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Revision: 2

Date: 11-15-19

VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL

6.2-9

6.2.5 STRUCTURAL REPAIRS

No major repair or alterations, as outlined in ASTM F2483, FAR 43, or in this manual are
authorized at this time.

To obtain engineering approvals for any major repairs or alterations, please contact Vashon

Aircraft at:

Vashon Aircraft

™

19825 141ST PL NE

Woodinville, WA 98072

USA

Tel: +1 425 527 9940

Email:

[email protected]

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Summary of Contents for RANGER R7

Page 1: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL Page TITLE PAGE i AIRCRAFT MAINTENANCE MANUAL Serial Number _______________________ N Number _______________________...

Page 2: ...Date 11 15 19 Revision 2 Page TITLE PAGE ii VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL Vashon Aircraft 19825 141st Pl NE Woodinville WA 98072 www vashonaircraft com...

Page 3: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL Page TITLE PAGE iii INTENTIONALLY LEFT BLANK...

Page 4: ...Revision 11 15 19 JJR 5 5 2 Major Revision 11 15 19 JJR 5 6 2 Major Revision 11 15 19 JJR 5 7 2 Major Revision 11 15 19 JJR 5 7 1 2 Major Revision 11 15 19 JJR 5 7 2 2 Major Revision 11 15 19 JJR 5 7...

Page 5: ...ty changed from 6 quarts to 5 quarts Verify oil level changed from 6 quarts to 5 quarts 01 14 19 KAH KLK A 2 Major Revision 11 15 19 JJR 6 2 Major Revision 11 15 19 JJR 6 1 2 Major Revision 11 15 19 J...

Page 6: ...ANUAL 5 1 1 GENERAL SPECIFICATIONS TORQUES DATA AND FORMS 5 2 1 PERIODIC AND CONDITION INSPECTION REQUIREMENTS 5 3 1 MAINTENANCE OVERVIEW SERVICING OF FLUIDS AND PERSONNEL AUTHORIZATION 5 4 1 REPAIR O...

Page 7: ...Date 11 15 19 Revision 2 Page 0 iv VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 8: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL Page 0 v SECTION 1 SCOPE...

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Page 10: ...The owner is reminded that it is her his responsibility to ensure that Vashon Aircraft has the appropriate contact information so that flight safety and other important information can be communicated...

Page 11: ...ght safety directly to Vashon Aircraft using the form on the website Alternatively complete the form on page 6 and e mail fax or mail to the address in Section 1 1 PILOT OWNER SERVICING AND MAINTENANC...

Page 12: ...inor repair and minor alteration tasks that can be accomplished by a holder of an LSA repairman certificate with either an inspection or maintenance rating Furthermore it also instructs on heavy maint...

Page 13: ...er CURRENT OWNER Last First NEW OWNER Last First COMPANY ORGANIZATION COMPANY ORGANIZATION PREVIOUS ADDRESS Number and Street NEW ADDRESS Number and Street City City State Province Postal Code State P...

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Page 15: ...First COMPANY ORGANIZATION ADDRESS Number and Street City AIRCRAFT MODEL State Province Postal Code AIRCRAFT SERIAL NUMBER RANGER R7 Country AIRCRAFT REGISTRATION NUMBER TELEPHONE NUMBER S DESCRIPTION...

Page 16: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL Page 1 7 INTENTIONALLY LEFT BLANK...

Page 17: ...Date 11 15 19 Revision 2 Page 1 8 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL SECTION 2 REFERENCE DOCUMENTS...

Page 18: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL Page 1 9 INTENTIONALLY LEFT BLANK...

Page 19: ...r Maintenance and the Development of Maintenance Manuals for Light Sport Aircraft ASTM F2245 Specification for the Design and Performance of a Light Sport Aircraft ASTM F2295 Practice for Continued Op...

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Page 21: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL Page 2 3 SECTION 3 TERMINOLOGY...

