STC GROUP LLC 480 RUDDIMAN DRIVE MUSKEGON, MICHIGAN REPORT NO: G REV E TRIO AUTO PILOT INSTALLATION INSTRUCTIONS

Transcription

1 STC GROUP LLC 480 RUDDIMAN DRIVE MUSKEGON, MICHIGAN REPORT NO: G REV E TRIO AUTO PILOT INSTALLATION INSTRUCTIONS CESSNA MODEL 182 WITH PREVIOUS CESSNA EQUIPPED AUTO PILOT DATE: Original Issue 11 March, 2017 WRITTEN BY: Paul Odum APPROVED BY: Jeff Ley

2 STC GROUP LLC Page 1 REVISIONS Rev. Date: By: Checked By: - 6 March, 2017 Van Abel Paul Odum A 13 March 2017 Paul C. Odum Ernie P. Salmon B 11 June 2017 Paul C. Odum Mark Hollon C 28 June 2017 Paul C. Odum Jeff Ley D 28 June 2017 Paul Odum Jeff Ley E 2 July 2017 Paul Odum Jeff Ley F 17 August 2017 Paul Odum Jeff Ley ER No: 1006 Section: All Description Initial Release TRIO AP Provisions Installation Instructions Page 1

3 STC GROUP LLC Page 2 TABLE OF CONTENTS TABLE OF CONTENTS... 2 LIST OF TABLES... 3 LIST OF FIGURES... 4 REFERENCES... 5 ACRONYMS, ABBREVIATIONS, AND SYMBOLS TRIO AUTO PILOT PROVISIONS INSTALLATION ROLL SERVO INSTALLATION OEM AUTO PILOT EQUIPPED OEM Wing Servo Removal Roll Servo MTG - Angle Installation MTG Plate - Roll Servo Installation TRIO PITCH SERVO MOUNT INSTALLATION Pitch Servo Mount Installation MTG Plate Pitch Servo Installation Harness Installation Roll Servo Harness Installation Pitch Servo Harness Installation Trio Autopilot Controller TRIO AP Provisions Installation Instructions Page 2

4 STC GROUP LLC Page 3 LIST OF TABLES No table of figures entries found. TRIO AP Provisions Installation Instructions Page 3

5 STC GROUP LLC Page 4 LIST OF FIGURES Figure 1-1 CESSNA 100 SERIES INSTALLATION LOCATIONS... 7 Figure 2-1 ROLL SERVO ACCESS PANELS... 8 Figure 3-3 PITCH SERVO SHELF & ZEE BRACKETS ALIGNMENT TRIO AP Provisions Installation Instructions Page 4

6 STC GROUP LLC Page 5 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. DWG Trio Pro Pilot Autopilot Inst Model Cessna 182 DWG DWG DWG DWG DWG DWG DWG DWG Roll Servo Structural Mod Pitch Servo Structural Mod Mounting Plate Roll Servo Angle Roll Servo Tray Pitch Servo Zee Pitch Servo Support Trio Cessna 182 Wiring Harness D Trio Pro Pilot System Wiring Diagram Industry Specifications and Standards: 1. MMPDS-09 Metallic Materials Properties Development and Standardization 2. AC B Aircraft Inspection, Repair & Alterations Other Data: ER1006 STC GROUP LLC Program Engineering Record. TRIO AP Provisions Installation Instructions Page 5

7 STC GROUP LLC Page 6 ACRONYMS, ABBREVIATIONS, AND SYMBOLS ASSY Autopilot C.G. ER FAA ICA INCH LH OEM OUTBD PCS Recover RH Servo STC WS Assembly Trio Pro Pilot Autopilot Center of Gravity Engineering Record Federal Aviation Administration Instructions for Continued Airworthiness Inches Left Hand Original Equipment Manufacturer Outboard Pilot Controlled Steering Recover Button Right Hand Trio Gold Stand Servo Supplemental Type Certificate Wing Station TRIO AP Provisions Installation Instructions Page 6

