STC GROUP LLC Page Ruddiman Drive PA-28 & PA-32 Trio Pro Pilot Installation Instructions North Muskegon, Michigan 49445

Transcription

1 STC GROUP LLC Page 1 STC GROUP LLC 480 RUDDIMAN DRIVE MUSKEGON, MICHIGAN DOCUMENT NO: REVISION D TRIO PRO PILOT INSTALLATION INSTRUCTIONS PIPER AIRCRAFT CORPORATION PA-28 AND PA-32 DATE: Original Issue 15 September, 2017 WRITTEN BY: Paul Odum APPROVED BY: Jeff Ley Page 1 of 46

2 STC GROUP LLC Page 2 List of Revisions Rev. Date: By: Checked By: - 15 September 2017 Paul Odum Jeff Ley A 30 October 2017 Paul Odum Jeff Ley B 24 January 2018 Paul Odum Jeff Ley C 21 March 2018 Paul Odum Curtis Stoltz D 09 April 2018 Paul Odum Jeff Ley ER NO: 1006 Section: Description Rev. - All Rev. A Cover Rev. B Sec. 2 Rev. C Table of Contents List of Figures List of Images References Acronyms, etc. Section 1 Section 2 Section 3 Section 4 Section 5 Rev. D Initial Release Rolled Revision, Change Header, Changed Title Removed roll template requirement Page Number Updated Section numbers Updated Figure numbers Updated Image numbers Added references Added Acronyms Contact information. Edit entire section Edit entire section New Section Edited from Section 3 New Section Edited from Section 3 Section 2.2 Hershey Bar Wing Roll Servo Installation Page 2 of 46

3 STC GROUP LLC Page 3 TABLE OF CONTENTS List of Revisions... 2 List of Figures... 4 List of Images... 5 REFERENCES... 6 ACROYMNS, ABBREVIATIONS, AND SYMBOLS TRIO Autopilot Installation ROLL SERVO INSTALLATION Taper Wing Roll Servo Installation Roll Servo Bracket Installation for Taper Wing Roll Servo Installation Wing Inspection Cover Reassembly Straight Wing Hershey Bar Roll Servo Installation Roll Servo Preparation Roll Servo Bracket Installation for Straight Wing Hershey Bar Models Roll Servo Installation for the Hershey Bar Wing PITCH SERVO BRACKET INSTALLATION Pitch Bracket Servo Mounting Installation Pitch Servo Installation Stabilator Pitch Clamp Assembly STABILATOR BALANCE WEIGHT ASSY Stabilator Balance Balancing Equipment Balancing Stabilator Tailcone Reassembly Appendix A ClickBond Nutplate Installation Instructions Appendix B Torque Values - A2 Stainless Steel Screws Appendix C Recommended Installation Tools Page 3 of 46

4 STC GROUP LLC Page 4 List of Figures Figure 2-1 ClickBond Nutplate Installation Figure 2-2 Roll Servo Installation & Servo Arm Alignment Figure 2-3 Roll Servo Arm Push Pull Tube Attachment Figure 2-4 Aileron Pushrod Connection Figure 2-5 Complete Roll Servo Assembly Figure 2-6 Mounting Plate & Servo Assembly Figure 2-7 ROLL SERVO & MOUNTING PLATE INSTALLATION Figure 2-8 ROLL SERVO & MOUNTING PLATE INSTALLATION 3 View Figure 2-9 Roll Servo Push Pull Tube Installation Figure 3-1 Stabilator Pitch Clamp Assembly Figure 3-2 Pitch Servo Assembly Attached to Stabilator Balance Weight ASSY Figure 3-3 Pitch Servo Push Pull Rod Attached to the Servo Arm Assembly Figure 3-4 Pitch Servo Push Pull Rod Attached to the Servo Arm Assembly Figure 3-5 Pitch Servo Push Pull Rod Attached to the Servo Arm Assembly Figure 4-1 Pitch Servo Push Pull Rod Attached to the Servo Arm Assembly Figure 4-2 Stabilizer Balance Page 4 of 46

