stc group llc north muskegon, michigan …...faa stc project st09202ch-a date: original issue 17...

STC GROUP LLC 480 RUDDIMAN DRIVE

NORTH MUSKEGON, MICHIGAN 49445-2783

REPORT NO: 1006104 REVISION A

TRIO AUTO PILOT PROVISIONS INSTALLATION INSTRUCTIONS 1953 CESSNA 180 THROUGH 1962 180D 1956 CESSNA 182 THROUGH 1961 182D

FAA STC PROJECT ST09202CH-A

DATE: Original Issue 17 September, 2017

WRITTEN BY:

Paul Odum

APPROVED BY:

Jeff Ley

STC GROUP LLC Page 1 480 Ruddiman Drive TRIO AP Installation Instructions North Muskegon, Michigan 49445-2783 1006104 Rev A

TRIO AP Provisions Installation Instructions Page 1

CONFIDENTIAL & PROPRIETARY. CONTAINS TRADE SECRETS PROTECTED BY THE UNIFORM TRADE SECRETS ACT AND OTHER PROPRIETARY INFORMATION, EXEMPT FROM PUBLIC DISCLOSURE UNDER FOIA [5 US Code sec. 552(b)(4)]

REVISIONS

Rev. Date: By: Approved By:

- 17 September 2017 Paul Odum Jeff ley

A 22 September 2017 Paul Odum Jeff Ley

ER No: 1002

Section: Description

All Initial Release

Rev A Chapter 2, Chapter 3




TABLE OF CONTENTS

TABLE OF CONTENTS ................................................................................................... 2

LIST OF TABLES ................................................................................................................ 3

LIST OF FIGURES .............................................................................................................. 4

REFERENCES 5

Tools needed 6

ACRONYMS, ABBREVIATIONS, AND SYMBOLS ..................................................... 7

1.0 Trio pro pilot autopilot installation ......................................................... 8

2.0 General .................................................................................................... 9

3.0 Roll Servo Installation – Right (Starboard) Wing ................................... 10

4.0 Pitch Servo Installation ........................................................................... 19

5.0 Mounting Pitch servo To The Servo Tray ............................................... 21

6.0 Pitch Servo fuselage Angle Installation .................................................. 22

7.0 Pitch Servo Setup .................................................................................... 24

8.0 Wiring Harness Installation ..................................................................... 28




LIST OF TABLES

No table of figures entries found.




LIST OF FIGURES

FIGURE 1 AUTOPILOT INSTALLATION FIGURE 2 WING ACCESS COVER LOCATIONS CESSNA 182 FIGURE 3A WING ACCESS COVER LOCATIONS CESSNA 180 FIGURE 4 ROLL SERVO & MOUNTING PLATE INSTALLATION FIGURE 3A ROLL SERVO & MOUNTING PLATE INSTALLATION FIGURE 5 ROLL SERVO BRACKET ASSEMBLY AT FS STA 100.5 FIGURE 5 WS 100.5 SERVO MOUNT RIB LOCATION FIGURE 6 VIEW LOOKING OUTBOARD AT STA 100.5 RIB FIGURE 7 ROLL SERVO HUB DRIFT PIN AND LOCKING PIN HOLE ALIGNMENT FIGURE 8 ROLL SERVO PUSH PULL TUBE ASSEMBLY FIGURE 9 ROLL SERVO ARM INSTALLATION FIGURE 10 AILERON BELLCRANG INSTALLATION FIGURE 11 AILERON BELLCRANK INSTALLATION FIGURE 12 ZEE BRACKET POSITION ON FUSELAGE ANGLES FIGURE 13 RIVET HOLE AND CLECO TEMPORARY FASTENER LOCATION FIGURE 14 PITCH SERVO ARM POSITION FIGURE 16 PITCH SERVO ANGLE POSITION FIGURE 17 PITCH SERVO ARM ALIGNMENT FIGURE 17 PITCH SERVO ARM ALIGNMENT FIGURE 18 ELEVATOR IDLER BELCRANK PUSH PULL TUBE INSTALLATION FIGURE 19 PITCH SERVO ARM PUSH PULL TUBE INSTALLATION




REFERENCES

The following documents form a part of this report. Unless a specific revision of one of these documents is specified, the revision in effect at the time of original issue of this document shall apply.