8 STC GROUP LLC Page TRIO AUTO PILOT PROVISIONS INSTALLATION This installation procedure provides information and data necessary to install bracketry, hardware, servos, harness, and controller for the Trio Auto Pilot in Cessna Aircraft Model 182 previously equipped with Cessna Aircraft Co. installed auto pilots. Aircraft not previously equipped with an auto pilot will use installation instructions for Non-Auto Pilot equipped aircraft. Areas of modification FIGURE 1-1 CESSNA 100 SERIES INSTALLATION LOCATIONS TRIO AP Provisions Installation Instructions Page 7

9 STC GROUP LLC Page ROLL SERVO INSTALLATION OEM AUTO PILOT EQUIPPED 2.1 OEM Wing Servo Removal 1. Remove RH wing inspection panels located at WS 103.5, 112.0, and 144.8, Ref Figure If the airplane is equipped with the OEM installed servo, disconnect the servo electrical harness connector and servo drive cable and remove the servo. 3. Remove the cable guide wheel and bracket, located at RH WS by removing the attachment bolts or drilling out the attachment rivets common to the guide wheel bracket and the aft spar web. 4. Cap, coil, and stow the servo wiring harness forward of the aft spar for use as a pull string when installing the TRIO roll servo wire harness. 5. Weigh and record all removed parts for weight and balance calculations. 6. Retain the old autopilot components in a suitable storage container. Wing Access Panels WS 103.5, & FIGURE 2-1 ROLL SERVO ACCESS PANELS TRIO AP Provisions Installation Instructions Page 8

10 STC GROUP LLC Page 9 FIGURE 2-2 TRIO PRO PILOT INSTALLATION Note: If any issues arise during installation of the bracket assemblies or autopilot contact The STC Group LLC immediately at (888) or (231) Support Assistance may be reached at extensions 1, 4, 5, 6, 7, 8. TRIO AP Provisions Installation Instructions Page 9

11 STC GROUP LLC Page TRIO Auto Pilot Roll Servo Mount Installation Roll Servo MTG - Angle Installation 1. Lay out and drill (4) #40 drill size pilot holes through the Angle as shown in Section D-D of drawing , Figure FIGURE ROLL SERVO MOUNTING ANGLE INSTALLATION FIGURE 2-4 ROLL SERVO FLAP CLOSEOUT ANGLE INSTALLATION TRIO AP Provisions Installation Instructions Page 10

12 STC GROUP LLC Page 11 Wing Upper Skin 4 Cleco Clamps Forward Angle WS IMAGE INBOARD MOUNTING ANGLE INSTALLATION 2. Position the Angle on the WS rib as shown in Section D-D and Section C-C of drawing and, Figures 2-3, 2-4, 2-5 and Image 1. The forward face of the Angle should be positioned 3.3 inches aft of the aileron cable with the ailerons locked in the neutral position. FIGURE 2-5 ANGLE AND MTG PLATE FWD AFT POSITION CHECK TRIO AP Provisions Installation Instructions Page 11

13 STC GROUP LLC Page Using the Angle as a drill locator, drill four (4) equally spaced #40 drill size holes through the Angle and WS Flap Closeout Rib as shown in Section D-D of drawing , Figures 2-3, 2-4, and Image Using 3/32 inch through-hole Cleco clamps, secure the Angle in position as shown in Section D-D of drawing , Figure 2-3 and Image Using a #30 size drill, enlarge all holes for installation of (4) MS20470AD4-4 rivets. 6. Remove the Angle and deburr all drilled parts. 7. Reposition the Angle and install (4) MS20470 AD4-4 rivets, one at each of the (4) drilled locations as shown in Image 2. Note: If the airplane was previously modified with flap gap seals, CR CherryMax rivets may be used in lieu of driven fasteners at all blind locations. Flap gap seals may be removed and reinstalled if driven rivets are desired. Wing Upper Skin Angle WS Forward IMAGE 2 INBOARD ANGLE INSTALLATION AT WS TRIO AP Provisions Installation Instructions Page 12

14 STC GROUP LLC Page MTG Plate - Roll Servo Installation 1. Position the MTG Plate to align the outboard flange with the WS rib web and the forward face of the Angle, as shown in Section C-C of drawing , Figure 2-5, 2-6, and Image 3. Face of angle positioned 3.33 aft of aileron cable. See View C-C. FIGURE 2-6 ROLL SERVO MOUNTING PLATE INSTALLATION Angle WS MTG Plate Aft Pilot Hole IMAGE ANGLE AND MOUNTING PLATE INSTALLATION TRIO AP Provisions Installation Instructions Page 13

