Rans S-7S COURIER, Text Manual

Page 1: ...09 01 2014 S 7S COURIER TEXT MANUAL Serial Number Registration Number COPYRIGHT RANS DESIGNS 4600 HWY 183 Alt HAYS KANSAS USA 67601 785 625 6346 www rans com...

Page 2: ...3 Separate the sections with the tab inserts listed below 4 Cut out on solid lines fold on dotted line and slip in the labels to corresponding sections Tabs are designed for 1 1 4 Insertable Tabs 00 G...

Page 3: ...10 OPTIONS 10 OPTIONS 11 RIGGING 11 RIGGING 12 WEIGHT BALANCE 12 WEIGHT BALANCE 13 OPERATIONS 13 OPERATIONS 00 GENERAL 00 GENERAL 01 FUSELAGE SYSTEMS 01 FUSELAGE SYSTEMS 02 CONTROL SYSTEMS 02 CONTROL...

Page 4: ...00 03 Labels for the exterior spine of each manual may be made from self stick labels The format below may be used RANS S 7S COURIER TEXT MANUAL RANS S 7S COURIER PARTS MANUAL RANS S 7S COURIER FIGUR...

Page 5: ...785 625 6346 parts rans com When calling Technical Support or Parts Department please have the following ready Aircraft Model Serial Number Engine Model Parts Number Needed Parts Department Only Your...

Page 6: ...95 E mail General rans rans com E mail Aircraft Tech actech rans com E mail Aircraft Parts parts rans com Internet site www rans com Aircraft Technical Support 785 625 0069 Aircraft Parts Department 7...

Page 7: ...er for 1 8 holes Files Cleco Pliers Silver 40 Clecos Copper 30 Clecos Gold 11 Clecos POWER TOOLS Electric Hand Drill Small Electric Grinder Dremel Bench Disk Sander Soldering Gun Hot Knife Heat Gun CD...

Page 8: ...ill bits ranging from 3 32 to 5 8 is strongly recommended In addition to these the following number bits will be required to assemble your S 7S Courier NUMBERED BITS FRACTIONAL BITS 40 1 4 30 5 16 11...

Page 9: ...tton Switch Local Avionic shops can wire your avionic harnesses for you Switches circuit breakers and other electrical parts are also available from RANS Contact RANS Parts Department for pricing RED...

Page 10: ...o inventory the parts using the packing list provided It is your job to keep all parts organized and accounted for We cannot provide missing parts cost free after 60 days Use the supplied pack list to...

Page 11: ...TALLATION AL AILERON P PART AV AVIONICS S SUPPLIERS BS BRAKE SYSTEM V VIEW CS CONTROL SYSTEM CV COVERING CW COWLING DR DOOR EL ELEVATOR EM EMPENNAGE ES ELECTRICAL SYSTEM EX EXHAUST FL FLAP FS FUEL SYS...

Page 12: ...all our Tech Staff for information on damage tolerance All Welded steel parts will require primer and top coating We recommend a good two part epoxy primer Be sure the primer and paint you choose will...

Page 13: ...though we are careful there is always the chance of the packages being mis labeled So before riveting be sure to double check that you have the correct aluminum or stainless steel pop rivet for the pa...

Page 14: ...ERIAL NUMBER Refer to FIGURE 00 02 for the serial number location Please record your serial number and have it handy whenever you call into the factory for assistance HAVE FUN A RANS aircraft is almos...

Page 15: ...ASSEMBLY FLOW CHARTS DETAILED Note The headings in the general chart refer to headings in the detailed flow charts S 7S FUSELAGE PRE COVERING ASSEMBLY S 7S TAIL SURFACES PRE COVERING ASSEMBLY S 7S TA...

Page 16: ...RUDDER FRAME FUSELAGE FORMER INSTALLATION o VERTICAL STABILIZER FORMER o FUSELAGE SIDE FORMER o FUSELAGE BOTTOM FORMER o RIB VERTICAL STABILIZER MAIN GEAR ASSEMBLY AND INSTALLATION o MAIN GEAR FIT UP...

Page 17: ...omplete the following items BAGGAGE COMPARTMENT ASSEMBLY AND INSTALLATION SEAT BELT ASSEMBLY AND INSTALLATION AFTER PRIMING OF FUSELAGE FRAME BEFORE COVERING COVERING Refer to Section 7 PAINTING Manua...

Page 18: ...ASSEMBLY Refer to flow plan section TAIL SURFACES FINAL ASSEMBLY AND INSTALLATION Complete all items listed Refer to Section 2 and complete the following items FLAP LEVER ASSEMBLY AND INSTALLATION Ref...

Page 19: ...t panel to the fuselage frame in its approximate position to allow for cable routing and connection The panel should be in an assembly status allowing it to remain in its position CARB HEAT INSTALLATI...

Page 20: ...COWLING ASSEMBLY AND INSTALLATION o ASSEMBLY DOOR ASSEMBLY LEXAN AND TRIM DOOR LATCH AND DOOR INSTALLATION SPINNER ASSEMBLY AND INSTALLATION o INSTALLATION COWLING ASSEMBLY AND INSTALLATION o INSTALLA...

Page 21: ...ING AND PAINT OF FUSELAGE RUDDER CABLE GUARD INSTALLATION STATION 3 CLOSE OUT INSTALLATION THROTTLE CABLE COVER INSTALLATION CONTROL STICK COVER INSTALLATION Refer to Section 9 and complete the follow...

