400 Fax 208 448 1644 ISSUE PAGE 4 20 06 Incorporated FILE NO TITLE Service Manual and I C A REVISION DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack REVISION Rev 0 was approved by FAA without signature sheet STATEMENT Rev 1 CERTIFICATION This manual complies with Federal Aviation Association FAA Airworthiness Requirements Part 23 FAA Acceptance Date 5 The above certifi o revisions or amendments made after the date of initial certification by other Approved Organizations Revisions or amendments
3. Figure 6 1 3 Parts Listing for 10 10015 Door Assembly 4 20 06 TITLE REVISION DATE 3 22 12 SUBTITLE Incorporated 25 28 FILE NO Service Manual and I C A 10033 5 Aerocet 206 Cargo Pack 2 DETAIL A SCALE 1 4 10 10010 2 POD ASSEMBLY BOTTOM HINGING DOOR CONFIGURATION LTEM QTY TYPE PART NUMBER DESCRIPTION 1 1 PART 10 10010 21 AEROCET 206 CARGO POD SHELL 2 amp 3 OPTIONS 2 1 ASSY 10 10030 1 DOOR PANEL ASSEMBLY 3 1 PART 10 10038 TRIM RING AND DOOR INSET 4 PART 10 10051 LATCH RAMP 5 2 PART 10 10053 CARGO 6 12 MS20426AD4 5 RIVET 100 COUNTERSUNK LENGTH 7 6 HRDWR MS21083C3 NUT SELF LOCKING LOW HEIGHT STAINLESS 8 6 HRDWR MS24694C52 MACHINE SCREW FLAT COUNTERSUNK HEAD 100 9 6 HRDWR NAS1149CO363R WASHER FLAT STAINLESS 10 12 HRDWR NAS1149FN432P WASHER FLAT Figure 6 1 4 Parts Listing for 10 10010 2 Door Configuration Incorporated 4 20 06 26 of 28 FILE NO TITLE Service Manual and I C A 10033 REVISION REVISION DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack 2 INSTALL WITH LOCTITE 222 Luces alge MFG RECOMMENDATION DETAIL A SCALE 1 4 DETAIL B SCALE 1 2 10 10030 1 BOTTOM HINGING DOO
4. ADHESIVE BACKED 1 8 X 1 2 PLACED AROUND ENTIRE PERIMETER NOT SHOWN IN PARTS LISTING 10 10010 1 POD ASSEMBLY BOTTOM HINGING DOOR ORIGINAL CONFIGURATION ITEM QTY TYPE PART NUMBER DESCRIPTION 1 1 PART 10 10010 11 AEROCET 206 CARGO POD SHELL 1 OPTIONS 2 1 ASSY 10 10015 DOOR PANEL ASSEMBLY 3 PART 214 16 CAMLOCK END 4 HRWDR 4002 7W STUD CAMLOC P N 5 PART 4002 N GROMMET 6 6 HRDWR MS20426AD4 4 RIVET 100 COUNTERSUNK HEAD LENGTH A R 7 6 HRDWR MS21044c08 NUT SELF LOCKING REGULAR HEIGHT STAINLESS 8 6 HRDWR MS24694C6 MACHINE SCREW FLAT COUNTERSUNK HEAD 100 9 6 HRDWR NAS1149CO332R WASHER FLAT STAINLESS 10 SNAP RING P N Figure 6 1 2 Parts Listing for 10 10010 1 Door Configuration EROCET Incorporated FRGS FILE NO TITLE Service Manual and I C A A 10033 4 20 06 24 of 28 REVISION REVISION DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack 2 DETAIL A SCALE 1 4 10 10015 ORIGINAL DOOR ASSEMBLY ATEM QTY TYPE PART NUMBER DESCRIPTION 1 1 PART 10 10016 DOOR PANEL 2 9 521044 08 NUT SELF LOCKING REGULAR HEIGHT STAINLESS 3 9 HRDWR 524694 6 MACHINE SCREW FLAT COUNTERSUNK HEAD 100 4 9 HRDWR NAS1149CO332R WASHER FLAT STAINLESS 5 3 HRDWR SD 202511 1 DOOR HINGE
5. 10010 3 Door Configuration Figure 6 1 7 Parts Listing for 10 10010 3 Door Panel Assembly ISSUE PAGE 4 20 06 Incorporated 22 of 28 FILE NO TITLE Service Manual and I C A 10033 REVISION REVISION DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack 2 Cargo Pod Door Versions 10 10010 1 Original Door design utilizing Camloc latches and three bottom positioned door hinges Available for repair and replacement parts only once 2 and 3 versions available Refer to Figures 6 1 2 and 6 1 3 for exploded views and part lists 10 10010 2 New Door design utilizing Aerocet developed rotational latches and a piano hinge along the bottom edge An available option on all new 206 Pod orders Refer to Figures 6 1 4 and 6 1 5 for exploded views and part lists 10 10010 3 New Door design utilizing Aerocet developed rotational latches and a piano hinge along forward edge An available option on all new 206 Pod orders Refer to Figures 6 1 6 and 6 1 7 for exploded views and part lists 10 10010 3 FORWARD HINGING NEW VERSION Figure 6 1 1 206 Cessna Pod Assembly Versions Incorporated PROS 4 20 06 23 of 28 FILE NO TITLE Service Manual and I C A A 10033 REVISION REVISION DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack 2 DETAIL A 4 SCALE 1 4 CROSS LINKED POLYETHLENE FOAM