STC Group LLC Document Number 1006901 – Cessna 182 Illustrated Parts Catalog

Industry Specifications and Standards:

1. MMPDS-09 Metallic Materials Properties Development and Standardization 2. AC 43.13-1B Aircraft Inspection, Repair & Alterations

Other Data:

ER1006 – STC GROUP LLC Program Engineering Record.




TOOLS NEEDED

Drills • Cordless • 90-degree air drill • 45-degree air drill • #40 drill bits • #40 ¼ x 28 threaded drill bits • Silver Cleco P Series Temporary Fasteners • Copper P Series Temporary Fasteners • Side grip cleco clamps • Cleco pliers • 24” ruler or tape measure • 6” ruler • Light • Foam knee pad




ACRONYMS, ABBREVIATIONS, AND SYMBOLS

Autopilot Clip C.G.

Trio Pro Pilot Autopilot Part Number 1006237 Center of Gravity

ER Engineering Record

FAA Federal Aviation Administration

ICA Instructions for Continued Airworthiness

LH Left Hand

OEM Original Equipment Manufacturer

OTBD PCS Recover

Outboard Pilot Controller Steering (Red) Button Recover Button

RH Servo

Right Hand Trio Pro Pilot Gold Standard Servo

STC Supplemental Type Certificate

WS Autopilot

Wing Station Trio Pro Pilot Autopilot




1.0 TRIO PRO PILOT AUTOPILOT INSTALLATION

This installation procedure provides information and data necessary to install bracketry and hardware provisions for mounting the Trio Auto Pilot Pitch and Roll servos in Cessna Aircraft Model including the 1953 Cessna 180, S/N 30000 through 1962 180D, S/N 18051183 and 1956 Cessna 182 S/N 33000 through 1961 Cessna 182D S/N 18253598. In 1961 the serial number format was changed with the model number being placed in front of the consecutive 5-digit serial number.

FIGURE 1 AUTOPILOT INSTALLATION

Areas of modification




2.0 GENERAL

Thank you for your purchase of the TRIO Auto Pilot for the Cessna 180 and Cessna 182. This document is written to ensure your installation is easy, ensures safety, and is professionally completed. Before you begin Read All Instructions. Call Jeffrey Ley at The STC Group LLC at (661) 524-6157 call/text/phone mail if you have questions. Check all items included in the kit to ensure all parts are accounted for. Installation drawings are denoted in the References section above and throughout these installation instructions. Drawings may be downloaded along with the Illustrated Parts Catalog from The STC Group LLC website at www.thestcgroup.net.

Note

The aileron and elevator control surfaces must be locked into the neutral flight position before starting the installation procedure. Remove control lock first. Care should always be taken to avoid marring or scratching any surfaces of autopilot assemblies including anodized surfaces. Painters tape may be used to prevent marring hardware surfaces.

http://www.thestcgroup.net/




3.0 ROLL SERVO INSTALLATION – RIGHT (STARBOARD) WING

1. Remove the inspection panels at WS 112.00 and WS 144.80 as depicted in Figure 2.

FIGURE 2 WING ACCESS COVER LOCATIONS – CESSNA 182

FIGURE 2A WING ACCESS COVER LOCATIONS CESSNA 180




2. Insert the servo bracket assembly, p/n 1006233-1, through the access hole at STA 112 and align with STA 100.5 rib as depicted in Figure 3.

3. Center punch and drill the upper rear hole though the WS 100.5 trim piece as shown in Figure 3A using a #40 drill. Drill from outside the aircraft as depicted in Figure 3A.