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Page 23: ...manufacturer s maintenance manual 3 1 6 Light Sport Aircraft aircraft designed in accordance with ASTM standards under the jurisdiction of Committee F37 Light Sport Aircraft for example Specification...

Page 24: ...d by the original manufacturer or a facility approved by the original manufacturer of the product 3 1 14 Overhaul Facility facility specifically authorized by the aircraft or component manufacturer to...

Page 25: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL Page 3 3 SECTION 4 SIGNIFICANCE AND USE...

Page 26: ...Date 11 15 19 Revision 2 Page 3 4 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 27: ...SIGNIFICANCE AND USE The purpose of this maintenance manual is to provide guidance to owners mechanics airports regulatory officials and aircraft and component manufacturers who may accomplish mainten...

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Page 29: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL i SECTION 5 AIRCRAFT MAINTENANCE MANUAL...

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Page 31: ...5 7 10 ENGINE 5 7 10 1 5 7 11 ENGINE MOUNT 5 7 11 1 5 7 12 FUEL SYSTEM 5 7 12 1 5 7 13 INDUCTION SYSTEM 5 7 13 1 5 7 14 EXHAUST SYSTEM 5 7 14 1 5 7 15 POWERPLANT IGNITION 5 7 15 1 5 7 16 PROPELLER 5 7...

Page 32: ...Date 11 15 19 Revision 2 5 2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL OVERHAUL 5 9 1 5 9 1 AUTHORIZATION TO PERFORM OVERHAULS 5 9 2 APPENDIX A 1...

Page 33: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 3 INTENTIONALLY LEFT BLANK...

Page 34: ...y Aircraft will have optional equipment for which there will be specific drawings that will either be included with the aircraft s documentation on delivery or be available from Vashon Aircraft Inc LA...

Page 35: ...be made available to aircraft owners and repair shops on a subscription basis Revisions will be sent to registered subscribers as they become available Revisions may also be obtained by submitting a r...

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Page 37: ...2 7 WEIGHT AND BALANCE DATA 5 2 8 TIRE INFLATION 5 2 8 APPROVED OILS AND CAPACITIES 5 2 8 RECOMMENDED FASTENER TORQUES 5 2 8 8 1 Definitions 5 2 8 8 2 Torquing Requirement 5 2 8 8 3 Use of Torque Wren...

Page 38: ...rting in front of the nose of the airplane at a point 2540 mm 100 in forward of the wing leading edge WL Water Line is a vertical reference designation measured parallel to the ground from a point 970...

Page 39: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 2 3 Figure 5 2 1 Vashon Ranger datums and dimensions...

Page 40: ...pe Cantilever High Wing Airfoil Section NACA 23018 Chord 1400 mm 55 118 in Dihedral 0 Area 12 6 m2 135 63 ft2 Aspect Ratio 6 43 3 AILERONS Area both ailerons 1 2 m2 12 96 ft2 4 FLAPS Area both flaps 0...

Page 41: ...7 04 ft Wheel Base nose to main 1 70 m 5 58 ft 8 CONTROL SURFACE DEFLECTIONS a Aileron Trailing Edge UP 30 0 Trailing Edge DN 15 0 2 0 b Flaps Take Off Position 20 0 2 0 Landing Position 40 0 2 0 c El...

Page 42: ...5 7 16 For more information on the latest equipment please see the component s respective section in the Maintenance Repairs and Alterations part of this manual or contact Vashon Aircraft PURCHASE PAR...

Page 43: ...Rated Power at Seal Level 100 HP 2750 RPM Rated Manifold Pressure 29 5 in Hg Oil Pressure at Cruising 30 60 psi Minimum Idling Oil Pressure 10 psi Minimum Oil Temperature 75 F Maximum Oil Temperature...

Page 44: ...least one full thread through the nut but prior to the tightening of the joint also called tightening torque or installation torque Assembly Torque The torque required by design engineering in order t...

Page 45: ...ied shall not be backed off and re torqued but shall be removed rejected and rendered unserviceable If there is any doubt a fastener has been under torqued the nut shall be backed off one complete rot...