6. Over sized rivets may be substituted where holes have been drilled out Bolts and screws shall have a minimum of one thread visible through the nuts upon final torque Washers may be rearranged if necessary to accommodate proper fit up to two washers beneath the nut and one beneath the fastener head Typically Aerocet intends to put one thin washer beneath the fastener head and one thicker washer beneath the nut 2 3 0 Fastener Reuse Fasteners are to be inspected for condition per Section 6 of this manual Such fasteners that are acceptable may be cleaned re lubricated and re installed as determined Self locking nuts shall meet the minimum prevailing torque as listed in Figure 2 2 2 or shall be replaced ISSUE PAGE 4 20 06 Incorporated 13 of 28 FILE NO TITLE Service Manual and I C A 10033 REVISION REVISION DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack 2 SECTION 3 Repairing Composite Structure 3 1 General Description Composite structure repair done correctly will obtain the strength required to return the cargo pack to normal service and show little or no cosmetic evidence of damage having taken place The materials used for original construction and repair are conventional to the industry Contact Aerocet Inc prior to beginning a repair to obtain correct materials resin resins have shelf lives catalyst cloth gel coat resin thickeners In t
7. large enough supply backing to hold the shape of the original contour Put a parting agent on this backing to assure its release 3 2 3 3 Replace the fabric on a ply for ply basis overlapping 1 2 minimum on each succeeding ply using impregnation of fabric as described in section 3 3 Any smooth areas need to be sanded with 80 grit sandpaper to assure proper bonding ISSUE PAGE 4 20 06 Incorporated 14 of 28 FILE NO TITLE Service Manual and I C A 10033 REVISION REVISION DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack 2 3 2 3 4 If damage has occurred where there is sandwich construction and involving core then work each layer separately Fix either the outside or inside skins Then cut to fit like core material to replace the damaged core Bond the core onto the repaired skin using the proper resin and thickener A mixture of Hydrex resin and Aerosil 202 thickener should be applied to the bonding surface of the core using a squeegee Torin Corebond alt OK A film of approximately 015 should be used Pressure needs to be applied for the bond to assure proper adhesion to the skin eliminating air voids This pressure can be applied to small area core bonding by weights ex lead shot bags with a release film to keep from sticking to any excess Larger areas require core bonding using a vacuum bag Consult Aerocet Inc for this procedure Fill any seam voids with