4. The hole in Step 3 above should be drilled through the trim piece midway between the first and second rivet locations closest to the trailing edge as shown in Figure 3A. Questions? Call us before drilling.

5. Cleco the servo bracket into position using the hole drilled in Step 3. A draw cleco may be required.

6. From inside the wing center punch through the servo bracket nutplate into the W.S 100.5 rib. Refer to Figure 4.

FIGURES 3 - ROLL SERVO & MOUNTING PLATE INSTALLATION

FIGURES 3A - ROLL SERVO & MOUNTING PLATE INSTALLATION

Forward

Rear Spar Web

Drill this hole first See Figure 3A below

First Hole at WS 100.5 Drill from outside of aircraft and locate between first & second trim piece rivets as shown.

First Trim Piece Rivet




FIGURE 4 ROLL SERVO BRACKET ASSEMBLY AT FS STA 100.5

7. Move the bracket out of the way and pilot drill the punched site using a #40 drill bit. Deburr & cleco the bracket back into position using a silver cleco.

8. Center punch through the remaining nutplates onto the W.S. 100.5 rib. Refer to Figures 4 & 6.

FIGURE 5 – WS 100.5 SERVO MOUNT RIB LOCATION

9. Remove the servo mounting bracket.

Holes drilled in servo bracket to clear rivets.

Installation Area

First hole drilled from outside through trim piece

Second Hole




FIGURE 6 VIEW LOOKING OUTBOARD AT STA 100.5 RIB

10. Pilot drill the marked holes made in Step 8 using a #51 or #40 drill bit. 11. Cleco the servo mounting bracket back into position and check for fitment. 12. Correct the fitment if required. 13. Remove the servo mounting bracket and enlarge the four (4) holes made in Step 10 above

using a #30 drill bit and cleco into position using copper clecos. 14. If satisfied with bracket alignment and fitment drill to final size using a #18 drill bit. 15. Deburr all holes. Clearance holes for existing rivets may be required as shown in Figure 4. 16. Coat the four (4) M3 screws supplied in the autopilot hardware kit with Blue Loctite

(Medium) 242 thread locker. Allow to dry completely before installation. 17. Fasten the servo arm to the servo hub using the four (4) M3 (metric) screws supplied. Refer to Figures

7, 8 and 9. 18. Mount the roll servo to the bracket assembly using the four (4) MS27039-0807 screws. The

bracket assembly and servo must be joined together inside the wing. Note

The Roll Servo hub roll pin hole must be aligned with the servo stop as depicted Figure 7 before attaching the crankarm to the hub.

FS STA 100.5 Flap Closeout Rib

Servo Bracket Screws - 1 hidden

First Hole WS 100.5




FIGURE 7 – ROLL SERVO HUB DRIFT PIN AND LOCKING PIN HOLE ALIGNMENT

Note:

The push pull tube assembly has been terminated on a single end to allow for manufacturing variations between Cessna models. The STC Group LLC has decided to eliminate fully terminated push pull tube assemblies to allow for variations between aircraft.

19. Ensure that the aileron surfaces are locked in the neutral flight position. This can be accomplished with the control lock if desired.

Note:

The push pull tube should be protected from damage by using painters tape or equivalent.

20. Install the push pull tube through the access hole at WS 144.80 with the rod end oriented towards the roll servo arm.

21. The rod end should have four (4) threads showing. 22. Attach the push pull tube to the roll servo arm as depicted in Figure 9. 23. The servo arm should be at 90-degrees from the servo case, facing forward towards the rear spar web. 24. Measure the push pull tube from the center of the servo arm to the center of the aileron bellcrank

mounting position. Refer to Figures 9 and 10. 25. Mark the push pull tube with a permanent marker at this location on the painter’s tape. This mark

represents the center to center distance between rod ends. 26. Remove the push pull tube from the wing.