Page 46: ...sions must be measured in the same units i e both in inches both in feet etc for each calculation Different units must not be mixed 8 4 Torquing Patterns Whenever applicable one of the patterns shown...

Page 47: ...ed between 15 19 in lbs The torque required on AN5 5 16 nuts varied between 18 22 in lbs This value must be added to the torque value Item Chapter Section Reference Minimum Dry Torque Inch Pounds Maxi...

Page 48: ...5 MS20739 MS20004 THRU MS20024 NAS144 THRU NAS158 NAS333 THRU NAS340 NAS538 THRU NAS590 NAS624 THRU NAS644 NAS1303 THRU NAS1320 NAS172 NAS174 NAS517 STEEL SHEAR BOLT NAS1103 NAS1104 NAS1105 AN3D THRU...

Page 49: ...2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 2 13 3 8 16 160 185 95 100 7 16 14 235 255 140 155 All final torquing shall be carried out with certified torque wrenches or torque scre...

Page 50: ...nd or for the starter to be inadvertently engaged Never operate the engine with untrained personnel around everyone who is essential to be in the area should be reminded that a spinning propeller may...

Page 51: ...hon Aircraft of any safety of flight issue or significant service difficulty upon discovery After completing the form below e mail or mail it to Vashon Aircraft 19825 141ST PL NE Woodinville WA 98072...

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Page 53: ...Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 3 1 PERIODIC AND CONDITION INSPECTION REQUIREMENTS TABLE OF CONTENTS GENERAL 5 3 2 CONDITION INSPECTION TASKS 5 3 4 PERIODIC INSPECTION TA...

Page 54: ...sequently Inspection Groups and Criteria 1 Visual Inspection Visual inspections will normally apply to those areas surfaces and or items that become visible by the removal or opening of access doors p...

Page 55: ...operational inspection does not require quantitative tolerances 3 Functional Inspection When called for by an inspection task a functional inspection is a quantitative check to determine if one or mor...

Page 56: ...ed in ASTM F2483 must perform the inspection A signed and dated record must be maintained as each inspection task is completed When the last task of the inspection has been completed the Inspection Re...

Page 57: ...rs The 100 hour interval between inspections should never be exceeded by more than 10 hours and then only if additional time is required to reach a place where the inspection can be satisfactorily acc...

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Page 59: ...UIDS AND PERSONNEL AUTHORIZATION TABLE OF CONTENTS 100 HOUR INSPECTION 5 4 2 CONDITION INSPECTION 5 4 2 SERVICING OF FLUIDS 5 4 2 REPLACEMENT INTERVALS 5 4 6 AUTHORIZATION TO PERFORM LINE MAINTENANCE...

Page 60: ...tenance intervals when operating under abnormal environmental conditions such as high humidity and moisture saltwater environments dusty atmospheric conditions extreme temperature ranges unimproved ai...

Page 61: ...0 or SAE 50 Below 40 F SAE 20W 50 or SAE 15W 50 Brake Fluid MIL H 5606G As required Main Tire Pressure 6 00 x 6 Dry Air 25 3 psi Nose Tire Pressure 6 00 x 6 Dry Air 22 2 psi NOTE The engine must be op...

Page 62: ...ADE 3 CLASS I Aileron Torque Tube Bearings LPS 2 MIL C 16173E GRADE 3 CLASS I Aileron Pushrod Bearings LPS 2 MIL C 16173E GRADE 3 CLASS I Aileron Bellcrank Bearings LPS 2 MIL C 16173E GRADE 3 CLASS I...

Page 63: ...earings LPS 2 MIL C 16173E GRADE 3 CLASS I WING Aileron and Flap Pushrod Bearings LPS 2 MIL C 16173E GRADE 3 CLASS I Aileron Hinge Bearings LPS 2 MIL C 16173E GRADE 3 CLASS I Flap Hinge Pin LPS 2 MIL...