8. made by other Approved Organizations must be separately certified and recorded on separate record sheets STATEMENT OF Rev 2 CERTIFICATION The changes in revision C are classified as minor and do not affect the FAA approved sections of this manual The changes to the IPC include data that has FAA design data approval ISSUE PAGE 4 20 06 Incorporated 3 of 28 FILE NO TITLE Service Manual and I C A A 10033 REVISION REVISION DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack 2 LOG OF REVISIONS PAGE REV PAGES DESCRIPTION DATE APPROVED AFFECT o Initial Release 4 2006 Changed Continued Airworthiness to 7 01 10 Recommended Airworthiness Table of Contents Section 4 Added Section 5 Airworthiness Limitations and Section 6 Illustrated Parts Catalogue to Table of Contents Added sub sections 1 1 Availability 1 2 Component Maintenance Manuals 1 3 Installation Manual 1 4 Dimensions Locations and Nomenclature Figures 1 4 1 and 1 4 2 to document Added Sections 2 1 Fastener Torque 2 2 Fastener Torque Values and 2 3 Fastener Use and Discretion to document Added Warnings 3x beginning section 3 4 Resin Mixing Added 274 paragraph Gel times should be assessed Section 3 4 Resin Mixing Added Obsolete use Hydrex 100 33350 not shown at Typical Gel Times Hydrex 3
9. mixing with accelerators and catalysts Gel times can be adjusted significantly by varying the amounts of these materials Gel times also will vary significantly with the batch size if left in a bucket or with a very thick laminate ISSUE PAGE 4 20 06 Incorporated 15 of 28 FILE NO TITLE Service Manual and I C A A 10033 REVISION REVISION DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack 2 Gel times should be assessed with each new batch or type of resin system used in the working environment Ambient air and resin temperatures shelf life and catalyst ratios may affect the gel times significantly As previously stated thicker laminates and or resin pots will cure more quickly due to accumulation of heat during gel process Thin laminates such as specified for use in many Aerocet products will often gel in double the amount of time needed to gel a 100g in a 4 in diameter pot Resin catalysis shall not be accomplished in ambient air temperatures of less than 50 F except under extreme circumstances for the purposes of a temporary field repair In no case shall more than 2 catalyst mixture be used and in no case shall less than the recommended 75 catalyst mixture be used TYPICAL GEL TIMES HYDREX 33 253 Obsolete Use Hydrex 100 33350 not shown 100g castings only laminate times typically double 33 Catalyst Resin Qty No
10. 3 253 table heading Deleted Warning which was duplicate of 1 of 3 Warnings added previously Changed Section 4 heading Recommended Airworthiness was Continued Airworthiness Added Section 5 Airworthiness Limitations to document Added Section 6 Illustrated Parts Catalogue to document 3 22 12 Rev 2 certification statement New Figure showing washers on rivets for Fig 6 1 3 6 1 4 6 1 5 6 1 6 4 20 06 REVISION DATE 3 22 12 TITLE SUBTITLE Incorporated Service Manual and I C A Aerocet 206 Cargo Pack This page intentionally left blank PAGE 4 of 28 FILE NO A 10033 REVISION 2 Incorporated 4 20 06 TITLE Service Manual and I C A REVISION DATE 3 22 12 suBTITLE Aerocet 206 Cargo Pack Table of Contents Description PAGE 5 of 28 FILE NO A 10033 REVISION 2 Section Introduction and General Information Cargo Pack Maintenance Repairing Composite Structure Recommended Airworthiness Service Schedule General Practices and Product Listings for Service 1 2 3 4 Airworthiness Limitations Illustrated Parts Catalogue 4 20 06 REVISION DATE 3 22 12 TITLE SUBTITLE Incorporated Service Manual and I C A Aerocet 206 Cargo Pack This page inte