Page 22: ...SEMBLY AND INSTALLATION o FIT UP AND PRE COVERING ASSEMBLY BEFORE PRIMING OF HORIZONTAL STABILIZER AND ELEVATOR FRAMES PREP AND PRIME HORIZONTAL STAB AND ELEVATOR FRAMES o FIT UP AND PRE COVERING ASSE...

Page 23: ...NSTALLATION Refer to Section 9 and complete the following items CONTROL SURFACE MASS BALANCE o ELEVATOR Refer to Section 1 and complete the following items HORIZONTAL STABILIZER AND ELEVATOR ASSEMBLY...

Page 24: ...ON AILERON BELL CRANK AND CABLE INSTALLATION WING WING RIB SHEET METAL INSTALLATION o WING RIB ASSEMBLY o WING RIB INSTALLATION o RIB STRINGER INSTALLATION o UPPER AND LOWER ROOT SKINS o LEADING EDGE...

Page 25: ...WING TIP ASSEMBLY AND INSTALLATION o WING TIP FIT UP AND ASSEMBLY o INSTALLATION ROOT SKIN INSTALLATION o INSTALLATION LIFT STRUT ASSEMBLY o INSPECTION OF STRUTS o ASSEMBLY FUEL AND VENT LINE INSTALL...

Page 26: ...RIVETS CROSS REFERENCE LIST...

Page 27: ...llows NUT AND COTTER PIN SIZES LGTJ D f A M m R 3 318 4 5 518 Use the parts manual for other part identification The drawings depicr a fairly accurate likeness of the real thing Other par are labeled...

Page 28: ...1 T E 0703 TI ON 1 9 1 I I 8 T d 3 d d 0 3 OE O N t Z...

Page 29: ...rd to touch the vertical attach tubes on stations 4 5 and 6 2 Mark the location of the tubes where they contact the former centerline Remove the former and drill 1 4 holes at these locations through t...

Page 30: ...i chafe tape around the fuselage frame and safety wire former in place 12 The upper and center aft side formers are fabricated from 1 2 diameter tubing Both formers are attached with rivets from the i...

Page 31: ...and crimp the rib flanges slightly between the holes at the notch locations 17 The rib is mounted on top of the vertical stabilizer frame cross brace and is riveted from the topside to the 3 welded ta...

Page 32: ...s Drawings 5 Top Main Gear Clamp Plate should be orientated per FIGURE 01A 05 Be sure the Top Main Gear Clamp Plate fits tight against the Fuselage Longeron File upper side of clamp plate if required...

Page 33: ...ing technique for bearings without integrated seals is to tighten the axle nut until the wheel stops spinning freely and then back off to the nearest locking feature THIS TECHNIQUE WILL NOT WORK ON A...

Page 34: ...de of Station 2 crossing tube to help seal against Gear Legs and Boot Cowl NOTE Install D Cell to inboard side of Top Clamp Plate Do NOT place between Clamp Plate and Fuselage 15 Install Main Gear to...

Page 35: ...nly finger tighten these two bolts and to attach the tangs later when the tail is installed 5 During final assembly it is important that all bolts retaining the tail spring are tight Check the tightne...

Page 36: ...ap between the tip of the horizontal stabilizer and the overhang of the elevator 3 With the elevator correctly positioned slide each retaining collar against the hinges Position the retaining collars...

Page 37: ...rizontal stabilizer are now ready for covering Refer to COVERING for instructions INSTALLATION OF HORIZONTAL STABILIZERS AFTER COVERING AND PAINT OF HORIZONTAL STABILIZER 14 Use a hot iron to burn hol...

Page 38: ...t may be necessary to hold the stabilizer in a vertical position to obtain hole alignment Install cotter pins 20 Support the stabilizer in horizontal position Attach jam nuts and tie rod ends to tail...

Page 39: ...to FIGURE 01C 30 for fairing orientation Check for clearance to servo and transfer drill 40 through the exit ring Cleco as you go 31 Remove fairing and drill out holes in fairing only to 30 32 After...

Page 40: ...corresponding horizontal stabilizer 41 Lubricate hinge points and check for free movement without binding or excessive friction 42 Connect elevators to elevator yoke as per parts manual IMPORTANT Mak...

Page 41: ...lace 7 Prep prime and paint each trim tab half and both horns as desired AFTER PAINT OF TAB 8 Drill the two holes in center rib doubler and center rib to 30 Rivet doubler to center rib Refer to FIGURE...

Page 42: ...vo to the half travel position You can do this by applying current to the appropriate wires and moving the servo to its limiting positions Make a pencil mark on the servo arm for each limit Mark half...

Page 43: ...the floorboards at this time This will be done after the floorboards receive their finish 5 Install 3 16 nut plates to the bottom side of the 12 tangs holding the forward floorboard and the forward r...

Page 44: ...09 01 2014 01E 02 FINAL INSTALLATION For final installation refer to RUDDER PEDAL INSTALLATION...

Page 45: ...in place with the hardware shown in the parts manual 5 Check that all pedals swivel freely The pedals should move easy without excessive friction 6 Install the rudder pedal push pull tubes as per part...

Page 46: ...h retaining collar through the leading edge spar of the rudder Rivet collars in position as per parts manual 5 Remove rudder from fuselage 6 The rudder frame is now ready for prep and priming The rudd...