5 STC GROUP LLC Page 5 List of Images IMAGE 2-1 ROLL SERVO LOCATION RIGHT WING IMAGE 2-2 IMAGE 2-3 IMAGE 2-4 IMAGE 2-5 IMAGE 2-6 IMAGE 2-7 Image 2-8 Image 2-9 IMAGE 2-10 IMAGE 3-1 IMAGE 3-2 IMAGE 3-3 IMAGE 3-4 IMAGE 3-5 IMAGE 3-6 IMAGE 3-7 IMAGE 3-8 IMAGE SERVO BRACKET MOUNTING PLATE ALIGNMENT MOUNTING PLATE WITH SERVO BRACKET SERVO BASEPLATE, SERVO STOP, AND ROLL PIN ALIGNMENT ROLL SERVO ASSEMBLY PUSH NUTS ON MS SERVO BASEPLATE SCREWS ROLL SERVO & MOUNTING PLATE INSTALLATION 3 VIEW ROLL SERVO & MOUNTING PLATE INSTALLATION 3 VIEW ROLL SERVO & MOUNTING PLATE INSTALLATION 3 VIEW ROLL SERVO HUB DRIFT PIN / LOCKING PIN ALIGNMENT PITCH SERVO ASSEMBLY PITCH SERVO DRILL TEMPLATE REMOVE TAIL CONE ASSEMBLY ELT ACCESS AREA DRILL TEMPLATE CLAMPED INTO POSITION TEMPLATE AFTER HOLES ARE DRILLED AND HEX NUT DRAW CLECOS INSTALLED CLICKBOND CN614CR08P INSTALLED ON GUSSETS CLICKBOND CN614CR08P INSTALLED ON GUSSETS THE FIRST MS SCREW INSTALLED Page 5 of 46

6 STC GROUP LLC Page 6 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 System Wiring Diagram Industry Specifications and Standards Piper Aircraft Corporation PA28 Cherokee Service / Maintenance Manual Applicable to the Piper PA28 Aircraft Model Piper Aircraft Corporation PA28 & PA28R Cherokee Parts Catalog Applicable to the Piper Aircraft Model Piper Aircraft Corporation PA32 Cherokee Service / Maintenance Manual Applicable to the Piper PA32 Aircraft Model MMPDS-09 AC B Metallic Materials Properties Development and Standardization Aircraft Inspection, Repair & Alterations Page 6 of 46

7 STC GROUP LLC Page 7 ACROYMNS, ABBREVIATIONS, AND SYMBOLS ASSY Autopilot C.G. ELT ER FAA FS GPS HSS ICA INCH LH OEM OUTBD P/N RH Servo STA STC Assembly Trio Pro Pilot Autopilot Center of Gravity Emergency Locator Transmitter Engineering Record Federal Aviation Administration Fuselage Station Global Positioning System High Speed Steel Instructions for Continued Airworthiness Inches Left Hand Original Equipment Manufacturer Outboard Part Number Right Hand Trio Gold Standard Servo Station (Arm) Supplemental Type Certificate Page 7 of 46

8 STC GROUP LLC Page 8 WS Wing Station Page 8 of 46

9 STC GROUP LLC Page TRIO Autopilot Installation Thank you for your purchase of the TRIO Pro Pilot Autopilot for your Piper PA28 Cherokee with the taper wing and the Hershey Bar wing. This installation procedures provided contain all information and data necessary to install bracketry and hardware for mounting the Trio Autopilot pitch and roll servos in most Piper Model PA28 aircraft with the taper wing and the Hershey Bar wing. This document is written to ensure your installation is easy, ensures safety, and is professionally completed. Before you begin Read All Instructions. You may contact The STC Group LLC for Technical Support questions. Tim Storey may be reached at Jeff Ley may be reached at (661) If you reach voic please leave a message. Tim and Jeff are working on autopilot installations and Research and Development projects. Tim and Jeff are happy to assist you with your hardware installation questions and will return your call as soon as possible. Tim is available Monday through Friday between 0900 and 1700 Pacific Time. Jeff Ley available Sunday through Friday 0900 to You may contact Chuck Busch at Trio Avionics with all autopilot related questions at (619) seven days per week. Please check all items included in the kit to ensure all parts are accounted for. All documentation required is available on The STC Group LLC website. The Illustrated Parts Catalog contains additional parts and drawings and may be downloaded from The STC Group LLC website at Note The aileron and stabilator 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. Page 9 of 46

