STC GROUP LLC NORTH MUSKEGON, MICHIGAN 49445-2783 · PDF fileNORTH MUSKEGON, MICHIGAN 49445-2783 ... Cessna 172 Parts Catalog . ... Center punch and drill the upper rear hole though

STC GROUP LLC 480 RUDDIMAN DRIVE

NORTH MUSKEGON, MICHIGAN 49445-2783

REPORT NO: 1006102 REV C

TRIO PRO PILOT AUTOPILOT INSTALLATION INSTRUCTIONS CESSNA 172 AND CESSNA 175

FAA STC PROJECT ST09202CH-A

DATE: Original Issue 17 July, 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 1006102 Rev C

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 July 2017 Paul Odum Jeff ley

A 19 July 2017 Paul Odum Jeff Ley

B 22 September 2017 Paul Odum Jeff Ley

C 27 September 2017 Paul Odum Jeff Ley

ER No: 1006

Section: Description

All Initial Release

TOC Updated Table Of Contents




TABLE OF CONTENTS

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

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

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

REFERENCES 5

ACRONYMS, ABBREVIATIONS, AND SYMBOLS ..................................................... 6

1.0 Trio Pro Pilot Autopilot Installation ........................................................ 7

2.0 General .................................................................................................... 8

3.0 Roll Servo Installation – Right (Starboard) Wing ................................... 9

4.0 Pitch Servo Installation ........................................................................... 18

5.0 Wiring Harness Installation ..................................................................... 29

5.1 Roll Servo Harness Installation ............................................................... 29

5.2 Pitch Servo Harness Installation .............................................................. 29

5.3 Trio Autopilot Controller ........................................................................ 29

6.0 Appendix A - DWG 41300007 .............................................................. 30




LIST OF TABLES

No table of figures entries found.




LIST OF FIGURES

FIGURE 1 AREAS OF AUTOPILOT INSTALLATION

FIGURE 2 WING ACCESS COVER LOCATIONS

FIGURE 3 ROLL SERVO & MOUNTING PLATE INSTALLATION

FIGURE 4 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 PITCH SERVO INSTALLATION DIAGRAM

FIGURE 13 RIGHT RUDDER CABLE PULLEY

FIGURE 13A (TOP VIEW) PITCH SERVO BRACKET ASSEMBLY

FIGURE 14 PITCH SERVO CLIP INSTALLATION

FIGURE 15 BRACKET (CLIP) MEASURMENT BELOW FS 142.00

FIGURE 16 BRACKET (CLIP) TO REAR SHELF ALIGNMENT

FIGURE 17 POSITION OF RIVET HOLES IN CLIP (1006237)

FIGURE 18 TENSION CLAP TO HOLD CLIP INTO POSITION

FIGURE 19 ANGLE TO BRACKET CLEARANCES

FIGURE 20 UPPER PITCH CABLE

FIGURE 21 LH AND RH ANGLE REFERENCE LINES AND MOUNTING HOLE LOCATIONS

FIGURE 22 LH AND RH ANGLES FASTENED TO ACCESSORY TRAY

FIGURE 23 SERVO HUB TO LOCK PIN ALIGNMENT (SEE NOTE)

FIGURE 24 PITCH SERVO LINKAGE ATTACHMENT

FIGURE 25 PITCH SERVO ARM ALIGNMENT – NEUTRAL POSITION




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 172 Parts Catalog

STC Group LLC Document Number 1006101 – Cessna 172 Installation

STC Group LLC Document Number 1006203 – Cessna 172 Roll Servo Provisions

STC Group LLC Document Number 1006204 – Cessna 172 Pitch Servo Provisions

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.




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 172.

FIGURE 1 AUTOPILOT INSTALLATION

Areas of modification




2.0 GENERAL

Thank you for your purchase of the TRIO Auto Pilot for the Cessna 172. 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 172




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. Align bracket to drawing and measurements.

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. 16. Clearance holes for existing rivets may be required as shown in Figure 4. Mark the rib

through the pre-drilled holes to help in locating where to drill for clearance holes in bracket. 17. 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. 18. Fasten the servo arm to the servo hub using the four (4) M3 (metric) screws supplied. Refer to Figures

7, 8 and 9. 19. 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.