Page 47: ...ings to match the angle of the steer chain linkage and attach the steer springs and chain to the rudder 15 Drill the two welded tabs on bottom crossing tube of station 3 to 11 Refer to FIGURE 01G 15 f...

Page 48: ...ated Unibit step drill 3 Refer to FIGURE 01H 03 Fabricate the firewall closeout as shown to fit the firewall in the corresponding position Use the provided raw stock The hole in the closeout will late...

Page 49: ...1 Install the 3 small rubber grommets in the appropriate mount holes as shown 12 Install the large rubber grommet at the right lower side of the firewall as shown This is the battery cable exit locati...

Page 50: ...le at the approximate middle of its adjustment range AFT SIDE FIREWALL ITEMS INSTALLATION 21 Refer to FIGURE 01H 21 for aft side mounted items 22 Install the four 90 degree fittings in the parking bra...

Page 51: ...the engine mount tubes with the IN fitting to the right and forward 31 The oil tank comes standard from the engine manufacturer with a drain plug in the bottom The standard drain plug may be replaced...

Page 52: ...own as desired and tighten locking nuts Do NOT forget the cotter pins 4 Check that the pedals and the brake pedals move freely 5 The two brake lines connected to the wheels are secured to the left and...

Page 53: ...the reservoir cap 11 Install the reservoir cap AFTER INSTRUMENT PANEL INSTALLATION 12 Mount the park brake control cable in the instrument panel as shown in the parts manual and in FIGURE 01I 12 Refer...

Page 54: ...ates to the inside of the battery access doorframe 2 Position transfer drill 30 and rivet doorframe to the tabs on fuselage station 6 Refer to parts manual 3 The door should be fitted by drilling the...

Page 55: ...3 To install the fuel fittings into the tank obtain a piece of wire Safety wire works well Insert wire through one of the fitting holes in the tank and up through the threaded neck Refer to FIGURE 01K...

Page 56: ...install the valve to the three tabs of the fuselage steel frame NOTE Valve should be ON when valve handle is forward and OFF when valve handle is inboard Use the mount brackets as shown in FIGURE 01K...

Page 57: ...all Low Fuel Warning Switch into Header Tank Be sure to orientate the switch to allow electrical continuity closed circuit when installed Use a continuity tester Ohmmeter to be sure Refer to FIGURE 01...

Page 58: ...entated lengthwise with the Torque Tube 4 Move Nut Plates to inside of Torque Tube and rivet in place HINT A stick or small tube with a loop of Masking Tape on it will help hold the Nut Plate in place...

Page 59: ...he bottom of the Torque Tube Check to be sure side plates are vertical when positioning Be sure Stop clears fuselage tubes when Torque Tube is rotated Stop should hit against each Stop Bolt Transfer d...

Page 60: ...1 4 hole Clear Silicon Seal or spiral wrap can help prevent chaffing Make sure that the wires do not bind chafe or interfere with the control system Secure as required 31 If NOT installing OPTIONAL P...

Page 61: ...d Bushings aft of Station 4 Be sure to include the washers on outboard side of each Bell Crank Assembly Check for free movement 7 Proceed with 1 1 2 AFT Push Pull Tube and Elevator Yoke Assembly INSTA...

Page 62: ...from the front 7 Temporarily bolt Rod End between upper holes in Bell Crank Assemblies Tighten bolt after final adjustment in RIGGING 8 Bolt Elevator Yoke to aft end of Push Pull Tube The aft ends of...

Page 63: ...e upper set of pulley shackles cable keepers and small pulleys to the pulley mounts located on the top cross tube of station 3 as shown in the parts drawing Position the cable keepers straight down IM...

Page 64: ...used to retain the keepers in position The keepers are retained in position by the tightening of the bolt 12 Proper cable tension turnbuckle adjustment will be determined during rigging Refer to RIGGI...

Page 65: ...Bushings need to be able to rotate The bushings act as rollers as they ride against the notches of the Side Plates Tighten the bolt to the point the bushings still roll Apply light grease to the roll...

Page 66: ...er side of Torque Tube aft Pillow Blocks NOTE Teleflex Cables should be routed outboard of Rudder Cable Guides on Station 3 16 Route under diagonal belly tube forward of Station 3 then forward and upw...

Page 67: ...each lever 8 Slide the second set of washers onto the lugs 9 Install and tighten the retaining nuts and check for play within each set of levers The levers should feel solid and snug and rotate with j...

Page 68: ...y the top half of the retention block to 30 The machine screw will self tap into the bottom 16 The forward downward facing holes in the cable housing stub are drilled 11 to accept the cable housing IM...

Page 69: ...e bushings IMPORTANT Check bolts for tightness after the first several hours of operation SPECIAL NOTE 3 8 diameter bolts are used thru the rubber isolators of the Engine Suspension Frame Assembly The...

Page 70: ...all the drain lines from the carburetor drip trays to the drain tubes located on the firewall Refer back to FIGURE 01H 07 and the parts manual NOTE The fuel overflow lines should route continuously do...

Page 71: ...he Gascolator Mount should have been riveted to the firewall during ENGINE ACCESSORY INSTALLATION 6 Install fittings in Optional Gascolator Orientate fittings per parts page drawing Remove wire bail f...