Roll servo hub drift pin hole

Roll servo locking pin




27. Measure from the center of the servo arm rod end to the mark that was made on the push pull tube in Step 25.

28. This measurement will be the Center to Center Rod End measurement with four (4) rod end threads showing on each end.

29. Trim the push pull tube as required to meet the above center to center distance. 30. Deburr and smooth the push pull tube. 31. Insert the threaded rod end provided in the hardware kit into the unterminated (trimmed) end of the

push pull tube. 32. Using a V Block drill through the push pull tube using a #30 drill bit and deburr. Refer to Figure 9A

for rivet positioning. 33. Insert the threaded rod end back into the push pull tube and install two MS20470AD4-10 rivets into

the holes drilled in Step 32. 34. Thread the rod end and jam nut into the threaded rod insert with four threads showing. 35. Tighten the jam nut (four threads showing) and mark with tamper proof torque seal. 36. Install the Push Pull tube assembly. Refer to Figures 9, 10, & 11. 37. The Servo arm should be next to upper wing skin as depicted. 38. Attach the DB9 connector to the servo DC9 connector after completing the Wiring harness

installation in Section 5. 39. Install the servo mounting bracket and roll servo using the AN525 screws supplied.

FIGURE 8 ROLL SERVO PUSH PULL TUBE ASSEMBLY




FIGURE 9 ROLL SERVO ARM INSTALLATION

FIGURE 9A ROLL SERVO ARM INSTALLATION

Trim to length as required




FIGURE 10 AILERON BELLCRANG INSTALLATION




FIGURE 11 AILERON BELLCRANK INSTALLATION




4.0 PITCH SERVO INSTALLATION

4.1 Servo Angle Preparation 1. Place the angles on a bench with the hole side down.

Note:

Refer to Figure 12 for this section.

2. The pitch servo Zee Brackets, P/N 1006254, are positioned 9.5 inches from one end of the angle. 3. The opposite end of the Zee brackets will be 18.5 inches from the end of the angle. 4. Position the 90-degree bend of the Zee Brackets on the inside of the angle. 5. Clamp the Z brackets in place at each end using side grip cleco clamps. 6. The bottom flange of the Zee Brackets should cover 4 rivet holes on the angle. 7. There should be even rivet hole spacing from either the end of the Zee bracket.

FIGURE 12 ZEE BRACKET POSITION ON FUSELAGE ANGLES

9.5”

18.5”

Zee Bracket




8. Drill two (2) #40 holes through the Zee Brackets and fuselage angles one inch from the end of the Zee Bracket.

9. Deburr all holes. 10. Secure the Zee brackets into position using 3/32” Silver Cleco P Series Temporary Fasteners.

Refer to Figure 13. 11. Drill one (1) #40 hole in the middle of the fuselage angle. 12. Remove the Silver P Series Temporary Fasteners. 13. Deburr the hole. 14. Secure into position once more using Silver P Series Temporary Fasteners. 15. Enlarge the holes drilled in the previous steps using a #30 drill bit. 16. Deburr all holes. 17. Cleco the Zee Brackets into position using 1/8th inch Copper P Series Temporary Fasteners.

FIGURE 13 RIVET HOLE AND CLECO TEMPORARY FASTENER LOCATIONS

#40-hole Locations




5.0 MOUNTING PITCH SERVO TO THE SERVO TRAY

1. Coat the servo arm screws with Blue Loctite 242 and allow to dry. 2. Fasten the servo arm to the servo with the four (4) M3x0.5x10 mm screws, p/n 1011-1006-

0032, supplied in the hardware kit. Refer to Figure 14. 3. The servo arm must be positioned in the vertical position with the servo hub in the neutral

position. Note:

The servo arm will be able to move +/- 75 degrees in each direction from the vertical

4. The outer four (4) holes of the pitch servo baseplate may need to be enlarged to accommodate the MS270390807 screws supplied in the hardware kit.

5. To enlarge the pitch servo baseplate holes, enlarge the holes with a long #18 drill bit using an air drill or drill press. Use painters tape to protect all surfaces.

6. Fasten the pitch servo to the pitch servo tray, P/N 1006253 by positioning the supplied MS270390807 screws in the outer four (4) of the servo baseplate.