20. 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.

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

22. The rod end should have four (4) threads showing. 23. Attach the push pull tube to the roll servo arm as depicted in Figure 9. 24. The servo arm should be at 90-degrees from the servo case, facing forward towards the rear spar web. 25. 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. 26. 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. 27. Remove the push pull tube from the wing.

Roll servo hub drift pin hole

Roll servo locking pin




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

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

30. Trim the push pull tube as required to meet the above center to center distance. 31. Deburr and smooth the push pull tube. 32. Insert the threaded rod end provided in the hardware kit into the unterminated (trimmed) end of the

push pull tube. 33. Using a V Block drill through the push pull tube and threaded rod end using a #30 drill bit and

deburr the tube and threaded rod end holes. Refer to Figure 9A for rivet positioning. 34. Insert the threaded rod end back into the push pull tube and install two MS20470AD4-10 rivets into

the holes drilled in Step 32. Figure 9A which shows MS20470AD4-11. These may be too long. 35. Thread the rod end and jam nut into the threaded rod insert with four threads showing. 36. Tighten the jam nut and mark with tamper proof torque seal. 37. Install the Push Pull tube assembly. Refer to Figures 9, 10, & 11. 38. The Servo arm should be next to upper wing skin as depicted. 39. Attach the DB9 connector to the servo DC9 connector after completing the Wiring harness

installation in Section 5. 40. 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

1. Carefully study this section before starting the pitch servo installation. 2. Call Jeff Ley of The STC Group LLC for technical assistance. +1 661-524-6157. You can

leave TEXT or Phone Message if there is no answer. 3. Review these drawings for proper installation of the brackets prior to installation. 4. Neutralize the elevators and lock them into position with padded blocks, AN4 bolts, and

a nut, or equivalent fasteners. 5. For easier installation, assemble the pitch servo to the servo brackets before starting the

measuring process. 6. This step will simplify bracket orientation and location. 7. Remove the baggage compartment cover to access the installation area. 8. Locate upper pitch cable at FS-124 and mark rear of shelf FS-124.00 and bulkhead at FS-142.00 with

the location of the cable. Refer to Figure 6 and DWG 1006204.

FIGURE 12 PITCH SERVO INSTALLATION DIAGRAM

FS 142.00

FS 124.00

Upper Pitch Cable




9. With the elevator locked in neutral, locate and mark the starboard side bulkhead right rudder cable pulley at FS-142.00. Refer to Figure 13.

FIGURE 13 RIGHT RUDDER CABLE PULLEY

Right rudder cable pulley

Elevator lower cable pulley

Left rudder cable pulley Right rudder pulley centering bolt

Pitch Servo




FIGURE 13A (TOP VIEW) PITCH SERVO BRACKET ASSEMBLY

10. The port edge of the pitch servo bracket is located 1.37 inches from the cable. Mark F.S. 124.00 with this measurement. Refer to Figure 13A.

11. The outboard edge of the Clip is located approximately 1.185” from the center of the cable centering bolt. Mark the FS 142.00 bulkhead with this measurement. This measurement may vary due to manufacturing differences.

12. This measurement defines the right most edge of clip, p/n 1006237. Refer to Figures 13A, 14 & 15.

FIGURE 14 PITCH SERVO CLIP INSTALLATION

0.70” to 1.0” below lip of FS 142.0

Step 11 measurement location Clip = p/n 1006237

Approximately 1.185” to edge of clip This measurement may vary.

Step 10 measurement




13. Measure 0.70” to 1.00” inch below the of FS142 and mark the bulkhead as depicted in Figure 15.

FIGURE 15 BRACKET (CLIP) MEASURMENT BELOW FS 142.00

14. This measurement indicates the top surface of clip, p/n 1006237. Refer to Figure 14 & 15. 15. Align bracket (clip) square with the rear of shelf at FS-124.00. Refer to Figure 16.

FIGURE 16 BRACKET (CLIP) TO REAR SHELF ALIGNMENT

0.70” to 1” below lip of FS 142.00. This rivet location will determine distance above shelf. Rivet may contact the bottom of the clip.