Page 72: ...tube Zip tie the cable housing to the diagonal between station 1 and station 2 Refer to FIGURE 09D 06 5 Tighten the screws in the retention block to retain the housings into the stub CAUTION Over tigh...

Page 73: ...ing Pull all slack out of the cable where it exits the aft side of the firewall 17 Install the push pull choke cable into the instrument panel For installation of control knob in instrument panel refe...

Page 74: ...3 Apply Loctite to bolts and assemble the upper and lower mounts to the cooler using the threaded bushings NOTE To achieve the proper compression on the silicon rubber it might be necessary to add wa...

Page 75: ...line routing 11 Apply anti chafe and secure all lines as necessary 12 Cut to length and install the overflow line from the oil bottle filler neck to the 3 8 diameter aluminum overflow tube located on...

Page 76: ...engine starts allow 10 seconds for oil pressure to come up If there is no pressure indication within 10 seconds shut the engine off and repeat the previous procedures The engine will change sound quie...

Page 77: ...tor mount bracket on the front of the radiator 8 Fabricate a line reaching from the coolant expansion bottle on top of the engine to the approximate position of the coolant recovery bottle will be loc...

Page 78: ...m as required using the supplied shims 3 Install the exhaust manifolds and the muffler heater wrap assembly to the engine as shown in the parts manual 4 Adjust components for best fit NOTE To install...

Page 79: ...a duct hose from the right heater wrap flange to the right side of the engine gearbox Install to the heater wrap flange and route through the engine compartment 7 Insert inlet tube in the duct hose an...

Page 80: ...again for friction Orientate the shaft as per parts drawing 5 Mark valve and body to assure that each time you remove the valve you insert it in the same orientation Insert the valve and place it on t...

Page 81: ...drilled head bolts to each other 16 Cut two pieces of the duct hose to fit between the heat exchanger and the carburetor heat assembly and secure with clamps as per parts manual NOTE cut the duct hose...

Page 82: ...hrough the holes in the mount plate into the flanges of the side plate Rivet the mount plate to the side plate through the center two corner holes only Slide the Battery Bar through the holes in the b...

Page 83: ...to the frame Do not install ties or route the cable where they may come in contact with the fabric Bolt the Solenoid to Starter cable to the second pole on the solenoid and to the pole on the starter...

Page 84: ...rough welded tangs in fuselage 30 Rivet mount plates in place Note Do not rivet the most forward rivet on the ELT antenna mount plate at this time This rivet will be installed together with the skylig...

Page 85: ...oot and tip end of both the Leading and Trailing Spars refer to FIGURE 05 02 and 05 02A You must also determine the forward and aft side to each spar span wise 3 IMPORTANT Double check that you have t...

Page 86: ...ace as a handle insert the Doubler into the Spar from the root end until the center hole in the Doubler is in line with the Channels center hole in the Spar Using the center hole cleco the Doubler and...

Page 87: ...are slightly too long and may have to be filed down to the outer dimension of the Spar tubing 21 Drill out the Long Wing Channel and the U Bracket to allow for the 1 4 Bolts 22 Bolt the Strut Attach...

Page 88: ...l the Jury Strut Bracket to the forward bolt retaining the Flap Compression Tube Refer to FIGURE 05 26 30 Assemble the Teleflex Retainer and the Cable Guide to the Flap Compression Tube as per FIGURE...

Page 89: ...the pre drilled 40 hole in the Tip Bow with the pre drilled 30 hole in the Spars and chase drill the Tip Bow to 30 and cleco Remove one cleco at a time and drill out the four holes to 11 36 NOTE The T...

Page 90: ...ill the tank with water and let it sit for approximately 48 hours DOUBLE TRIPLE CHECK HOLE LOCATIONS BEFORE DRILLING 2 Locate and drill three 3 1 2 diameter holes for the fuel fittings at the location...

Page 91: ...tion resting on both the Root Compression Tube and the Outer Tank Support pull the Outer Tank Support into place against the tank NOTE The AFT end of the Outer Tank Support is cut diagonally to clear...

Page 92: ...RTANT When drilling be sure that the Vent hole will be orientated OUTBOARD and the Fuel Cap opening tab is orientated AFT Final installation will be completed later FUEL LINE INSTALLATION WING AFTER W...

Page 93: ...nk Arm Assemblies at this time NOTE The Lower Bell Crank Arm will need to be swung out of the way to rivet the Rib to the Rib Reinforcement during Rib Installation Do not forget the Spacer Bushing bet...

Page 94: ...n coating is recommended between the Ribs and Rib Clips 1 Select the necessary parts as shown in the parts drawing Refer to FIGURE 05C 01 for Rib location and position numbering 2 The ribs are pre pre...

Page 95: ...for Rib locations 4 11 Orientate with tabs facing inboard Rivet Clips to Spars 9 Modify Ribs per FIGURES 05C 09 thru 05C 09B Install Tinnerman Clips to lower flange of Root Rib 10 Rivet Rib Clips to...

Page 96: ...o Rib 2 from the Spars to aid in access for riveting Do NOT forget to rivet the Outboard Stringers with the Inboard Stringers at Rib 3 18 Re cleco Rib 2 to the Spars 19 Modify Tip Rib Stringer per FIG...

Page 97: ...Stiffeners will face AFT 28 Cleco Root Skin Stiffeners to upper side of Lower Root Skin Riveted flange of Stiffeners will face AFT 29 Rivet Stiffeners to Root Skins 30 Cleco Lower Root Skin to Root a...