15 STC GROUP LLC Page Verify the inbd and outbd ends of the MTG Plate are located aft of the aft spar web as shown in Section D-D (Figure 2-3), Section E-E (Figure 2-8) of drawing and as shown in Figure 2-5. FIGURE 2-7 ROLL SERVO ANGLE TO MOUNTING PLATE ATTACHMENT FIGURE 2-8 ROLL SERVO MOUNTING PLATE AT WS INSTALLATION TRIO AP Provisions Installation Instructions Page 14

16 STC GROUP LLC Page Using the Angle holes as a guide (see Image 3) use a center punch to mark into the MTG Plate. 4. Remove the MTG Plate, drill (2) #17 drill size holes and Cleco clamp back into position. Note: A 90-degree air drill is preferred for this operation to avoid marring the pilot holes. 5. Verify that the forward to Aft position of the SERVO MTG Plate is positioned as in Figure Center punch and drill (2) #17 drill size holes through the Plate return flange and WS rib web, refer to Figures 2-7, and Remove the Plate and deburr all drilled holes. 8. Reinstall the Plate using the suppled MS screws. 9. Install the Trio Roll Servo and Push Pull tube assembly as shown on DWG Rev. D, C- C & F-F (Figure 2-9), G-G (Figure 2-10), and H-H (Figure 2-11). The Servo crank arm should be next to upper wing skin as shown. 10. The Push-Pull Tube attachment will vary according to the year of the aircraft. Later model 182 aileron bellcranks allow the rod end to be positioned between the bellcrank arms. Earlier models may require the rod end to be positioned either on top or below the aileron bellcrank arm. FIGURE 2-9 ROLL SERVO AND PUSH-PULL TUBE INSTALLATION TRIO AP Provisions Installation Instructions Page 15

17 STC GROUP LLC Page 16 FIGURE 2-10 ROLL SERVO INSTALLATION ON MOUNTING PLATE FIGURE 2-11 PUSH-PULL TUBE ASSEMBLY TRIO AP Provisions Installation Instructions Page 16

18 STC GROUP LLC Page 17 Note: The Roll Servo hub roll pin hole must be aligned with the servo stop as shown in Image 4 before attaching the crankarm to the hub. Servo Hub Roll Pin Hole Servo Stop IMAGE 4 SERVO HUB ROLL PIN ALIGNMENT TRIO AP Provisions Installation Instructions Page 17

19 STC GROUP LLC Page TRIO PITCH SERVO MOUNT INSTALLATION FIGURE 3-1 TRIO PRO PILOT PITCH SERVO INSTALLATION TRIO AP Provisions Installation Instructions Page 18

20 STC GROUP LLC Page Pitch Servo Mount Installation 1. Install (4) 3/32 through-hole Cleco clamps common to the (2) ZEE angles and the four corners of the Pitch Servo Tray as shown in View B-B of drawing , Figure 3-2. FIGURE 3-2 PITCH SERVO TRAY INSTALLATION FIGURE 2-3 PITCH SERVO SHELF & ZEE BRACKETS ALIGNMENT TRIO AP Provisions Installation Instructions Page 19

21 STC GROUP LLC Page Remove (10) fasteners that secure the bottom empennage access panel as shown in Figure 3-3. IMAGE 5 ACCESS PANEL SCREWS AND ZEE ANGLE RIVET LOCATIONS 3. Position the Pitch Servo Tray Assembly between the left hand and right-hand stringers and slide aft until the ZEE angles vertical inner faces are coincident with the stringers as shown in View C-C of drawing FIGURE 3-4 ZEE ANGLE LAYOUT TRIO AP Provisions Installation Instructions Page 20