11. Dimensions Locations and Nomenclature See A 10014 values are reference here BASIC SPECIFICATIONS CHANGE IN WEIGHT AND BALANCE Maximum Weight 300 lbs Weight Increase 35 0 pounds net change Maximum Load 200 Ibs ft Arm 51 0 inches Internal Volume 16 ft2 Resultant Moment 1785 0 pound inches Overall Length 97 5 8 1 V2 Index 1 632 Opening for Baggage 10 1 x 27 1 Width along 30 of mid section 40 5 Mission Aviation Fellowship Used with permission www maf org Figure 1 4 1 Showing side view of Aerocet Cargo Pod on Cessna 206 Aircraft Figure 1 4 2 Showing front view of Aerocet Cargo Pod on Cessna 206 Aircraft Incorporated 4 20 06 9 of 28 FILE NO TITLE Service Manual and I C A 10033 REVISION REVISION DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack 2 SECTION 2 Cargo Pack Maintenance Corrosion is minimized due to the composite construction The cargo pack should be kept clean with soap and water External stains may be removed using commercially available marine fiberglass stain remover We have used a product called FSR with good success These surfaces may also be waxed to help in the cleaning process Do not use abrasive cleaners or pads these will scratch the white gel coat surface The gel coat color surface should always be maintained on external surfaces for ultraviolet protection Cargo door provides access for in
12. PPLY THE FOLLOWING FORMULAS TO OBTAIN THE CORRECTED TORQUE READING Short Open End Adapter TORQUE ADAPTER WRENCH DRIVE HANDGRIP CENTERLINE CENTERLINE PREDETERMINED WRENCH DRIVE 77 CENTERLINE Set Screw Adapter 5 FORMULA LE Y EXAMPLE WITH E AS PLUS DIMENSION T 135 LB IN Y UNKNOWN Hose Clamp Adapter L 10 0 IN 1 5 IN Y 117 LB IN LEGEN T ACTUAL DESIRED TORQUE Y APPARENT INDICATED TORQUE EFFECTIVE LENGTH LEVER EFFECTIVE LENGTH OF EXTENSION Open End Wrench TORQUE WRENCH Adapter WRENCH HANDGRIP JE DRIVE CENTERLINE CENTERLINE ADAPTER PREDETERMINED Flare Nut Wrench Adapter TxL FORMULA EXAMPLE WITH E AS MINUS DIMENSION T 2 135 LB IN Y UNKNOWN Spanner Wrench Adapter L 10 0 IN 1 5 IN Y 159 LB IN Figure 2 2 3 Torque Wrench with Various Adapters from AC43 13 1B Figure 7 2 Incorporated FRGS 4 20 06 12 of 28 FILE NO TITLE Service Manual and I C A A 10033 REVISION REVISION DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack 2 2 3 Fastener Use and Discretion 2 3 1 Fastener Lengths Rivets Where replacement or repair of rivets is required use rivets of proper specifications only For instance MS203426AD4 xxx Lengths may be determined by measuring the thickness of the material s to be assembled and adding 1 5 X Diameter of the rivet to be used
13. R ASSEMBLY ITEM ary TYPE PART NUMBER DESCRIPTION 1 1 PART 10 10031 DOOR PANEL BOTTOM HINGING 2 a 10 10082 LATCH HANDLE 3 3 PART 10 10034 LATCH BUSHING 4 8 PART 10 10035 PANEL LATCH POSITION PLACARD 5 3 PART 10 10037 LATCH POST 6 1 HRDWR 10 10039 EPDM FOAM RUBBER SEAL 1 2 0 PROFILE 7 1 assy 10 10040 1 HINGE ASSEMBLY AEROCET 206 CARGO POD 8 3 PART 35 80004 NUT HEX NYLON 1 2 20 THREAD 9 1 HRDWR LOCTITE 222 THREAD LOCKER 10 HROWR 516562 240 SPRING PIN 11 12 HRDWR MS20426AD4 5 RIVET COUNTERSUNK LENGTH A R 12 HRDWR 524694 49 MACHINE SCREW FLAT COUNTERSUNK HEAD 100 18 12 HRDWR NAS1149FN432P WASHER FLAT Figure 6 1 5 Parts Listing for 10 10030 1 Bottom Hinging Door Assembly Incorporated 4 20 06 27 of 28 FILE NO TITLE Service Manual and I C A A 10033 REVISION REVISION DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack 2 DETAIL A SCALE 1 4 4 2 DESCRIPTION 1 1 10 10010 21 AEROCET 206 CARGO POD SHELL 2 amp 3 OPTIONS 1 10 10030 2 DOOR PANEL ASSEMBLY FORWARD HINGING 3 1 10 10038 TRIM RING AND DOOR INSET 4 3 10 10051 LATCH RAMP 5 2 10 10053 CARGO 6 5 HRDWR MS20426AD4 9 RIVET COUNTERSUNK LENGTH A R 7 6 HRDWR 521083 3 NUT SELF LOCKING LOW HEIGHT STAINLESS 8 6