10 STC GROUP LLC Page ROLL SERVO INSTALLATION The Roll servo installation for the PA28 with a taper wing is documented in paragraph 2.1. Roll servo installation for the PA28 with a Hershey Bar wing is documented in paragraph Taper Wing Roll Servo Installation Roll Servo Bracket Installation for Taper Wing 1. The Roll Servo Bracket is mounted on the RH wing rib at WS Remove the RH Wing inspection cover as shown in Image 2-1. Image 2-1 Roll Servo Location Right Wing 3. Align P/N Servo Bracket Mounting Plate to the wing rib as shown in Image 2-2. Note the cutout at the top of the plate. Tape the Servo Bracket Mounting Plate into position on the wing rib using painters tape or equivalent. Page 10 of 46

11 STC GROUP LLC Page 11 Image Servo Bracket Mounting Plate Alignment 4. All brackets have been pre-drilled. 5. Using a center punch, or equivalent, mark the position of the four outer holes on the wing rib for drilling. Note: 45-degree and 90-degree air drills that utilize threaded inserts are required for all drilling operations to prevent aircraft damage. Do not start the installation without the tools listed in Appendix C. 6. Use the three (3) step drilling method to match drill through the wing rib starting with a #40 drill bit using the Servo Bracket Mounting Plate as a guide. 7. Secure the plate into position using Silver Cleco P Series Temporary Fasteners. Note: It is recommended to enlarge the holes with a #30 drill bit, and then enlarge with a #18 drill bit. 8. Enlarge all holes to a final size using a #18 drill bit. 9. Remove the Servo Bracket Mounting Plate and deburr all drilled holes. 10. Prepare all surfaces for ClickBond nutplate installation using the ClickBond surface preparation kit provided. 11. Install four (4) ClickBond CN614CR08P nutplates on the inboard side of the wing rib using the ClickBond adhesive supplied. Refer to Figure 2-1 and Appendix A. Note: Page 11 of 46

12 STC GROUP LLC Page 12 This is a critical operation. Follow the ClickBond installation instructions on the ClickBond website. ClickBond nutplate installation requires clean hands, a clean environment, and properly prepared surfaces. Careful adherence to ClickBond installation instructions is required for successful nutplate installation. The STC Group LLC takes no responsibility if ClickBond installation instructions are not followed. Figure 2-1 ClickBond Nutplate Installation 12. After the ClickBond nutplates have been installed allow the ClickBond adhesive a minimum of three (3) hours to cure. 13. Insert Servo Bracket Mounting Plate into the wing and attach Servo Mounting Bracket, onto the mounting plate using the MS screws supplied. Torque the screws to lb-in. 14. Install the Servo Bracket Mounting Plate, P/N , with the Servo Mounting Bracket, P/N , onto the wing rib, using the MS fasteners supplied. Torque the screws to lb.-in. Refer to Image 2-3. Page 12 of 46

13 STC GROUP LLC Page Roll Servo Installation Image Mounting Plate with Servo Bracket 1. Lightly coat the four M3 x.5 x 10mm servo arm attachment screws with Loctite #242 (blue) compound. 2. Remove any excess compound from the screws. a. If you have received M3 servo arm screws pre-coated with Loctite 202 disregard these instructions. Do not add additional Loctite to the screws. b. Permanent damage to the servo mechanism will occur and The STC Group LLC and Trio Avionics are not responsible if Loctite 242 seeps into the servo mechanism. 3. Insert the M3 screws through the properly positioned Roll servo arm, p/n or and fasten them to the servo bushing. Refer to Figure 2-2 and Image Torque to the screws lb-in. using a calibrated screwdriver with the proper tip inserted. 5. Mark each screw with Torque Seal after installation. 6. Painters tape should be used to protect the servo surfaces. 7. Enlarge the four (4) outer holes on the servo baseplate using an air drill or drill press and a long (12 inch) #18 drill bit as shown in Image 2-4. Page 13 of 46

14 STC GROUP LLC Page The STC Group LLC prefers that installer use a drill press with a 12-inch drill bit for this operation to prevent marring the Roll Servo. 9. Deburr the baseplate holes. Servo Hub Roll Pin Hole Servo Stop Image 2-4 Servo Baseplate, Servo Stop, and Roll Pin Alignment 10. Position the Roll Servo onto the servo mounting bracket as shown in Figure 2-2 and Image 2-5. Figure 2-2 Roll Servo Installation & Servo Arm Alignment Note: Four (4) pushnuts, p/n10085, have been supplied in the roll servo hardware kit. Page 14 of 46