FIGURE 14 PITCH SERVO ARM POSITION

+ / -75 °

Baseplate Holes L i




6.0 PITCH SERVO FUSELAGE ANGLE INSTALLATION

1. Set the aircraft trim to a Nose Up position. 2. Take the angles and the servo and tray into the airplane with the following tools:

a. Drill and #40 drill bit b. Light c. #40 P Series Clecos d. Cleco pliers e. Steel ruler f. Tape measure

3. Position the fuselage angles so the Zee Brackets are on the forward end of the angle. Refer to Figure 15.

FIGURE 15 PITCH SERVO ANGLE POSITION

FS 172

FS 206

20.625”

Lower Fuselage Access Panel




4. Position the fuselage angles drilled side face down on the fuselage skin between FS 172 and FS 209 bulkheads. Refer to Figure 15.

Note:

The skin should be clean and free of debris.

5. The vertical surface of the fuselage angle faces outboard. 6. Position the tray under the cables with the servo on the starboard side of the aircraft. 7. Cleco the pitch servo tray to the top of the Zee brackets using the pilot holes provided. 8. Position the fuselage angles outboard and on either side of the lower access panel double. 9. Use a tape measure or 24” rule to position the aft edge of the pitch servo tray 20.625 inches

from the bottom of the FS 209 bulkhead. Refer to Figure 15.




7.0 PITCH SERVO SETUP

1. The lower elevator cable must not be deflected. 2. Position the forward end of the angles to attain the following dimensions:

a. The center of the elevator cable to the face of the servo arm is a distance of .750” to .875”. Refer to Figure 16.

3. Face the servo arm forward as depicted in Figure 16. 4. The distance between the end of the servo arm and the trim chain must be a minimum of

.375”.

FIGURE 16 PITCH SERVO ARM ALIGNMENT




FIGURE 17 PITCH SERVO ARM ALIGNMENT

5. Verify the angles are still in position at the access panel. 6. Using a #40 drill bit match drill through the aircraft skin at the first hole in the angle forward

of the servo tray. 7. Secure the fuselage angle using a 3/32” Silver Cleco P Series Temporary Fastener. 8. Verify the servo tray and angles did no move. 9. Using a #40 drill bit match drill one hole in the skin either side of the access panel. 10. Secure the fuselage angle using a 3/32” Silver Cleco P Series Temporary Fasteners. 11. Verify the measurements taken in Steps 2a. and 4. 12. Using a #40 drill bit match drill holes through both of the angles in the skin just forward and

aft of the servo tray. 13. Secure the fuselage angle using a 3/32” Silver Cleco P Series Temporary Fasteners. 14. Remove the servo and servo tray. 15. Mark the Zee brackets and angles as left and right. 16. Remove the Zee brackets. 17. Using a #40 drill bit match drill all the remaining holes through the angles into the skin. 18. Install 3/32” Silver Cleco P Series Temporary Fasteners every 2nd hole. 19. Remove the clecos from the holes that will be covered by the Zee brackets.




20. Re-install the Zee brackets and secure using 3/32” Silver Cleco P Series Temporary Fasteners through the side of the angle. Refer to Figure 13.

21. Move outside the airplane and back drill the Zee Brackets using the holes that were drilled in Step 17.

22. Secure the Zee bracket from the underside on the aircraft fuselage skin using 3/32” Silver Cleco P Series Temporary Fasteners.