22 STC GROUP LLC Page 21 Note: Verify distance between the aft end of the Pitch Servo Tray and FS frame web is as shown in View B-B (Figure 3-2) of drawing (approx 4.25 ). FIGURE 3-5 PITCH SERVO SHELF ASSEMBLY POSITIONING 5. Identify the existing OEM tailcone skin-stringer fasteners that intersect with the ZEE angles, Ref. View C-C of drawing and Image 5. Note: Skin-stringers fasteners must align with the ZEE angles with a minimum edge distance of 0.20 inch from the ends and edges of the ZEE angles. Fasteners that will intersect the ZEE angles less-than 0.20 inches are to be omitted. 6. Drill out a minimum of (4) fasteners each with common alignment to the LH and RH tailcone skin stringers as shown in View C-C of drawing Caution: Take care to prevent enlarging the fastener holes when drilling off rivet heads. 7. While holding the Pitch Servo Tray Assembly in place back drill the ZEE brackets using the removed tailcone skin- stringer fastener holes as the locaters. 8. If the original rivet holes have not been enlarged use a #40 drill bit to pilot drill the ZEE Angles then Cleco into position. 9. Enlarge the pilot holes and ZEE Angles using using a #30 size drill bit. Caution: Take care to prevent enlarging fastener holes in the tailcone skin. 10. Remove the Pitch Servo Tray Assembly and deburr all drilled holes. TRIO AP Provisions Installation Instructions Page 21

23 STC GROUP LLC Page Match drill (4) pilot holes in the Pitch Servo Tray and ZEE angle with a #17 (0.173) size drill. 12. Install (4) MS21075L08N #8-32 nutplates, two on each of the return flanges of the ZEE angels as shown in View B-B of drawing (Figure 3-2). 13. Cleco the ZEE Angles into position and rivet into position. 14. MS20470AD4-4 driven rivets or CherryMax CR rivets may be used in lieu of driven rivets. 15. Install (4) MS screws common to the Pitch Servo Tray and ZEE angles. Typical OEM Tailcone Skin-Stringer Fasteners Tailcone Access Panel IMAGE 6 ZEE BRACKET RIVET LOCATIONS MTG Plate Pitch Servo Installation 1. Mount the Pitch Servo to tray and assemble push pull tube to location in drawing Refer to Figures 3-1, 3-4, 3-6, and 3-7. TRIO AP Provisions Installation Instructions Page 22

24 STC GROUP LLC Page 23 FIGURE 3-6 ELEVATOR PUSH PULL TUBE INSTALLATION FIGURE 3-7 ROLL SERVO PUSH PULL TUBE INSTALLATION 2. Verify push pull tube has proper clearance from control cables. a. Due to manufacturing differences, there may be a clearance problem with the lower pitch cable. If there is an interference, perform step 3 otherwise skip to step 4 3. If there is interference with the cables, the pitch servo tray mounting holes may be elongated by approximately 0.15 so that the tray sits more to the starboard side of the aircraft. 4. Contact the STC Group prior to performing any modifications to the pitch servo installation. The following modification should correct any manufacturing differences between aircraft years. a. Un-mount the servo but leave the unit assembled. Remove the pitch servo tray. b. Mark the tray and center punch. c. Drill a pilot hole using a #51 drill bit in that location. d. Using a #17 drill (0.173 ) enlarge the pilot hole. Deburr and reinstall the pitch servo tray. e. Mount servo and recheck clearances. If a problem remains recheck push pull tube assemble for correct positions of spacers and washers. If the problem continues contact The STC Group for technical support. TRIO AP Provisions Installation Instructions Page 23

25 STC GROUP LLC Page Tighten down all screws once aligned. 6. Check for full range of motion on pitch controls and recheck for clearance on cables. TRIO AP Provisions Installation Instructions Page 24

26 STC GROUP LLC Page 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. 4.1 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 Attach DB 9 connector to Trio Roll Servo. 7. Secure harness cable end at the servo end with supplied clamp or equivalent. 4.2 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. 4.3 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 for this step and all following steps. 3. Refer to DWG Utilize Trio DWG and The STC Group for the following steps. 5. Install supplied 5 ampere circuit breaker within easy reach of the pilot and label per DWG If a Panel Mount unit is ordered install the supplied power switch and label per DWG Terminate supplied DB37 connector per Trio drawing in Step 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 Install Recover button in an available convenient location within easy reach of the pilot and label AP Recover per DWG Ensure that the analog alarm out is connected to the un-switched audio input on the Audio Panel. TRIO AP Provisions Installation Instructions Page 25