Page 98: ...uired hole size Clean debris from tank Install fuel fittings if not already done 42 Modify Cover Ring per FIGURE 05C 42 Orientate Scupper per FIGURE 05C 42A Cleco Scupper Capture Ring and Cover Ring o...

Page 99: ...ng of the Tip Wrap The Tip Wrap will lay under the Leading Edge wrap when final installed 48 Slip the Tip Wrap under the Leading Edge Wrap and position the Tip Wrap around the Leading Edge Spar and Ti...

Page 100: ...Spar with ONLY the adhesive It is important that you make a good bond between the Wrap and the Spar CAUTION Do NOT drill or install any rivets into the Spar HINT Masking tape on the Spar just forward...

Page 101: ...Assembly and should extend out of the AFT side of the Wing Root approximately 3 at this time 64 Use the pre located hole in each Rib per FIGURE 05C 63 Wrap the Pitot and Static Lines with Anti chafe...

Page 102: ...Cable as per FIGURE 05C 69 and secure with plastic ties as shown to the Compression Tube and Inner Drag Brace NOTE In the Left Wing the Pitot and Static Lines secure together with the Flap Teleflex C...

Page 103: ...Use a hot iron a soldering iron or wood burning tool works well to burn holes through the fabric at the attach points for the Flap Hinges the Flap and Aileron Attach Angles and through Drain Grommets...

Page 104: ...the Hinges and cut the Gap Seal to length with 45 degree miters on each end See FIGURE 05D 13 HINT Cut the ends square then use a disk sander to miter the 45 degree ends 15 Position the Gap Seal so t...

Page 105: ...the Aileron Push Pull Tube Exit and Flap Teleflex Cable Exit to lay flat on the Wing Trim out the AFT opening of the Aileron Push Pull Tube Exit Refer to FIGURE 05D 19 NOTE Cutouts in the Flap Cable...

Page 106: ...out with 250 350 and finally 400 grit wet or dry sandpaper Sanding out such defects is an effective way of restoring the strut to a safe full strength status Any nicks or scratches that require more t...

Page 107: ...lecos Remove one cleco at a time and rivet with Stainless Steel Rivets CCPQ 64 9 Check the fit of Upper Strut Fittings on the Strut Attach Plates on the Wing File out the inside of the fitting as requ...

Page 108: ...id movement 5 Use a hole finder to mark and drill 40 holes in the Wing Tip to match the pre drilled holes in the Tip Rib Cleco as you drill making sure the Wing Tip fits tightly 6 Slide the AFT Closur...

Page 109: ...ic lines 4 Be sure all hardware is installed in fuel tanks for Fuel Withdrawals and Fuel Sight Gauges Cleco Root Closeouts to Root Rib Position Sight Gauge Decal centered between the Grommets Refer to...

Page 110: ...is more comfortable to have two helpers Refer to parts page 005 01 1 Drill out the 1 U Brackets stainless steel to fit a 5 16 Bolt Drill the attach hole to the Fuselage only 2 Bolt the 1 U Brackets at...

Page 111: ...in the parts manual 10 Temporarily insert the forward wing attach bolt through the Leading Edge Spar into the Wing Carry Thru Bushing 11 Connect the FWD Lift Strut to the Strut Attach Plate at the Lea...

Page 112: ...he front hole 14 Insert Leading Edge Spar Attachment Bolt and tighten Tighten bolt enough to take out play 15 Connect the upper end of the Aft Lift Strut to the Lift Strut Plate at the Trailing Edge S...

Page 113: ...ust the Push Pull Tube with the Control Stick centered for the correct Aileron neutral position as per RIGGING instructions 27 Route the Flap Teleflex Cable inside the Fuselage as shown in FIGURE 05H...

Page 114: ...e left Wing Leading Edge Spar Refer to WING SPAR ASSEMBLY Position the aft end even with the end of the Mount Angle and secure with two hose clamps NOTE Be sure the end of the Pitot Static Tube is dow...

Page 115: ...seout as per FIGURE 06 02B Note the orientation of the Closeout Drill 30 to welded frame tabs IMPORTANT Do NOT drill through Boot Cowl at the Tabs Transfer drill through Boot Cowl Closeout and Boot Co...

Page 116: ...nt Panel to one Vertical Instrument Panel Frame Transfer drill Panel mount holes to 11 Un cleco panel and rivet nutplates to Panel Frame 15 Position the remaining un drilled Vertical Instrument Panel...

Page 117: ...ole lines rivets will be placed under the unglued foam and fabric in a later step and allow to dry Allow overlap over the edges Glue Panel Fabric over foam allowing about 1 4 overlap on all edges IMPO...

Page 118: ...leco to fuselage frame 30 IMPORTANT Apply high temp Silicone Sealant along the entire forward seam between Firewall and Boot Cowl It is recommended to squeeze some Silicon between these parts to achie...

Page 119: ...09 01 2014 06 05 36 Check that the panel clears the fuselage frame to avoid vibration transmitted directly to the panel...

Page 120: ...rylic can break easily As much as possible of the protective plastic should be left in place until the aircraft is ready to be flown 2 The windshield will require some trimming 3 With the wings attach...

