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STC GROUP LLC 480 Ruddiman Drive Cessna Model 177/177RG Autopilot Installation Instructions North Muskegon, Michigan 49445 1006008 Rev A

STC GROUP LLC 480 RUDDIMAN DRIVE

NORTH MUSKEGON, MICHIGAN 49445-2783

DOCUMENT NUMBER 1006008 REVISION A

TRIO PRO PILOT AUTOPILOT INSTALLATION INSTRUCTIONS CESSNA 177 AND CESSNA 177RG

DATE: Original Issue 14 December, 2017

WRITTEN BY:

Paul Odum

APPROVED BY:

Jeff Ley

STC GROUP LLC Page 1 of 25 480 Ruddiman Drive Cessna Model 177/177RG Autopilot Installation Instructions North Muskegon, Michigan 49445 1006008 Rev A

Page 1 of 25

REVISIONS

Rev. Date: By: Approved By:

- 14 December 2017 Paul Odum Jeff Ley

A 15 December 2017 Paul Odum Jeff Ley

ER No: 1006

Section: Description All Rev. A, Sec. 5.3

Original issue Renamed Section 5 to Appendix A. Added T Fittings and Tubing specifications.


Page 2 of 25

TABLE OF CONTENTS

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

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

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

LIST OF IMAGES .............................................................................................................. 5

REFERENCES ................................................................................................................. 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 ........................................................................ 16

APPENDIX A TRIO PRO PILOT AUTOPILOT INSTALLATION ....................... 21

APPENDIX B PRO PILOT SYSTEM WIRING DIAGRAM .................................... 24


Page 3 of 25

LIST OF TABLES

No table of figures entries found.


Page 4 of 25

LIST OF FIGURES

FIGURE 1-1 AUTOPILOT INSTALLATION ................................................................ PAGE 7

FIGURE 3-2 ROLL SERVO & MOUNTING PLATE INSTALLATION .................... PAGE 10

FIGURE 3-2 ROLL SERVO MOUNTING PLATE INSTALLATION LOCATION PAGE 10

FIGURE 3-3 MOUNTING PLATE AND SERVO ASSEMBLY ................................... PAGE 11

FIGURE 3-4 PUSH PULL TUBE ATTACHMENT AT SERVO ARM ........................ PAGE 13

FIGURE 3-5 PUSH PULL TUBE ATTACHMENT AT AILERON BELLCRANK .. PAGE 13

FIGURE 4-3 PITCH SERVO BRACKET ASSEMBLY ................................................. PAGE 15

FIGURE 4-4 PITCH SERVO ASSEMBLY ...................................................................... PAGE 15

FIGURE 4-5 PITCH SERVO ALIGNMENT................................................................... PAGE 18

FIGURE 4-6 SERVO ARN AND CABLE CLAMP ASSEMBLY.................................. PAGE 19


Page 5 of 25

LIST OF IMAGES

IMAGE 0-1 WING ACCESS COVER LOCATIONS ..................................................... PAGE 9

IMAGE 3-2 ROLL SERVO BRACKET MOUNTING HOLES .................................... PAGE 11

IMAGE 3-3 ROLL SERVO HUB DRIFT PIN / LOCKING PIN ALIGNMENT ........ PAGE 12

IMAGE 3-4 ROLL SERVO INSTALLATION ................................................................ PAGE 12

IMAGE 3-5 PUSH PULL TUBE ATTACHMENT AT AILERON BELLCRANK ..... PAGE 14

IMAGE 0-2 PITCH SERVO ASSEMBLY (SHOWN IN PITCH NEUTRAL) ............. PAGE 16

IMAGE 0-3 PITCH SERVO TRAY ORIENTATION .................................................... PAGE 17

IMAGE 0-4 TENSION CLAMP ........................................................................................ PAGE 18

IMAGE 0-5 CABLE CLAMP ORIENTATION .............................................................. PAGE 19

IMAGE A-0-6 GROEN CONSTANT PRESSURE CLAMP .......................................... PAGE 21


Page 6 of 25

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 1177800 – Cessna 177 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.


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ACRONYMS, ABBREVIATIONS, AND SYMBOLS

Autopilot Clip C.G.

Trio Pro Pilot Autopilot Part Number 1177316 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


Page 8 of 25

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 Models 177 & 177RG.