Clip upper surface should be level with the accessory tray.




16. Align the clip so that one rivet hole is starboard of the pulley bracket and that one rivet hole is positioned under the RH rudder pulley bolt hole position. It may be necessary to adjust the clip position side to side for proper fit. Use tension clamps to hold the clip into position. Refer to Figure 18. There may be manufacturing deviations on clip width between manufacturers. Adjust as required.

FIGURE 17 POSITION OF RIVET HOLES IN CLIP (1006237)

FIGURE 18 TENSION CLAP TO HOLD CLIP INTO POSITION

17. Fasten the pitch servo to the pitch servo angle assemblies, part numbers 1006241 and 1006242, using the MS27039-0807 screws supplied in the kit as depicted in Figure 16. This step holds the angles square.

18. Prior to drilling any holes position the angle assemblies square with the clip (1006237) and FS 124.0 accessory shelf. Clamp the LH and RH angles into position on the shelf and to the clip.

19. Recheck positioning to agree with the dimensions depicted on DWG 1006204 Detail C-C. Refer to Figure 19.

20. The upper pitch cable should be located “a minimum horizontal distance” of 1.37 inches from the edge of the LH (port side) angle assembly, part number 1006242, at FS 124.0. This clearance dimension is required to be maintained fore and aft of the LH angle assembly. The dimension should not exceed 1.45 inches at FS 124.0. Take measurements at FS 124.0 and FS 142.0. Refer to Figures 19 & 20.

Position this hole under the RH rudder pulley bolt hole.




FIGURE 19 ANGLE TO BRACKET CLEARANCES

21. Clamp the angle assemblies into position using cleco clamps or equivalent. Take care to protect anodized surfaces.

1006237 Clip




FIGURE 20 UPPER PITCH CABLE

22. Ensure that the clip (p/n 1006237) is clamped securely to the FS 142.0 bulkhead. 23. The clip is pre-drilled with four (4) #40 holes. 24. Using the clip as a drill guide, drill four (4) #40 holes through the FS 142.00 bulkhead. 25. Drill the outboard holes first then drill the inner two (2) holes. 26. Cleco the clip into position after drilling each hole. 27. Enlarge the holes using a #30 drill bit. 28. Deburr the holes in the FS 142.00 bulkhead and the clip. 29. Using the AD4 rivets supplied with the kit (or Cherrymax equivalent) rivet the clip into place. 30. Fasten the RH and LH angles to the clip using the MS27039-0807 screws supplied in the kit. 31. Clamp the LH and RH angles into position at FS 124 as depicted in Figure 19 & 20. 32. Remeasure the upper pitch cable clearance dimensions at FS-124 and FS 142 as in described Step 19. 33. Mark the FS-124 accessory tray as depicted in Figure 20 with the locations of the LH and RH angles. 34. These marks will assist in the location of the mounting holes for angles. 35. Using the edge of the accessory tray and using a colored marker, draw a reference line across the LH

an RH angles as depicted in Figure 21. 36. Measure the distance from the reference line to the center of the LH and RH mounting holes. These

holes are pre-drilled and have MS21075L08N nutplates installed in them. Accuracy is important.

Upper Pitch Cable

LH & RH Angle Screws

1.37 inches minimum FS124.00 and 142.00




FIGURE 21 LH AND RH ANGLE REFERENCE LINES AND MOUNTING HOLE LOCATIONS

37. Using the accessory tray edge as a guide measure the distance taken in Step 35 and mark the LH and RH angle hole locations a depicted in Figure 21.

38. Use a center punch to mark the LH and RH angle mounting hole locations. 39. Remove the clamps from the LH angle and let it hang below the shelf. 40. Drill a pilot hole through the center punch mark using a #40 drill bit. Do not allow the drill bit to

extend below the angle more than .125 inch or less. Use a drill stop for this step. 41. Clamp the LH angle back into position and check the hole alignment with the nutplate. 42. Unclamp the LH rail and enlarge the hole using a #30 drill bit. 43. Using a #30 cleco clamp secure the LH angle into position. 44. Repeat Steps 36 through Step 42 for the RH angle. 45. Unclamp the LH angle and let it hang free. 46. Enlarge the mounting hole using a #17 drill bit. Deburr both sides of the hole. 47. Repeat Step 44 and 45 for the RH angle 48. Fasten the LH and RH angles into position on the accessory tray, as depicted in Figure 22, using the

MS27039-0807 screws supplied in the kit. 49. Remeasure the dimensions as in Step 19.