Page 121: ...ndshield meets the boot cowl A Dremel tool with a fiber reinforced cut off wheel works well Sand the edges smooth with a sanding block Start with 120 grit and work progressively to a finer grit 13 Pul...

Page 122: ...rilling the ends of mating strip assembly Cleco Mating Strip Spacer between Mating Strips making sure the forward side is tight against the aft edge of the windshield 20 Mark support ribs 1 4 aft of m...

Page 123: ...Mark and trim cuffs flush with edge of windshield 30 Remove cuff and place 3 4 masking tape on leading edge spar extending outboard from wing attach bolt Top edge of tape should be in line with bolt s...

Page 124: ...ne Tape in place and use sandbags or similar weight to help press wing cuff to windshield until adhesive dries 40 Remove weight and tape 41 It is recommended to apply a fillet of silicon seal all the...

Page 125: ...in low concentration Rinse thoroughly and dry with a clean soft cloth or towel RANS recommends Brillianize for windshield care Brillianize is available from RANS Parts Department NOTE Never use gasoli...

Page 126: ...pper and lower window trim strips in position centered on frame tube Mark and trim each strip to allow it to fit between the perimeter trim strips With the window trim strips cut to length drill in th...

Page 127: ...age install the door assemblies Trim the upper forward door trim strip so that there is 1 16 gap between the trim strip and the edge of the windshield NOTE There should be a smooth flush transition be...

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Page 133: ...osition and alignment Mark cut lines take cowling bottom off and trim closed to the line HINT Aviation snips drum sanders and sanding blocks work well for trimming Do not trim all the way to the line...

Page 134: ...l bit drill both mount holes for the receptacles Remove the receptacles and drill the quarter turn holes on the bottom cowl out to 5 16 Countersink the 40 rivet holes to allow the rivet heads to sit f...

Page 135: ...irons as described A model airplane iron is also useful in shrinking up tight areas A regular clothing iron may be used for over all shrinking The best ones are the old Steel irons New irons are usual...

Page 136: ...then here is how to do it Use a straight edge or a round template and a soft pencil to mark the outline of the patch on the fabric Use sizing material and a soft brush to size along the cut line Let...

Page 137: ...of the provided drawings KP 100 A FRAME STAND KP 103 WING ROOT ATTACH KP 107 T LOCK HANDLE KP 108 PAINT STAND FOR FLAPS AILERONS KP 109 PAINT STAND FOR HORIZONTAL STABILIZER KP 111 FWD FUSELAGE ATTAC...

Page 138: ...applied to the metal under surfaces helps prevent pin holing in the paint finish Make sure to remove brush hairs from the surface if necessary 6 Perform pre covering check using the following items As...

Page 139: ...of the Leading Edge Spar about 2 wide at this time Pull light tension into the fabric as you go 13 Bond the fabric around the Tip Bow and the upper Root Rib pulling in light tension 14 Iron the surfac...

Page 140: ...nd last hole Remove the protective paper on top of the double stick tape and glue on the Cover Strap Make sure the Cover Strap is centered over the holes in the ribs 29 Use a hot knife with a pointed...

Page 141: ...p Bow and ending on AFT centerline of the Tip Bow TRAILING EDGE SPAR TIP BOW 2 tape centered on AFT centerline of the Trailing Edge Spar over lapping the lower fabric seam by 1 4 starting flush with t...

Page 142: ...around the Leading Edge Spar wrapped around the Trailing Edge Spar and than glued to the Leading Edge Spar 7 The fabric should extend past both ends of frames about 2 8 Glue fabric to Leading Edge Spa...

Page 143: ...t plates Rudder pedal attach tabs received nut plates Rudder pulleys at station 7 installed Rudder cable guides at station 5 installed Rudder cables routed through pulleys at station 7 placed in plast...

Page 144: ...out and cut the fabric to length The fabric panel has to cover the entire left side from the bottom to the vertical stabilizer former top center of fuselage including the left side of the vertical st...

Page 145: ...ole Remove the protective paper on top of the double stick tape apply the Lexan strap Make sure the strap is centered over the holes in the ribs 28 Use a hot knife with a pointed tip or a soldering ir...

Page 146: ...xit rings reinforcement rings access ring drain grommets the rudder cable exit fairings and the vertical stabilizer rib receive a fabric patch on top 37 Iron all surface tape and patches concentrating...

Page 147: ...have to cut the fabric in the corners around the stabilizer attach bushings 7 Let dry and iron all fabric edges down 8 Pre iron the fabric surface only enough to take wrinkles out 9 Glue fabric secon...

Page 148: ...zor blade 16 Insert a rivet in each hole and rivet 17 Apply drain grommets to the bottom side patches and tapes in this order 18 Refer to FIGURE 07D 18 NOTE Only the right horizontal stabilizer receiv...

Page 149: ...ic surface only enough to take wrinkles out 8 Glue fabric second side all the way around the frame tubes and past the centerline as shown in FIGURE 07D 06 9 Let dry and pre iron the surface only enoug...

Page 150: ...07D 06 You have to cut the fabric in the corners around the moving part of the hinge and the trim tab attach 6 Let dry and iron all fabric edges down 7 Pre iron the fabric surface only enough to take...

Page 151: ...utside 5 Glue fabric first side all the way around the frame tubes The fabric should be glued to 3 sides of the square frame tubes You have to cut the fabric in the corners 6 Let dry and iron all fabr...

