Service Manual and I.C.A. FILE NO. A-10033

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. ISSUE DATE: 4/20/06 Incorporated PAGE 8 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 2 1.4 Dimensions, Locations and Nomenclature (See A-10014, values are reference here) BASIC SPECIFICATIONS: Maximum Weight: 300 lbs. Maximum Load: 200 lbs/ft 2 Internal Volume: 16 ft2 Overall Length: 97.5” (8’1 ½”) Opening for Baggage: 10.1” x 27.1” Width (along 30” of mid-section): 40.5” CHANGE IN WEIGHT AND BALANCE: Weight Increase: 35.0 pounds (net change) Arm: 51.0 inches Resultant Moment: 1785.0 pound-inches Index: 1.632 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. ISSUE DATE: 4/20/06 Incorporated PAGE 9 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 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 inspection 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 2.1.1 Torque Value Conversion: To convert in.-lbs. to ft.-lbs: Value (ft.-lbs.) x 12 = Value (in-lbs.) To convert ft.-lbs. to in.-lbs: Value (in-lbs.) x 0.0833 = Value (ft.-lbs.) 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. 2.1.3 Hardware Cleanliness: All hardware is to be free of dirt, grit and grease. All dirty hardware shall be thoroughly cleaned and lubricated with a dry film lubricant 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. All other fasteners shall be torqued as shown in this section unless otherwise noted. ISSUE DATE: 4/20/06 Incorporated PAGE 10 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 2 2.2 Fastener Torque Values (Except where otherwise noted) Figure 2.2.1 Recommended Torque Values (inch-pounds) (From AC43.13-1B, Table 7-1) 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. ISSUE DATE: 4/20/06 Incorporated PAGE 11 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 2 Figure 2.2.3 Torque Wrench with Various Adapters (from AC43.13-1B, Figure 7-2) ISSUE DATE: 4/20/06 Incorporated PAGE 12 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 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. 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. 2.3.2 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 DATE: 4/20/06 Incorporated PAGE 13 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 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-the-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 – All 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. Cut 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 a 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. If the area is 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 DATE: 4/20/06 Incorporated PAGE 14 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 2 3.2.3.4. If damage has occurred where there is sandwich construction and involving the 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 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 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 DATE: 4/20/06 Incorporated PAGE 15 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 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%MEKP %Catalyst Resin Qty 50°F 60°F 70°F 80°F .75% 100gm 55 min 38 min 28 min 23 min 1.00% 100gm 40 min 27 min 20 min 15 min 1.50% 100gm 30 min 21 min 14 min 11 min 2.00% 100gm 23 min 17 min 12 min 8 min Note: Under no circumstances should more than 2.0% 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 3.5.1. 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. All surface coats must be applied to a thickness of 10 to 15 mil. Use a mil gauge and check often. 3.6.2. All surface coats must be catalyzed with 2% MEKP. 3.6.3. Thinning of surface coats can only be done to manufacturers recommendations. ISSUE DATE: 4/20/06 Incorporated PAGE 16 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 2 This page intentionally left blank. ISSUE DATE: 4/20/06 Incorporated PAGE 17 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 2 SECTION 4. Recommended Airworthiness Service Schedule, General Practices and Product Listings for Service 4.1. Recommended Service Schedule – Table 1 TABLE 1 INSPECTION TIME INTERVALS HOURS/(MONTHS) (Whichever occurs first ) Notes 25 50 100 (12) 200 (24) Exterior Inspect for damage, surface coat (gel coat - UV protection). X Interior Inspect for evidence of damage. X Cargo Door Inspect seals, latches and hinges for proper function, corrosion and damage. X Hardware Spray coat protection according to Note #1, Hardware according to Note #2 (if desired). X Placards Inspect for placement & legibility. (See installation manual for proper locations). X Exhaust Extensions Inspect for stress cracking and corrosion (applicable to Cessna T206H only). X 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 & 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 cargo 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 Incorporated PAGE 18 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 2 4.3. General Practices 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) 4.4.1 Rust (corrosion) Protection – ACF-50, Corrosion X, or Boeing Co. Boeshield T9 4.4.2 Bolt Protection - PUR-AL-KETONE (Distributed by Lake & 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 DATE: 4/20/06 Incorporated PAGE 19 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 2 Section 5. Airworthiness Limitations 5.1 GENERAL The Airworthiness Limitations section is FAA approved and specifies inspections and other maintenance required under §§43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved. 5.2 DESCRIPTION 1. TIME LIMITED ITEMS. None. 2. REQUIRED INSPECTIONS INTERVAL. None. 3. SCHEDULED MAINTENANCE: None (for Aerocet recommended Inspection or Replacement, refer to Section 4. ISSUE DATE: 4/20/06 Incorporated PAGE 20 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 2 This page intentionally left blank. ISSUE DATE: 4/20/06 Incorporated PAGE 21 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 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 A-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 10-10010-3 Door Configuration Figure 6.1.7. Parts Listing for 10-10010-3 Door Panel Assembly ISSUE DATE: 4/20/06 Incorporated PAGE 22 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 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 are 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.) Figure 6.1.1. 206 Cessna Pod Assembly Versions ISSUE DATE: 4/20/06 Incorporated PAGE 23 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 2 Figure 6.1.2. Parts Listing for 10-10010-1 Door Configuration ISSUE DATE: 4/20/06 Incorporated PAGE 24 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 2 Figure 6.1.3. Parts Listing for 10-10015 Door Assembly ISSUE DATE: 4/20/06 Incorporated PAGE 25 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 2 Figure 6.1.4. Parts Listing for 10-10010-2 Door Configuration ISSUE DATE: 4/20/06 Incorporated PAGE 26 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 2 Figure 6.1.5. Parts Listing for 10-10030-1 Bottom Hinging Door Assembly ISSUE DATE: 4/20/06 Incorporated PAGE 27 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 2 Figure 6.1.6. Parts Listing for 10-10010-3 Door Configuration ISSUE DATE: 4/20/06 Incorporated PAGE 28 of 28 TITLE: Service Manual and I.C.A. FILE NO. A-10033 REVISION DATE: 3/22/12 SUBTITLE: Aerocet 206 Cargo Pack REVISION 2 Figure 6.1.7. Parts Listing for 10-10030-2 Forward Hinging Door Assembly End