23. Remove the fuselage angles and Zee Brackets 24. Deburr all holes. 25. Enlarge the pilot holes in the Zee Brackets and Servo Tray using a #18 drill bit. 26. Deburr all holes. 27. Install the MS21075L08N nut plates on the lower side of the top flange of the Zee Brackets

using the MS20426AD3-4 rivets provided in the hardware kit. 28. Rivet the Zee Brackets to the fuselage angles using the MS20470AD4-4 rivets provided in

the hardware kit. 29. Test fit the Servo Tray to the Zee brackets. 30. Rivet the angles and Zee Brackets to the aircraft skin with MS20470AD3-4 rivets. Provided

in hardware kit. 31. Install the servo and tray to the Z brackets with MS27039-0807 screws. 32. Install the rod ends on to the push pull tube with 4 threads showing following the instructions

provided in Steps 21 through 25 and Steps 27 through 32. 33. Align the rod ends and tighten the jam nuts. 34. Mark the jam nuts with tamper proof torque seal. 35. Attach the pitch push pull tube to the elevator idler bell crank using the hardware supplied.

Refer to Figure 18. 36. Attach the pitch push pull tube to and the servo arm. Refer to Figure 19.

Note:

Verify that spacer P/N 1006401-11 is positioned between the rod end and the servo arm.

37. Orient the bolts and castellated nuts to provide the most clearance between the nuts and the cables or the bell crank support structure.

38. Verify the servo arm has equal movement fore and aft with the elevator at full up and down deflection, if not adjust the push pull rod ends.

39. Ensure that the jam nut does not make contact with the servo arm. Use spacers as required to provide clearance between the jam nut and the servo arm.

40. If problems are encountered contact The STC Group LLC. 41. Install the cotter pins in the castellated nuts.




FIGURE 18 ELEVATOR IDLER BELCRANK PUSH PULL TUBE INSTALLATION

FIGURE 19 PITCH SERVO ARM PUSH PULL TUBE INSTALLATION




8.0 WIRING HARNESS INSTALLATION

NOTE: Prior to plugging harness DB9 or DB37 into servos or autopilot control perform a full power, ground, and data test on the harness. Refer to Trio Avionics DWG 41300007. Appendix A. 8.1 Roll Servo Harness Installation

1. Remove interior trim panels on cockpit passenger side 2. Remove existing Cessna factory autopilot wiring and set aside for weighing 3. Route Trio Harness Roll servo wiring along same path and using the same clamps as factory autopilot

wiring. 4. Take care to protect harness pins at end of harness. 5. Terminate supplied DB9 connector per Trio diagram. Refer to Trio DWG 41000000 6. Attach DB 9 connector to Trio Roll Servo. 7. Secure harness cable end at the servo end with supplied clamp or equivalent.

8.2 Pitch Servo Harness Installation 1. Remove co-pilot seat 2. Route Trio Harness Pitch servo wiring under cockpit floor taking care to secure away from other

aircraft wiring and moving components. 3. Route harness to Trio Pitch Servo location. 4. Take care to protect harness pins at end of harness. 5. Terminate supplied DB9 connector per Trio diagram. 6. Attach DB 9 connector to Trio Roll Servo. 7. Secure harness cable end at the servo end with supplied clamp or equivalent.

8.3 Trio Autopilot Controller 1. The Trio autopilot controller is ordered in Panel Mount or Instrument Mount versions. 2. Install the controller using best practices in either panel or hole locations. Refer to AC 43-13 for this

step and all following steps. 3. Refer to DWG 1006103. 4. Utilize Trio DWG 41300005 and The STC Group 1006103 for the following steps. 5. Install supplied 5 ampere circuit breaker within easy reach of the pilot and label per DWG 1006103. 6. If a Panel Mount unit is ordered install the supplied power switch and label per DWG 1006103. 7. Terminate supplied DB37 connector per Trio drawing in Step 3. 8. Terminate wiring with aircraft GPS or handheld. 9. If ARINC 429 is available from GPS terminate ARINC 429 connections. 10. Install the supplied PCS button on the left side of the pilots control yoke and label PCS per DWG

1006103. 11. Install Recover button in an available convenient location within easy reach of the pilot and label AP

Recover per DWG 1006103. 12. Ensure that the analog alarm out is connected to the un-switched audio input on the Audio Panel.

END




9.0 APPENDIX A

stc group llc north muskegon, michigan …...faa stc project st09202ch-a date: original issue 17...

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