FIGURE 1-1 AUTOPILOT INSTALLATION

Areas of modification


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2.0 GENERAL

Thank you for your purchase of the TRIO Pro Pilot Autopilot for your Cessna Cardinal. This document is written to ensure your installation is easy, ensures safety, and is professionally completed. Before you begin Read All Instructions. Call Jeff Ley at The STC Group LLC at (661) 524-6157 call/text/phone/VM if you have hardware installation questions. Check all items included in the kit to ensure all parts are accounted for. Jeff Ley of the STC Group LLC is available Sunday through Friday. You may contact Paul Odum at (805)304-5246 on Saturdays. Call Trio Avionics with all Trio Pro Pilot autopilot related questions. Trio Avionics may be reached (619) 448-4619 seven days per week. 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/


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3.0 ROLL SERVO INSTALLATION – RIGHT (STARBOARD) WING

1. Remove the three (3) inspection panels located between WS 138.00 and WS 189.00. Refer to Image 3-1.

IMAGE 3-1 WING ACCESS COVER LOCATIONS

2. Insert the servo bracket, p/n 1177501, through the access hole at W.S. 163.0 and align it with W.S 155.0 rib as depicted in Figure 3-2.

3. Center punch the upper forward hole through the MS21075L08N nutplate at WS 155.0 using the locating dimensions shown in Figure 3-2.

4. Move the bracket out of the way and pilot drill the center punched location using a #40 drill bit. 5. Secure the bracket into position using Silver (3/32”) P Series Cleco Fastener or equivalent. 6. Center punch the upper rear hole through the MS21075L08N nutplate at WS 155.0 using the

locating dimensions shown in Figure 3-2. 7. Move the bracket out of the way and pilot drill the center punched location using a #40 drill bit. 8. Enlarge the two locating holes using a #30 drill bit. 9. Deburr all holes. 10. Secure the bracket into position using Copper (1/8”) P Series Cleco Fasteners or equivalent. 11. Center punch the lower mounting holes through the nutplates. 12. Remove the bracket and pilot drill the center punched locations using a #40 drill bit. 13. Secure the bracket into position using P Series Cleco fasteners, or equivalent, as required. 14. Recheck lower pilot holes for correct position while inserting Cleco fasteners. 15. Remove the bracket and enlarge the lower pilot holes using a #30 drill bit and deburr all holes. 16. Enlarge all mounting bracket holes using a #18 drill bit deburr all holes on both sides of W.S. 155.00. 17. Coat the threads of the four (4) M3 screws supplied in the hardware kit with Blue Loctite 242 and allow

to dry completely.


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18. Fasten the servo arm to the roll servo as shown in Image 3-3. See Note.

FIGURE 3-1 ROLL SERVO & MOUNTING PLATE INSTALLATION

FIGURE 3-2 ROLL SERVO MOUNTING PLATE INSTALLATION LOCATION

Forward

W.S 155.0 Drill this hole first

Looking Outboard from W.S 138.00 towards W.S. 155.0

C to C 13/16” Approximate Forward

Drill this hole first

Second hole

Second hole


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IMAGE 3-2 ROLL SERVO BRACKET MOUNTING HOLES

FIGURE 3-3 MOUNTING PLATE AND SERVO ASSEMBLY

First hole Second Hole


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IMAGE 3-3 ROLL SERVO HUB DRIFT PIN / LOCKING PIN ALIGNMENT

Note:

The Roll Servo hub roll pin hole must be aligned with the servo stop as depicted Figure Image 3-3 above before attaching the crankarm to the hub. The four (4) outer baseplate holes must be enlarged using a #18 drill bit.

19. Mount the servo, p/n 30000000, to the servo mounting bracket as shown in Figure 3-3 using MS27039-0807 screws supplied.

20. Secure the servo mounting plate assembly to W.S. 155.00 using the AN525-832R7 screws supplied.

IMAGE 3-4 ROLL SERVO INSTALLATION

21. Secure the push pull tube to the servo arm as shown in Figures 3-3 and 3-4. Refer to the Illustrated Part Catalog for fastener and spacer part numbers at https://www.thestcgroup.net/documents for details.

Enlarge 4 corner mounting holes using #18 drill bit Servo Stop aligned with servo hub drift pin

https://www.thestcgroup.net/documents


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Note:

The AN310-3 castellated nut shown in Figures 3-4 and 3-5 must be preloaded (torqued with a calibrated wrench) to 20 to 25 inch pounds before the MS24665-134 cotter pin is inserted.

FIGURE 3-4 PUSH PULL TUBE ATTACHMENT AT SERVO ARM

22. Secure the push pull tube to the aileron bellcrank as shown in Figures 3-4 and Image 3-5. Refer also to Illustrated Part Catalog at https://www.thestcgroup.net/documents for details.

FIGURE 3-5 PUSH PULL TUBE ATTACHMENT AT AILERON BELLCRANK

https://www.thestcgroup.net/documents


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IMAGE 3-5 PUSH PULL TUBE ATTACHMENT AT AILERON BELLCRANK

23. Check servo travel for binding by rotating control yoke to the port and starboard stops. 24. The aircraft controls should reach the aileron stops before the Trio servo reaches its physical stops.