14. SHEAR TORQUE LIMITS Thread Size Tension type nuts Shear type nuts MS20364 Nuts MS20365 and Nuts MS20364 and MS20365 AN310 and 20 24 000 psi AN310 90 000 psi in AN320 54 000 psi in 40 000 psi in bolts bolts bolts FINE THREAD SERIES 8 36 12 15 7 9 20 12 10 32 20 25 12 15 1 4 28 50 70 30 40 5 16 24 100 140 60 85 3 8 24 160 190 95 110 7 16 20 450 500 270 300 1 2 20 480 690 290 410 9 16 18 800 1000 480 600 5 8 18 1100 1300 600 780 3 4 16 2300 2500 1300 1500 7 8 14 2500 3000 1500 1800 1 14 3700 5500 2200 3300 1 1 8 12 5000 7000 3000 4200 1 1 4 12 9000 11 000 5400 6600 Figure 2 2 1 Recommended Torque Values inch pounds From AC43 13 1B Table 7 1 MINIMUM PREVAILING THREAD SIZE TORQUE THREAD SIZE MINIMUM PREVAILING TORQUE Figure 2 2 2 Minimum Prevailing Torque Values for Re used Self Locking Nuts from AC43 13 1B Table 7 2 Self Locking Nuts Self locking nuts when re used must have at least the minimum prevailing torque listed in figure to the left Nuts that are smaller than those listed in the table shall not be used if they can be run up by hand EROCET PAGE 4 20 06 Incorporated 11 of 28 FILE NO TITLE Service Manual and I C A A 10033 REVISION DATE 3 22 12 suBTITLE Aerocet 206 Cargo Pack REVISION 2 WHEN USING A TORQUE WRENCH ADAPTER WHICH CHANGES THE DISTANCE FROM THE TORQUE WRENCH DRIVE TO THE ADAPTER DRIVE A
15. a resin glass bubble mixture Apply the final laminates accordingly to finish the repair 3 3 Impregnation of Fabric Resin impregnation can be accomplished by laying cloth cut to a suitable pattern on a flat table and applying resin mixture with a squeegee so as to achieve an even impregnation Similarly it may also be done directly on the part with the cloth being applied with either a squeegee or a brush assuring that voids and starved areas are not produced It is very helpful to apply a thin coat of resin to the area to be laminated Then lay the cloth down rolling the cloth into the resin Any air in the laminate should be squeegeed or brushed out See section 8 4 regarding resin mixing 3 4 Resin Mixing WARNING Observe all safety regulations and recommendations of the manufacturer according to the Material Safety Data Sheet MSDS and or other instructions for the safe use and handling of all resin related products WARNING Cobalt should never be mixed directly with MEKP catalyst A violent reaction will occur which may result in fire or explosion Cobalt should be stored separately from the catalyst WARNING Be careful with the MEKP catalyst Contact with eyes must be prevented Flush eyes immediately contact a physician immediately Never mix MEKP without eye protection Read recommendations on catalyst supply bottle Gel time or pot life is the time it takes the resin to set up in the container after proper and thorough
16. ces and Product Listings for Service 4 1 Recommended Service Schedule Table 1 TABLE 1 INSPECTION TIME HOURS MONTHS INTERVALS Whichever occurs first 100 200 25 50 12 24 Inspect for damage surface coat gel coat UV Interior Inspect for evidence of damage Inspect seals latches and hinges for proper function corrosion and damage Spray coat protection according to Note 1 Hardware according to Note 2 if desired Inspect for placement amp legibility See installation manual for proper locations Inspect for stress cracking and corrosion applicable to Cessna T206H only Cargo Door Hardware Placards Exhaust Extensions Note 1 Spray coat of a migrating corrosion material ACF 50 Boeshield T9 or Corrosion X Note 2 Coat hardware with PUR AL KETONE or LPS 3 4 2 Exceptional Inspections In a variety of circumstances it is necessary to perform prompt inspections for damage Details relating to these investigations are addressed in Sections 2 amp 3 of this manual and Table 1 above It is the responsibility of the pilot to determine the severity of damage and the flightworthiness of the aircraft in the field Inspections and repairs are to be performed as necessary and per practices outlined throughout this manual A list of possible scenarios includes but is not limited to the following 4 2 1 Harsh landings especially when heavy ca