15 STC GROUP LLC Page Insert the four (4) MS screws supplied in the hardware kit through the servo baseplate and secure using the push nuts. Refer to Image Mount the roll servo to the servo mounting bracket using four (4) MS screws supplied. Torque the screws to lb.-in. Refer to Image 2-5.[C1][PO2] Image 2-5 Roll Servo Assembly 13. Attach the roll servo pushrod assembly, p/n , to the roll servo arm using the hardware supplied. Torque the nut to lb. in. Refer to Figure 2-3. Ensure the NAS1149F0332P washer, supplied, is placed under the AN3 bolt head. Image 2-6 Push Nuts on MS Servo Baseplate Screws Page 15 of 46

16 STC GROUP LLC Page 16 AN3 Bolt Servo Arm / -5 Aurora Rod End AN970-3 AN310-3 MS [C3] Figure 2-3 Roll Servo Arm Push Pull Tube Attachment 14. Attach the aileron end of the pushrod assembly to the aileron bell crank using the AN3-13 bolt. 15. If the roll servo arm is 90 to the pushrod assembly as shown in Figure 2-5 go to step If the roll servo arm is not 90 to the pushrod assembly as shown in Figure 2-5 remove the pushrod assembly from the bell crank. 17. Loosen the jam nuts on each end of the pushrod assembly. 18. Adjust the length of the pushrod assembly as required. Make sure each end of the pushrod assembly is adjusted equally. NOTE Make sure not more than 8 threads are showing at each end of the pushrod assembly. 19. Tighten the jam nuts on each end of the pushrod assembly. 20. Attach the aileron end of the pushrod assembly to the aileron bellcrank using the AN3-13 bolt, spacer, NAS1149F0332P washers and AN310-3 nut. Torque the nut to lb.-in. Refer to Figure 2-4. Ensure the NAS1149F0332P washer is placed under the AN3 bolt head. 21. Release the restraints holding the aileron control surfaces into the neutral flight position. 22. Check to make sure there is full roll axis motion. Page 16 of 46

17 STC GROUP LLC Page Make sure the servo arm is 90 to the pushrod assembly at center of motion and avoid hitting the servo stops. If not, repeat step Torque the AN310-3 nut to lb.-in. Refer to Figure 2-4. Ensure the NAS1149F0332P washer, supplied, is placed under the AN3 bolt head. AN310-3 MS AN970-3 Aurora Rod End AN3 Bolt Figure 2-4 Aileron Pushrod Connection Page 17 of 46

18 STC GROUP LLC Page 18 Figure 2-5 Complete Roll Servo Assembly Wing Inspection Cover Reassembly 1. Reinstall RH Wing inspection cover as shown in Figure 2-1. Page 18 of 46

19 STC GROUP LLC Page Straight Wing Hershey Bar Roll Servo Installation The Roll Servo Bracket is mounted behind the pilot s seat aft of the wing spar box carry through structure. Fuselage Station location will vary by aircraft. Installation instructions are the same for all models of straight wing (Hershey Bar) models Roll Servo Preparation 1. Remove the aircraft interior as required to gain access to the installation location. 2. Painters tape should be used to protect all Trio servo and installation plate, p/n , surfaces. 3. Painters tape is required to mark the adapter plate, p/n , installation location prior to drilling mounting and rivet holes. 4. Enlarge the four (4) outer holes on the servo baseplate using an air drill or drill press and a long (12 inch) #18 HSS drill bit. Note: A long drill bit is preferred to avoid marring servo surfaces. 5. Deburr the baseplate holes. Note: You should have received M3 servo arm screws pre-coated with Loctite 202. Do not apply additional Loctite to the screws. Permanent damage to the servo mechanism will occur and The STC Group LLC and Trio Avionics are not responsible if Loctite seeps into the servo mechanism. 6. Insert the M3 (16) screws through the properly positioned roll servo arm, p/n / -5, fasten them to the servo bushing, and mark with Torque Seal. Refer to Figure 2-6. Page 19 of 46

20 STC GROUP LLC Page 20 Figure 2-6 Mounting Plate & Servo Assembly 7. Torque to the screws lb.-in. using a calibrated screwdriver with the proper tip inserted. 8. Mark each screw with Torque Seal after installation Roll Servo Bracket Installation for Straight Wing Hershey Bar Models 1. Carefully study this section before starting the roll servo installation. 2. Call The STC Group LLC if you require technical assistance. You can leave a TEXT or a voice mail if there is no answer. 3. Review these drawings for proper installation of the brackets prior to installation. 4. Neutralize the ailerons and lock them into position with padded blocks, AN4 bolts, a large area washer (AN970-4) and a nut, or equivalent fasteners. 5. Protect the fuselage skin from damage by using painters tape or equivalent. 6. Align the roll servo mounting plate, p/n with the left aileron cable in the wing spar box carry through structure and tape into position. Refer to Figure 2-7. Page 20 of 46