Refer to Image 3-3, Servo Stop Alignment for example of stop location. 25. If the servo reaches its stops before the ailerons reach their stops, contact The STC Group LLC at the

phone numbers supplies in Section 2. 26. Attach the DB9 connector to the servo connector after completing the Wiring harness installation in

Section 5.


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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 a TEXT or a voice mail if there is no answer. 3. Review all drawings and images in order to understand the proper installation of the brackets. 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 bracket assembly prior to starting the

measuring process. This will simplify bracket orientation and location. Refer to Figure 4-1. 6.

FIGURE 4-1 PITCH SERVO BRACKET ASSEMBLY

7. The bracket assembly consists of Part Numbers 1177312 (LH rail), 1177314 (RH rail), and two (2) 1177316 clips

8. Remove the baggage compartment cover to access the installation area. 9. Locate the upper and lower pitch cables located FS 160.00 and F.S. 185.00 and mark them with

painter’s tape or equivalent. Refer to Image 4-1.

FIGURE 4-2 PITCH SERVO ASSEMBLY (SHOWN IN PITCH DOWN POSITION)

FS 160.00

FS 185.00

FS 185.00

FS 160.00

Maintain 1.50” distance Fore & Aft between LH Angle & Lower pitch cable


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IMAGE 4-1 PITCH SERVO ASSEMBLY (SHOWN IN PITCH NEUTRAL)

10. Place the pitch servo tray into the proper orientation. Refer to Image 4-2. 11. The pitch servo tray is aligned so that the port edge of the tray assembly is 1.50” from the lower pitch

cable. Refer to Figure 4-1 & Image 4-1. 12. 1.50” spacing must be maintained fore and aft along the left pitch servo angle. 13. The Clips must be level side to side. 14. Clamp the pitch servo assembly into position using tension clamps or equivalent. Refer to Image 4-3. 15. Mark F.S. 160.00 and F.S. 185.00 with location of the Left Angle at 1.50”. This is your reference

mark for the pitch servo assembly. Refer to Figure 4-1 & Image 4-1.

Upper Pitch Cable

Right Rudder Cable

Lower Pitch Cable

Lower pitch cable to tray edge is 1.50”.

Left Angle


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16. The AFT clip assembly at F.S. 185.00 on the port side of the aircraft is located 0.150” below the lip of F.S. 185.00. The forward port edge of the left Angle will be located “approximately” 0.100” above F.S. 160.00. Refer to Image 4-2.

IMAGE 4-2 PITCH SERVO TRAY ORIENTATION

F.S. 160.00

F.S. 185.00

Forward Left Angle Locating Mark. Edge of tray angle is above F.S. 160.00 bulkhead lip approx. 0.100”

AFT Left Angle Locating Mark

Servo Stop Pin

Servo Stop

Hub Roll Pin Hole


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17. The starboard forward edge of the pitch servo assembly should be flush with F.S. 160.00 bulkhead. Refer to Image 4-2.

IMAGE 4-3 TENSION CLAMP

18. Square the tray on the remaining corners and re-clamp into position using tension clamps or equivalent.

19. The clip assemblies have been fabricated with MS21075L08N nutplates installed. 20. Use a center punch, or equivalent, to mark the bulkhead through the clip assembly nutplates. 21. Remove the pitch servo tray assembly. 22. Pilot drill the hole locations that were center punched using a #40 drill bit. 23. Deburr the holes. 24. Secure the tray assembly into position using Silver P Series 3/32” Cleco fasteners. 25. Recheck the measurement (1.50”) between the left-hand Angle and the lower pitch cable fore and aft.

FIGURE 4-3 PITCH SERVO ALIGNMENT (PITCH SERVO ARM SHOWN IN FULL DOWN POSITION)

26. Remove the tray assembly and enlarge the holes using a#30 drill bit. 27. Enlarge the holes their final size using a #18 drill bit and deburr. 28. Mount the pitch the pitch servo tray assembly using the MS27039-0807 screws supplied.

Left Angle approx. 0.100” above F.S. 160.00


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29. Coat the four (4) M3 screws supplied in the hardware kit with Blue (Medium) 242 Loctite 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 in Image 4-2 before attaching the servo arm to the hub.