Page 152: ...will be on top of the tabs at Station 3 4 Adjust the assembly up or down at each side until the Sides lap about half way onto the fuselage tube Tape in place 5 Press the forward end of the Sides again...

Page 153: ...bric or paint as desired 13 If covered in fabric burn through mounting holes with a hot knife or soldering iron 14 Slip Baggage Compartment into fuselage Retain with Machine Screws CARGO NET 15 Cargo...

Page 154: ...t Refer to the parts drawing 7 Install the Seat Top Tubes into the Side Frames as shown in the parts drawing NOTE The Seat Back Cushion will retain the Top Tube Position the Seat Tensioning Bracket as...

Page 155: ...ldering iron melt a small hole at each location just above the wire 17 Remove the Seat Attach Channels and slip the covers onto the Seat Frames 18 Thread the Seat Cover tongues between the Seat Tensio...

Page 156: ...l the aft shoulder belt mount bolt into the bushing and temporarily finger tighten the nut onto the bolt IMPORTANT This bolt must be in place prior to covering AFTER COVERING AND PAINT OF FUSELAGE Aft...

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Page 158: ...ovide sufficient clearance for the Rudder Cables and the Control Stick Torque Tube 5 Mark and drill four 1 4 holes at the lower mount tang and the upper mount bracket locations Close Out will attach w...

Page 159: ...cate the 3 small dimples in the cover and drill 11 Two will be used for mounting to the welded stubs The dimple in the large recessed area will be for the Friction Knob Slightly slotting the mounting...

Page 160: ...EFORE MOUNTING 1 The Elevator must be completely assembled and painted 2 The Elevator Horns Trim Servo including push rod wires Trim Tab and Trim Exit Cover with screws must be installed 3 Refer to FI...

Page 161: ...oden blocks The aircraft must be rigid 3 Raise the Tail of the airplane by placing the Tail Wheel on a sawhorse or other support until the wing root is level Use the fabricated level placed with the 1...

Page 162: ...igging board so that it is contacting the bottom side of the leading edge spar and the bottom side of the trailing edge spar at approximate aileron half span The trailing edge of the aileron should re...

Page 163: ...iction FLAP RIGGING Neutral position AFTER WING INSTALLATION AFTER SETTING OF WASHOUT 19 Place flap handle in flaps retracted position 20 Using the modified wing washout rigging board as shown in FIGU...

Page 164: ...arance between flap and aileron is 0 2 Operational check 25 Move the flap lever in the cockpit throughout the full range of deflection Check for Correct engagement of the roller in the grooves of the...

Page 165: ...stabilizers in reference to wing carry through upper member fuselage frame forward wing attach Take measurements at rear spar of horizontal stabilizers and approximate half span The misalignment shou...

Page 166: ...approximate half span Adjust Forward Pitch Stop on top of AFT 1 1 2 Push Pull Tube to rest against Pitch Stop Tube at Station 6 inside Fuselage to obtain the listed UP deflection Repeat with stick at...

Page 167: ...tions of control surfaces Interference of controls linkages surfaces with other components Excessive friction ELEVATOR TRIM TAB 13 The elevator trim tab is operated by servo Deflections 14 Measure def...

Page 168: ...Return Springs as needed Deflections 19 For deflection measurements move pedal in cabin hold at full travel position and measure at rudder Adjust stops as required Left 28 Tolerance is 3 0 0 0 Right...

Page 169: ...he air filter or on hot air coming from the heat exchanger ADJUSTMENT 4 Initial and re adjustment of valve position is possible with cable stops on each unit 5 The full open and full closed position m...

Page 170: ...full closed up with control knob in ON position NOTE The parking brake valve works as a one way valve when ON If this is not the case adjust by loosening the swivel stop for adjustment at the control...

Page 171: ...ensure that the airplane is loaded properly AIRPLANE WEIGHING PROCEDURES 1 Preparation Inflate tires to recommended operating pressure Parking brakes set Drain all fuel Service engine oil as required...

Page 172: ...ecurely in flight To figure the weight and balance use the Sample Loading Problem and Center of Gravity Envelope as follows Enter the following data on the chart Refer to FIGURES 10 01 or 10 01A Weigh...

Page 173: ...s apply Airspeed IAS Remarks VNE Never Exceed Speed 135 mph 117 knots Do not exceed this speed in any operation VA Maneuvering Speed at maximum gross weight 105 mph 91 knots Do not make full or abrupt...

Page 174: ...maximum weight VS at most forward CG with flaps retracted Upper limit is maximum structural cruising speed Yellow Arc 105 135 mph 91 117 knots Operation must be conducted with caution and in smooth ai...

Page 175: ...mate 0 30 US GAL NOTE Due to cross feeding between fuel tanks the tanks should be re topped after each refueling to assure maximum capacity The fuel quantity indicator is calibrated to read correct in...

Page 176: ...tems listed on the preflight checklist look for signs of visible ice if applicable The presence of ice on the aircraft wings and tail will adversely affect the aircraft s performance In all cases remo...

Page 177: ...ector Valve ON 7 Fuel Quantity Indicator CHECK QUANTITY 8 Throttle Lever MOVEMENT free 9 Seats ADJUST POSTION CHECK PINS 10 Cabin CHECK FOR FOREIGN ARTICLES 11 For Solo flight SECURE rear seat belts C...