21 STC GROUP LLC Page 21 Port Starboard Figure 2-7 ROLL SERVO & MOUNTING PLATE INSTALLATION Figure 2-8 ROLL SERVO & MOUNTING PLATE INSTALLATION 3 View Page 21 of 46

22 STC GROUP LLC Page Mark the Forward Port rivet hole with a Center Punch using the roll servo mounting plate as a template. 8. Drill the forward port hole though the belly skin Use a HSS #40 drill bit for this step. 9. Secure the mounting plate into position using Silver 3/32 P Series Cleco Temporary Fastener or equivalent. 10. Using the roll servo mounting plate as a template center punch and drill the forward starboard hole though the belly skin. Use a #40 drill bit for this step. Image 2-7 ROLL SERVO & MOUNTING PLATE INSTALLATION 3 View 11. Deburr the holes. 12. Remove the Cleco temporary fastener securing the roll servo mounting plate to the belly skin. Remove the roll servo mounting plate. 13. Secure the roll servo mounting plate to the outside of the belly skin with Silver 3/32 P Series Cleco Temporary Fasteners. Note: Ensure proper orientation of the servo mounting plate when securing the plate to the belly of the aircraft. Depending on aircraft model and equipment located in the installation area, you may be able to drill the remaining servo mounting plate rivet holes and servo mounting holes through the aircraft skin inside the aircraft. Page 22 of 46

23 STC GROUP LLC Page Center punch and drill the remaining eight (8) holes for the roll servo mounting plate through the belly skin and secure the mounting plate using Silver 3/32 Silver P Series Temporary Fasteners. 15. Using the roll servo mounting plate as a template center punch and drill four (4) roll servo mounting pilot holes though the belly skin. Refer to Figure Use a HSS #40 drill bit for this step. 16. Remove the Cleco Temporary Fasteners securing the roll servo mounting plate to the belly skin. 17. Remove the roll servo mounting plate. 18. Enlarge the (4) roll servo mounting pilot holes (not the rivet holes) drilled in the belly skin using a #30 drill bit. 19. Enlarge the ten (10) #40 roll servo mounting plate rivet holes drilled in the belly skin using a #30 drill bit. 20. Enlarge the (4) roll servo mounting pilot holes in the belly skin (not the rivets holes) using a #17 (0.173) size drill bit. 21. Deburr all holes and remove debris before proceeding. 22. Position the roll servo mounting plate as depicted in Figure 2-7 and rivet into position using ten (10) MS20470AD4 rivets (or rivet size required for the specific model aircraft) Roll Servo Installation for the Hershey Bar Wing 1. Install the roll servo onto the roll servo mounting plate, from outside the aircraft, using the AN R7 screws, nuts and washers supplied in the hardware kit. Torque the screws to 12 to 15 lb.-in. using a calibrated screwdriver with the proper tip inserted. 2. Position the servo arm. Refer to Images 2-8 & The servo arm should face towards the top of the aircraft at approximately the 12 o clock position as shown. Page 23 of 46

24 STC GROUP LLC Page 24 Image 2-8 ROLL SERVO & MOUNTING PLATE INSTALLATION 3 View Image 2-9 ROLL SERVO & MOUNTING PLATE INSTALLATION 3 View 4. Adjust the length of the pushrod assembly as required. Make sure each end of the pushrod assembly is adjusted equally. NOTE Make sure no more than 8 threads are showing at each end of the pushrod assembly. The minimum MM-3 rod end engagement length inside the push pull rod is Page 24 of 46

25 STC GROUP LLC Page Tighten the jam nuts on each end of the pushrod assembly. 6. Attach the roll servo push pull tube to the servo arm using the AN3-7 bolt, spacer, NAS1149F0332P washers and AN310-3 nut. 7. Torque the nut to lb.-in. using a calibrated socket wrench. Refer to Figure Ensure the NAS1149F0332P washer is placed under the AN310-3 nut. Refer to Figure X3. 9. Attach the roll servo push pull tube cable clamp to the aileron cable using the AN3-14 bolt,.5 spacer, AN970-3 washers and MS nut; and two AN3-6A bolts, AN970-3 washers and two MS21044N3 nuts. Torque the nuts to lb-in. using a calibrated socket wrench. Figure 2-9 Roll servo push pull tube installation 10. Verify the roll servo push pull tube has proper clearance from control cables. 11. Apply torque seal to all jam nuts and bolts. Page 25 of 46