17. gh standard of service If you have moved since your original purchase have purchased a used product or otherwise have reason to believe that the contact information on file is incorrect please provide the following information to Aerocet Inc Aerocet contact information 1 on the front of this document Cargo Pod Information Cargo Pod S N Aircraft Information Aircraft Make Model Aircraft Registration Aircraft S N Owner Information as applicable Previous Owner Previous Address Present Owner Present Address Present Phone Number Present Email Address 1 2 Component Maintenance Manuals Certain accessories that are more complex that require additional inspection and maintenance procedures may be described in Component Maintenance Manuals CMM or Maintenance Manuals MM These documents would be provided as part of the documentation provided with your product At the time of this writing no such components are used with Aerocet 206 Cargo Pod This subsection is reserved in the case of such future use 1 3 Installation Manual Installation instructions are provided as a part of the documentation package provided with the original purchase or upon request as detailed above Refer to Aerocet Document Number A 10014 for instructions and installation parts lists Incorporated 4 20 06 TITLE Service Manual and I C A DATES 3 22 12 SUBTITLE Aerocet 206 Cargo Pack 1 4
18. he field epoxy patch kits may be used in an emergency if the damage is relatively small but the repair must be replaced with correct materials for equal strength status Damage larger than 4 in size requires consulting Aerocet Inc for proper laminate orientation and counts in the damaged area 3 2 Repair Types and Procedures repaired areas on the exterior must be surface coated gel coated with a minimum of 10 mil thickness to assure UV protection 3 2 1 Resin Starved Areas Exposed Fibers or Small Impact Damaged Soft Spots 1 2 Dia or less 3 2 1 1 If necessary sand surfaces to remove gloss 3 2 1 2 Use brush squeegee or hypodermic to work resin into defective area Use same resin as the original laminate 3 2 2 Small Bruises Punctures Less than 1 4 diameter or Surface Voids 3 2 2 1 Sand surface surrounding defect to remove gloss 3 2 2 2 Use same fabric as the original part 3 2 2 3 patches to fit correction area extending a minimum of 1 2 past the damaged area All patch corners must be rounded 3 2 2 4 Apply light brush coat of resin similar to original 3 2 2 5 Place one or more plies on detail covering correction area using impregnation of fabric as described in section 3 3 3 2 3 Cuts Fractures or Punctures 1 4 diameter or Larger 3 2 3 1 Cut back material as required to ascertain extent of damage Trim plies outward to a smooth oval 1 2 per ply generally 3 2 3 2 the area is
19. ntionally left blank PAGE 6 of 28 FILE NO A 10033 REVISION 2 Incorporated FRGS 4 20 06 7 of 28 FILE NO TITLE Service Manual and I C A A 10033 REVISION REVISION DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack 2 SECTION 1 Introduction and General Cargo Pack Information This service and maintenance manual is applicable to Aerocet 206 Cargo Pack and its general application to a variety of Cessna Model 206 airplanes The Aerocet 206 Cargo Pack is all composite construction and is mounted to the belly of the aircraft according to the approved installation document Reference the STC document for specific listing At the time