30. Fasten the servo arm to the servo hub using the four (4) M3 (metric) screws supplied. 31. Enlarge the outer four holes in the pitch servo as described in the Roll Servo instructions in

Section 3. 32. Mount the pitch servo to the pitch servo tray assembly as depicted above using four (4)

MS270390807 screw supplied. 33. Attach the pitch servo push pull tube cable clamp to the lower elevator cable. Refer to Figure

4-4 and Image 4-4. 34. Attach the push pull tube to the servo arm. Refer to Figure 4-4.

Figure 4-4 Servo Arn and Cable Clamp Assembly

IMAGE 4-4 CABLE CLAMP ORIENTATION


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APPENDIX A TRIO PRO PILOT AUTOPILOT 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 41300008 or latest approved version. Refer to Appendix B.

Call Trio Avionics at +1 619-448-4619 if you have additional questions or need assistance.

The Trio Pro Pilot autopilot controller must be integrated with the aircraft pitot and static system. A pitot and static system test must be performed prior to opening the pitot and static system.

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.

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.

Trio Autopilot Controller

1. The Trio autopilot controller is ordered in Panel Mount or Instrument Mount versions. 2. The Trio autopilot controller will support 12 to 30 volts. 3. The Trio controller is provisioned with Pitot and Static ports. 4. A pitot static system check must be performed before installation to verify system operation and

integrity. 5. The Trio Pro Pilot autopilot controller is provisioned with Pitot and Static ports on the rear of the

controller. 6. The controller pitot and static ports must be integrated (plumbed) into the aircraft pitot and static

systems. 7. Every aircraft Pitot and Static system is different. The following are for example only as the aircraft

systems will vary.


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8. The following components, or equivalent, will be used in most installations.: a. Tygon tubing. 2 each x 24” pieces. Aircraft Spruce P/N 05-00944, or equivalent. b. Nylo Seal fittings. 2 each. Aircraft Spruce P/N 264-N04. c. Nylo Seal Inserts. 8 each. Aircraft Spruce P/N 259-N04. d. Groen ¼” constant pressure clamp or equivalent. 2 each. Refer to Image 5-1.

9. Extend the pitot & static hoses & cable connector through the tray and out through the front of the instrument panel to allow for ease of servicing.

10. Mate the pitot and static hoses to the control head. 11. Apply constant pressure clamps to secure pitot and static connections at the rear of the autopilot

controller. Refer to Image 5-1. 12. Mate the 37 pin D connector to the control head using the screws provided. 13. If using an Instrument mount control head secure the control head using #6 brass instrument screws. 14. If using a Panel mount control head slide the control head into the tray, then tighten the securing

screw. Do not over tighten control head in the tray. 15. It is required that a pitot and static system leak test is performed after autopilot installation. 16. Install the controller using best practices in either panel or hole locations. Refer to AC 43-13 for this

step and all following steps. 17. Utilize Trio DWG 41300008 and The STC Group Illustrated Parts Catalog 1177800 Sheet 2 of 5 for

the following steps. 18. Install supplied 5 ampere circuit breaker within easy reach of the pilot and label per Illustrated Parts

Catalog 1177800. 19. If a Panel Mount unit is ordered install the supplied power switch and label. 20. Terminate supplied DB37 connector per Trio drawing in Step 3. 21. Terminate wiring with aircraft GPS or handheld. 22. If ARINC 429 is available from GPS terminate ARINC 429 connections. 23. Install the supplied PCS button on the left side of the pilots control yoke and label PCS. 24. Install Recover button in an available convenient location within easy reach of the pilot and label AP

Recover. 25. Ensure that the analog alarm out is connected to the un-switched audio input on the Audio Panel. 26. Install Limitation Placard, P/N 1006450-1, supplied in plain view of Pilot.

Trio Autopilot Data Connections

1. For the RS-232 connection set the output at the GPS unit to "Aviation w/ no altitude" or NMEA 0183 OUT.

2. If your aircraft is equipped with a GPS that has ARINC 429, set unit to output "GAMA" Low Speed.

3. Prior to making the connections to the GPS unit in the aircraft determine what else is connected.

4. It may be necessary to parallel the connections. a. If parallel connections are required, verify that the lines you are connecting to use, or

can use, the same data format that is required. 5. Both the RS-232 and the ARINC 429 can be paralleled with like connections.


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Trio Initial Setup and Checks

1. Refer to The Avionics Addendum Section 10 for initial checks and setup of the autopilot installation.

2. Autopilot gain settings have been programmed before shipment. 3. Individual aircraft may require fine tuning of servo gains on the first few test flights. 4. The Avionics Addendum may be downloaded at www.thestcgroup.net.

IMAGE A-1 GROEN CONSTANT PRESSURE CLAMP

http://www.thestcgroup.net/


Page 24 of 25

APPENDIX B - PRO PILOT SYSTEM WIRING DIAGRAM

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