26 STC GROUP LLC Page Install MS cotter pins in the castellated nuts on each end of the roll servo push pull tube. 13. Unlock the aileron controls previously locked. 14. Check the roll servo travel for binding by rotating control yoke to the port and starboard stops. 15. The aircraft controls should reach the aileron stops before the roll servo reaches its physical stops. 16. Refer to Image 2-10, Roll Servo Hub Drift Pin / Locking Pin Alignment for example of stop location. Servo Stop aligned with servo hub drift pin Image 2-10 Roll servo hub drift pin / locking pin alignment 17. If the servo reaches its stops before the ailerons reach their stops, contact The STC Group LLC at the phone numbers supplied in Section Replace the pieces removed earlier to facilitate the roll servo installation. Page 26 of 46

27 STC GROUP LLC Page PITCH SERVO BRACKET INSTALLATION 3.1 Pitch Bracket Servo Mounting Installation 1. The Pitch Servo Bracket Assembly, p/n , is mounted on the forward edge of the tailcone bulkhead gussets located at FS 268 and is accessed through the fuselage ELT inspection cover and the rear of the aircraft. Refer to Image 3-1. AFT Forward Image 3-1 PITCH SERVO ASSEMBLY 2. A drill template is available for rent with the installation kit to aid in drilling accuracy. Refer to Image 3-2 Image 3-2 PITCH SERVO DRILL TEMPLATE Page 27 of 46

28 STC GROUP LLC Page 28 Contact Gwena Odum at The STC Group LLC to arrange the Drill Template Rental. 3. The drill template is clamped into position prior to drilling. 4. Use a 90-degree air drill and HSS threaded drill bits for the pitch servo bracket installation. 5. Removal of the tailcone bulkhead will provide additional access. Refer to Image 3-3. Image 3-3 Remove Tail Cone Assembly 6. Remove the tailcone assembly as shown in Image Remove the tailcone by removing the Philips head screws around the perimeter of the bulkhead. 8. Remove the ELT inspection cover located on the RH rear side of the fuselage. Refer to Image 3-4. Page 28 of 46

29 STC GROUP LLC Page 29 Image 3-4 ELT ACCESS AREA Note: As you can see from Image 3-4 installation of the pitch servo bracket is two-person operation due to limited visibility and access in the installation location. One person will operate the air drill while a second person will assist with drill bit alignment and positioning. 9. Use painters tape on the bottom of the bracket to help determine alignment. Align the pitch servo bracket drill template on the upper surface of the two (2) lower steel airframe gussets. Refer to Image Draw lines on the tape on the template along the gusset interface with the template. 11. Remove the template. 12. Ensure the template holes are equal distance from each of the gusset lines. If not, redraw the lines to make the holes equal distance from each of the gusset lines. 13. Remount the template and align using the lines on the painters tape. Page 29 of 46

30 STC GROUP LLC Page 30 Image 3-5 Drill Template Clamped into Position 14. Clamp the drill template into position using Wing Nut or Hex Nut Draw Clecos clamps or equivalent. Refer to Image 3-5. NOTE The Template is ¾ in thickness. One (1) inch grip range draw clecos should be used. NOTE Use Boelube Push Tube, Multipurpose Lubricant or equivalent on drill when using template. Failing to do so will damage template. Template is only good to 200 degress. 15. Use a HSS threaded #40 drill bit and 90-degree air drill to drill pilot holes through the template into the gussets. Page 30 of 46

31 STC GROUP LLC Page Secure the drill template using Hex Wing Nut or Hex Nut Draw Clecos clamps or equivalent after each hole is drilled to ensure accuracy. Refer to Image 3-6. Image 3-6 Template After Holes Are Drilled And Hex Nut Draw Clecos Installed 17. Remove the drill template and use the three (3) step drilling method to enlarge the holes. Note: It is recommended to use a #30 after the #40 drill bit and enlarge to final hole size with a #18 drill bit. 18. Enlarge the holes to a final size of 11/64 (#18, ). 19. Deburr all drilled holes. Page 31 of 46