Page 178: ...rom all points until no contamination is found 2 Flap CHECK security 3 Aileron CHECK freedom of movement and security 4 Rear strut and jury strut attach CHECK security dents nicks 5 Fabric Surface CHE...

Page 179: ...ning back to the oil tank and can be noticed by a murmur from the open oil tank WARNING Do not stand within the arc of the propeller check ignition off throttle closed and park brake set before rotati...

Page 180: ...eflight Inspection COMPLETE 2 Passenger Briefing COMPLETE 3 Seat seat belts ADJUST and LOCK 4 Brakes TEST and SET 5 Radio Electrical Equipment OFF 6 Circuit Breakers CHECK IN 7 Fuel Selector Valve ON...

Page 181: ...3 Flight Controls FREE and Correct 4 Flight Instruments SET 5 Elevator Trim SET FOR TAKEOFF center of indicator 6 Fuel Selector Valve ON 7 Fuel Quantity CHECK 8 Throttle 4000 RPM a Magneto CHECK Magne...

Page 182: ...hrottle FULL OPEN 7 Brake RELEASE 8 Elevator Control LIFT TAIL WHEEL 9 Climb Speed 55 MPH until all obstacles are cleared 10 Flaps RETRACT slowly after reaching 60 MPH ENROUTE CLIMB NORMAL CLIMB 1 Air...

Page 183: ...Flaps on final AS REQUIRED below 69 MPH 3 Airspeed on final 64 MPH with full flaps 4 Touchdown MAIN WHEELS FIRST OR THREE WHEEL 5 Landing Roll LOWER TAIL WHEEL GENTLY AFTER MAIN WHEEL TOUCH DOWN 6 Br...

Page 184: ...F Slowly 5 Airspeed 60 MPH 6 Wing flaps RETRACT Slowly AFTER LANDING 1 Wing Flaps UP 2 Taxi SLOWLY 3 Carburetor Heat OFF 4 Fuel pump OFF SECURING THE AIRCRAFT 1 Parking Brake SET 2 Throttle IDLE 3 Rad...

Page 185: ...preflight inspection generally covers the critical areas that MUST be checked prior to each flight In addition EVERY component should be examined properly maintained correctly stored or transported a...

Page 186: ...strong crosswinds a little extra throttle will help the aircraft turn due to the increased airflow over the rudder Caution should be used not to use excessive throttle sudden throttle movements or ex...

Page 187: ...d be left in that position until all obstacles are cleared and a flap retraction speed of 60 MPH is reached SECURING THE AIRCRAFT If the aircraft must be left unattended outdoors always secure it with...

Page 188: ...and proper preflight planning However should an emergency arise the basic guidelines described in this section should be considered and applied as necessary to resolve the problem In any emergency fl...

Page 189: ...lane 1 Airspeed 64 MPH for best glide 2 Select Emergency Landing Area PROCEED To It 3 Attempt Engine RESTART 4 Ignition Check ON 5 Choke Check OFF 6 Throttle Lever CRACKED approximately 1 4 forward 7...

Page 190: ...wer 4500 5000 RPM for a few minutes 3 Engine SHUTDOWN and inspect for damage If Engine fails to Start 4 Continue cranking with throttle full open while ground attendants obtain fire extinguisher when...

Page 191: ...aileron and rudder in opposite direction of spiral dive 3 Cautiously apply elevator back pressure to slowly reduce the airspeed to below maneuvering speed SPINS Intentional spins in the S 7S aircraft...

Page 192: ...ht ahead with only small heading corrections to avoid obstructions Of course the number one priority is to land the aircraft as smoothly and accurately as possible Altitude and airspeed are seldom suf...

Page 193: ...direction of spiral dive 3 Cautiously apply elevator back pressure to slowly reduce the airspeed to below maneuvering speed SPINS Intentional spins in the S 7S aircraft are PROHIBITED Should an inadve...

Page 194: ...y DOORS The S 7S is equipped with two doors one on each side of the AC Always secure the doors before flight Only 1 door may be open in flight Open at or below 60 mph Do not exceed 100 mph If a door c...

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Page 198: ...so be done on covered wings Unroll the gray strobe wire and cut it in half Cut four 20 segments of 14 gauge wire Run the gray and 14 gauge wire through the trailing edge spar to the wing tip bow Secur...

Page 199: ...S Refer to FIGURE 11B 02 Rivet the Navigation Light Mount to the wing tip per FIGURE 11B 02 Use the nutplate rivets to retain the mount plate Drill the three 3 mounting holes in each Strobe Light Asse...

Page 200: ...ts are not bottomed out on the threads DANGER If bolts are bottomed out on the threads the prop is not properly torqued separation from the aircraft during operation may occur Torque the bolt from 180...

Page 201: ...rs Propeller Manufacturer Sensenich propeller Inc Propeller Model Number 2A1R5R70D N Number of Blades 2 Propeller Diameter 70 Propeller Type 2 blade adjustable pitch An N at the end of the part number...

Page 202: ...de angle and torque the 1 4 bolts retaining the blades to 120 inch pounds Torque the 5 16 bolts to 200 inch pounds in the pattern shown in FIGURE 06 14 NOTE Check the specifications provided with the...

Page 203: ...R If bolts are bottomed out on the threads the prop is not properly torqued separation from the aircraft during operation may occur 6 Install Spinner Backing Plate and bolt the prop assembly in place...