LH & RH Reference Lines LH and RH mounting hole locations




FIGURE 22 LH AND RH ANGLES FASTENED TO ACCESSORY TRAY

FIGURE 23 SERVO HUB TO LOCK PIN ALIGNMENT (SEE NOTE)

50. Coat the four (4) M3 screws supplied in the autopilot hardware kit with Loctite Blue (Medium) 242 thread locker. Allow to dry completely before use.




Note

The Pitch Servo hub roll pin hole must be aligned with the servo stop as depicted Figure 23 before attaching the servo arm to the hub.

51. Fasten the servo arm to the servo hub using the four (4) M3 (metric) screws supplied. The screws must be coated with Blue Medium strength Loctite before installation.

52. Assemble the pitch push pull tube linkage to the upper elevator cable as depicted in Detail D, Detail E in Figure 24 (spacer used 1006401-1 for clamp?)

FIGURE 24 PITCH SERVO LINKAGE ATTACHMENT

Note

Ensure that the elevator controls are locked in the neutral position for the following steps.

53. Attach the cable clamp, part number 9100606-1, to the upper elevator cable and lightly anchor so that it does not shift position easily. This is to allow for final adjustment after elevator travel checks.

54. Attach the push pull tube to the servo arm and upper elevator cable clamp as depicted in Figure 24.

55. Ensure that the servo arm is oriented with the upper elevator control cable as depicted in depicted in Figure 25.

1006401-1 Spacer

Upper Elevator Cable




FIGURE 25 PITCH SERVO ARM ALIGNMENT – NEUTRAL POSITION

56. Remove the blocks holding the elevator in the neutral position. 57. Have an assistant move the control yoke, or elevator, through the full up and down travel. 58. The servo arm should be positioned as depicted in Figure 25 when the elevator pitch controls

are in the neutral position. 59. Position the upper elevator cable clamp to allow the pitch controls to fully deflect with the

pitch servo arm centered. Refer to Figure 25. 60. Once complete tighten the upper cable clamp using the proper bolt torque. 61. The servo arm should be positioned as depicted in Figure 25 when the elevator pitch controls

are in the neutral position.

Upper Elevator Cable




5.0 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 by ringing the wires from plug to plug using PRO PILOT WIRING HARNESS DWG 41300007. Refer to Appendix A, The Trio Avionics CD, included with the autopilot kit, and the Trio website have links to DWG 41300007. You can call Trio Avionics at 1 619-448-4619 if you have additional questions or need assistance. 5.1 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 if so equipped. 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. 6. Attach DB 9 connector to Trio Roll Servo. 7. Secure harness cable end at the servo end with supplied clamp or equivalent.

5.2 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.

5.3 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. Install the supplied 5 ampere circuit breakers within easy reach of the pilot and label. 4. If a Panel Mount unit is ordered install the supplied power switch and label. 5. Terminate supplied DB37 connector per the Trio drawing 41300007. 6. Terminate wiring with aircraft GPS or handheld. 7. If ARINC 429 is available from GPS terminate ARINC 429 connections. 8. Install the supplied PCS button on the left side of the pilots control yoke and label PCS. 9. Install Recover button in an available convenient location within easy reach of the pilot and label AP

Recover. 10. Ensure that the analog alarm out is connected to the un-switched audio input on the Audio Panel.




6.0 APPENDIX A - DWG 41300007

Documents

STC GROUP LLC NORTH MUSKEGON, MICHIGAN 49445-2783 · PDF fileNORTH MUSKEGON, MICHIGAN 49445-2783 ... Cessna 172 Parts Catalog . ... Center punch and drill the upper rear hole though