32 STC GROUP LLC Page Prepare all surfaces for ClickBond nutplate installation. Refer to Appendix A and the Clickbond Nutplate Installation Instructions on the ClickBond website. This is a critical operation. Note: Clickbond nutplate installation requires clean hands, a clean environment, properly prepared surfaces, and careful adherence to Clickbond installation instructions for successful nutplate installation. The STC Group LLC takes no responsibility if ClickBond installation instructions are not followed to the letter. 21. Install the four (4) ClickBond CN614CR08P nutplates on the underside of the gussets using the ClickBond adhesive supplied. Refer to Image 3-1 and Image 3-7 & Image 3-8. Image 3-7 ClickBond CN614CR08P INSTALLED ON GUSSETS Page 32 of 46

33 STC GROUP LLC Page 33 Image 3-8 ClickBond CN614CR08P INSTALLED ON GUSSETS 22. Install the pitch servo bracket onto the lower steel gussets, using four (4) MS supplied. Refer to Image 3-9. Perform Step 3.2 before performing this step. Page 33 of 46

34 STC GROUP LLC Page 34 Image 3-9 The First MS Screw Installed 3.2 Pitch Servo Installation 1. Painters tape should be used to protect the servo surfaces. 2. Enlarge the four (4) outer holes on the servo baseplate using an air drill or drill press and a long (12 inch) #18 drill bit as shown in Image The STC Group LLC prefers that installers use a drill press with a 12-inch drill bit for this operation to prevent marring the Pitch Servo. 4. Deburr the baseplate holes. 5. Lightly coat the four M3 x.5 x 10mm servo arm attachment screws with Loctite #242 (blue) compound. 6. Remove any excess compound from the screws. a. If you have received M3 servo arm screws pre-coated with Loctite 202 disregard these instructions. Do not add additional Loctite to the screws. Page 34 of 46

35 STC GROUP LLC Page 35 b. Permanent damage to the servo mechanism will occur and The STC Group LLC and Trio Avionics are not responsible if Loctite 242 seeps into the servo mechanism. 7. Insert the M3 screws through the properly positioned Pitch servo arm, p/n S , and fasten them to the servo bushing. Refer to Image Torque to the screws lb-in. using a calibrated screwdriver with the proper tip inserted. 9. Mark each screw with Torque Seal after installation. 10. Position the pitch servo on the pitch servo bracket. Refer to Image Attach the pitch servo using the four (4) MS screws supplied. Torque the screws to lb-in. Note: Step 11 must be accomplished with the pitch servo mounting plate, p/n and pitch servo inside the aircraft. 3.3 Stabilator Pitch Clamp Assembly 1. Fasten the Stabilator Clamp Assembly, p/n , to the balance shaft, as shown in Image 3-1 and Figure 3-1. Note: The correct position of the forward face of the Stabilator Pitch Clamp Assembly is 1 aft of the cable mounting tabs on the Stabilator Balance Weight Assembly. Page 35 of 46

36 STC GROUP LLC Page 36 Servo arm & Pitch Push Pull Rob Assy Figure 3-1 Stabilator Pitch Clamp Assembly Page 36 of 46

37 STC GROUP LLC Page Stabilator Clamp Assy Pitch Servo Rod Assy STABILATOR BALANCE WEIGHT ASSY Mounting Plate Pitch Servo Servo Arm MS Screws Figure 3-2 Pitch Servo Assembly Attached To Stabilator Balance Weight Assy 2. Ensure the Stabilator Clamp Assembly arm is level as shown in Figure Secure the Stabilator Clamp Assembly using the NAS P or MS bolts supplied with the Clamp Assembly. Torque the bolts to lb-in. 4. Attach the p/n , Pitch Servo Push Pull Rod to the servo arm using the AN3-7 bolt, AN970-3 washer and a AN310-3 castellated nut. Torque the nut to lb-in. Install a MS cotton pin. Refer to Figures 3-3 and 3-4. Page 37 of 46

38 STC GROUP LLC Page 38 Figure 3-3 Pitch Servo Push Pull Rod Attached to the Servo Arm Assembly AN970-3 Washer AN3-7 Bolt MS Cotter Pin Servo Arm Figure 3-4 Pitch Servo Push Pull Rod Attached to the Servo Arm Assembly Page 38 of 46