of this writing Document A 10014 is applicable to all aircraft models 1 1 Availability One complete hard paper copy of this manual shall be provided with each new 206 Cargo pack Additional copies and minor revisions shall be available via email U S P S mail UPS or FedEx by request Fees and delivery charges may apply Notification of any changes that require service for airworthiness shall be distributed to all applicable Aerocet owners on record with Aerocet Inc In such a case copies of the applicable revised portions of this manual shall be provided Aerocet Inc maintains record of purchasers and or owners collected at the time of purchase in order to comply with the above as well as to maintain a hi
20. rgo is loaded or has shifted in a significant manner 4 2 2 Impact with an object during taxi take off or landing 4 2 3 Suspected damage incurred during tie down 4 2 4 Visible damage found during normal preflight inspection ISSUE DATE 4 20 06 TITLE REVISION DATE 3 22 12 SUBTITLE 4 3 General Practices Incorporated Service Manual and I C A Aerocet 206 Cargo Pack PAGE 18 of 28 FILE NO A 10033 REVISION 2 4 3 1 Metal Parts check for corrosion stress cracks or metal distortion elongation of holes rivet damage 4 3 2 Critical Bolts check for corrosion rust wear torque 4 3 3 Composite Parts check for stress cracks gel coat presence UV protection punctures 4 4 Product Listings our recommendations 4 41 Rust corrosion Protection ACF 50 Corrosion X or Boeing Co Boeshield T9 4 4 2 Bolt Protection PUR AL KETONE Distributed by Lake amp Air LPS Industries LPS 3 Zip Chemical Co Zip D 5029NS 4 4 3 Composite Materials for Hull Repair Contact Aerocet Inc for resin cloth gel coat resin thickeners ISSUE PAGE 4 20 06 Incorporated 19 of 28 FILE NO TITLE Service Manual and I C A 10033 5 5 DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack 2 Section 5 Airworthiness Limitations 5 1 GENERAL The Air
21. spection to view internal damage and to comply with the maintenance inspections See Table 1 in Section 4 for scheduled maintenance See also Exceptional Inspections Any penetration to the shell structure delamination of the cloth layers or gelcoat having worn through must be repaired according to hull repair Section 3 Significant damage i e damage caused by ground or animal strikes may warrant consultation with Aerocet Inc Significant damage may be categorized as damage that penetrates beyond the outside laminates to the core and or the inside laminates that is greater than 4 in diameter or that compromises attachment fasteners Latches and seals are to be maintained as needed for proper function If applicable Exhaust Extensions which are required only on Cessna T206H airplane applications should be inspected for stress cracking corrosion damage and condition 2 1 Fastener Torque 2 1 4 Torque Value Conversion To convert in lbs to ft lbs Value ft Ibs x 12 Value in lbs To convert ft Ibs to in Ibs Value in lbs x 0 0833 Value ft Ibs 2 1 2 Tooling Requirements Calibrated torque wrench Adapters that affect the length of the torque wrench will affect the required torque indication and must be calculated according to Figure 2 2 3 2 4 5 Hardware Cleanliness hardware is to be free of dirt grit and grease dirty hardware shall be thoroughly cleaned and lubricated with a dry film lubrican