39 STC GROUP LLC Page Temporarily attach the upper end of the Pitch Servo Push Pull Rod to the Stabilator Clamp Assembly using the AN3-11 bolt. Refer to Figure Release the restraints holding the stabilator control surfaces into the neutral flight position. 7. Check to make sure there is full pitch axis motion. 8. Make sure the pitch servo arm and the Pitch Servo Push Pull Rod are at 90 at the center of motion. Refer to Figure Adjust the length of the Pitch Servo Push Pull Rod as necessary. Make sure each end of the pushrod assembly is adjusted equally. Repeat step 7. Note Avoid hitting the servo stops at the end of the stabilator travel. Note Make sure there are no more than 8 threads showing at each end of the pushrod assembly. 10. Attach the upper end of the Pitch Servo Push Pull Rod to the Stabilator Clamp Assembly using the AN3-11 bolt, AN970-3 washer and a AN310-3 castellated nut. Torque the nut to lb-in. Install a MS cotter pin. Refer to Figure 3-5. AN Clamp Assembly MS Cotter Pin AN3-11 Figure 3-5 Pitch Servo Push Pull Rod Attached to the Servo Arm Assembly Page 39 of 46

40 STC GROUP LLC Page Stabilator Balance 1. Whenever a configuration change is made to the stabilator Piper recommends that the Stabilator be balanced in accordance with the applicable Piper Aircraft Corporation PA28 Cherokee and PA32 Cherokee Service / Maintenance Manual. 4.1 Balancing Equipment 1. Balancing must be done using a suitable tool capable of measuring unbalance in inch-pounds from the centerline of the control surface hinge pin. An example tool configuration is shown in Figure 4-1. Other tool configurations may be used if accuracy is maintained and recalibration capability is provided. The tool shown in Figure 4-1 may be calibrated by placing it on the control surface to be balanced with the balance points over the control surface hinge centerline and the balance bar parallel to the chord line. Position the trailing edge support to align the tool with the control surface chord line and secure in this position. Remove the tool without disturbing the trailing edge support. Balance the tool by adding weight to the light end as required. (The movable weight must be at the centerline.) Place the tool on the control surface perpendicular to the hinge centerline per Figure 4-2. Read the scale when the bubble level has been centered by adjustment of the movable weight. 4.2 Balancing Stabilator Refer to Figure To balance the Stabilator, the assembly must be complete including the trim tab, the tab push rod and end bearing, stabilator tips, and all attaching screws. Before balancing, tape the trim tab in the neutral position with a small piece of tape. Place the complete assembly on knife edge supports in a draft free area allowing unrestricted movement. Place the tool on the stabilator with the beam perpendicular to the hinge centerline. Do not place the tool on the trim tab. Calibrate the tool per balancing equipment. Read the scale when the bubble level has been centered by adjustment of the movable weight to determine static balance limit. If the static balance is not per limits in Figure 4-2, proceed as follows: a) If the stabilator is out of limits on the leading edge heavy side, remove balance plates from the mass balance weight until the static balance is within limits. Do not adjust the stabilator tip balance weight. Page 40 of 46

41 STC GROUP LLC Page 41 b) If the stabilator is out of limits on the trailing edge heavy side, add balance plates to the mass balance weight until the static balance is within limits. The Stabilator Clamp Assembly ( ) and the Pitch Servo Rod Assembly ( ) must be attached per Section 3.3. Page 41 of 46

42 STC GROUP LLC Page 42 From Figure 55-4 PIPER AIRCRAFT PA AIRPLANE MAINTENANCE MANUAL Figure 4-1 Pitch Servo Push Pull Rod Attached to the Servo Arm Assembly Page 42 of 46

43 STC GROUP LLC Page 43 From Figure 55-3 PIPER AIRCRAFT PA AIRPLANE MAINTENANCE MANUAL Figure 4-2 Stabilizer Balance 5.0 Tailcone Reassembly 1. Replace the tailcone bulkhead located at FS 268 using the removed Philips head screws. Install the tailcone assembly in reverse order of disassembly. Page 43 of 46

44 STC GROUP LLC Page 44 Appendix A ClickBond Nutplate Installation Instructions Page 44 of 46

45 STC GROUP LLC Page 45 Appendix B Torque Values - A2 Stainless Steel Screws Page 45 of 46

46 STC GROUP LLC Page 46 Appendix C Recommended Installation Tools Cleco P Series Temporary Fasteners 45-Degree Air Drills & Threaded Bits 90-Degree Air Drills Hex-Nut and Wing-Nut Draw Clecos Page 46 of 46