22. t such as LPS 1 or Teflon products per manufacturer instructions It is recommended that all stainless hardware be thoroughly lubricated with anti seize lubricant of good quality to prevent galling upon assembly 2 1 4 Torque Procedure Assure that hardware is clean and properly prepared for installation Assemble nuts to bolts measuring the tension required to turn the nut and add this to the required final torque Where possible apply torque to the nut and not to the fastener head Apply a smooth even pressure stopping and re torquing if chattering or premature loading occurs This may warrant disassembly and subsequent inspection for burrs or galling Replace any damaged hardware Cross recessed Machine pan head style screws should be torqued only to hand tight the fiberglass should exhibit only mild deformation A portable hand drill could be used provided that the clutch is set properly other fasteners shall be torqued as shown in this section unless otherwise noted EROCET Incorporated 4 20 06 10 of 28 FILE NO TITLE Service Manual and I C A A 10033 REVISION REVISION DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack 2 2 2 Fastener Torque Values Except where otherwise noted CAUTION THE FOLLOWING TORQUE VALUES ARE DERIVED FROM OIL FREE CADMIUM PLATED THREADS TORQUE LIMITS RECOMMENDED FOR INSTAL MAXIMUM ALLOWABLE TIGHTENING LATION BOLTS LOADED PRIMARILY IN
23. te Under no circumstances should more than 2 096 catalyst mixture be used Also do not use less than the recommended minimum amount of catalyst 75 or the resin may never completely cure resulting in a reduction of strength 3 5 Preparation of Fiberglass Materials 3 5 Fiberglass shall be trimmed on a clean table to prevent contamination 3 5 2 When laps are necessary lap widths of at least 1 2 shall be maintained for fiberglass pieces in any given ply and no more than one of the component plies shall be lapped at any one place The number of laps shall be kept to a minimum 3 6 Surface Coat Application Gel Coat 3 6 1 surface coats must be applied to a thickness of 10 to 15 mil Use a mil gauge and check often 3 6 2 Allsurface coats must be catalyzed with 2 MEKP 3 6 3 Thinning of surface coats can be done to manufacturers recommendations 4 20 06 REVISION DATE 3 22 12 TITLE SUBTITLE Incorporated Service Manual and I C A Aerocet 206 Cargo Pack This page intentionally left blank PAGE 16 of 28 FILE NO A 10033 REVISION 2 ISSUE PAGE 4 20 06 Incorporated 17 of 28 FILE NO TITLE Service Manual and I C A A 10033 REVISION REVISION DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack 2 SECTION 4 Recommended Airworthiness Service Schedule General Practi
24. worthiness Limitations section is FAA approved and specifies inspections and other maintenance required under 843 16 and 91 403 of the Federal Aviation Regulations unless an alternative program has been FAA approved 5 2 DESCRIPTION L TIME LIMITED ITEMS None 2 REQUIRED INSPECTIONS INTERVAL None 3 SCHEDULED MAINTENANCE None for Aerocet recommended Inspection or Replacement refer to Section 4 4 20 06 REVISION DATE 3 22 12 TITLE SUBTITLE Incorporated Service Manual and I C A Aerocet 206 Cargo Pack This page intentionally left blank PAGE 20 of 28 FILE NO A 10033 REVISION 2 ISSUE PAGE 4 20 06 Incorporated 21 of 28 FILE NO TITLE Service Manual and I C A A 10033 REVISION REVISION DATE 3 22 12 SUBTITLE Aerocet 206 Cargo Pack 2 Section 6 Illustrated Parts Catalogue Section 6 contains part listings for the Aerocet 206 Cargo Pod For installation related part listings refer to Aerocet installation manual 10014 6 1 LIST OF FIGURES Figure 6 1 1 206 Cessna Pod Door Versions Figure 6 1 2 Parts Listing for 10 10010 1 Door Configuration Figure 6 1 3 Parts Listing for 10 10010 1 Door Panel Assembly Figure 6 1 4 Parts Listing for 10 10010 2 Door Configuration Figure 6 1 5 Parts Listing for 10 10010 2 Door Panel Assembly Figure 6 1 6 Parts Listing for 10
Download Pdf Manuals
Related Search