Page 64: ...IN THIS MANUAL NOTES 1 Engine 2000 Hours X Refer to the latest revision of the manufacturer s maintenance manual 2 Propeller 5 7 16 See manufacturer s maintenance manual 3 Plane Power Alternator At e...

Page 65: ...atteries After 1 hour of cumulative transmitting Date marked on the batteries X 5 7 21 Refer to ACK Technologies Model E 01 Installation and Operation Manual 10 Remote ELT Switch Battery if installed...

Page 66: ...ined in FAA Advisory Circular 43 13 Table 5 4 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE BREAKDOWN DESCRIPTION OWNER OPERATOR OR ABOVE LSA REPAIRMAN I REPAIRMAN M A P OR REPAIR STATION LSA REPAIRMAN M A...

Page 67: ...udder Pedals Controls X WING INSTALLATION Wingtip Lights X Landing Lights X Ailerons X Flaps X Pitot Static AoA Head X Fuel Vent Lines X Fuel Tanks X Wing Attach Removal X ENGINE INSTALLATION Engine A...

Page 68: ...Brake Lines and Fittings X Windscreen X Front Windows X Rear Windows X Doors X Battery X ELT Assembly X ELT Battery X ELT Antenna X Instrument Panel Assembly X Instrument Panel Wiring X AFS Switch Mo...

Page 69: ...E MAINTENANCE TASKS The tasks listed in this Manual and considered to be Minor Maintenance Repairs or Alteration tasks as defined in ASM F2483 Section 3 1 12 and may be performed by the Pilot Owner an...

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Page 71: ...on 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 5 1 REPAIR OVERVIEW TABLE OF CONTENTS GENERAL 5 5 2 NON STRUCTURAL SHEET METAL REPAIRS 5 5 2 NON STRUCTURAL COMPOSITE MATERIAL REPAIRS...

Page 72: ...r similar means of the damaged primary structures secondary structures or flight control structures are to be forwarded to Vashon Aircraft accompanied by a suggested repair scheme NON STRUCTURAL COMPO...

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Page 74: ...sion 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 6 1 ALTERATIONS OVERVIEW TABLE OF CONTENTS COMPLIANCE WITH MANUFACTURER S SERVICE DIRECTIVE 5 6 2 MAJOR REPAIRS AND OR ALTERATIONS 5...

Page 75: ...e bulletins and notifications MAJOR REPAIRS AND OR ALTERATIONS All major repairs and or alterations require an approved MRA Major Repair and or Alteration form from Vashon Aircraft Requests for an MRA...

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Page 77: ...ELAGE 5 7 3 1 GENERAL 5 7 3 2 INSPECTION 5 7 3 3 DOORS 5 7 3 8 REPAIRS AND ALTERATIONS 5 7 3 9 5 7 4 WINGS 5 7 4 1 GENERAL 5 7 4 2 REMOVAL 5 7 4 4 INSTALLATION 5 7 4 12 REPAIRS AND ALTERATIONS 5 7 4 1...

Page 78: ...GINE 5 7 10 1 GENERAL 5 7 10 2 ENGINE SERVICING 5 7 10 2 TROUBLESHOOTING 5 7 10 2 OIL SYSTEM SERVICING 5 7 10 6 REPAIRS AND ALTERATIONS 5 7 10 11 5 7 11 ENGINE MOUNT 5 7 11 1 GENERAL 5 7 11 2 INSPECTI...

Page 79: ...S 5 7 19 1 GENERAL 5 7 19 2 THROTTLE 5 7 19 2 MIXTURE CONTROL 5 7 19 5 REPAIRS AND ALTERATIONS 5 7 19 9 5 7 20 ELECTRICAL POWER SYSTEMS 5 7 20 1 GENERAL 5 7 20 2 TROUBLESHOOTING 5 7 20 3 STARTER 5 7 2...

Page 80: ...2 PREPARATION 5 7 25 2 MEASURING WHEEL LOCATIONS 5 7 25 3 WEIGHING THE AIRCRAFT 5 7 25 3 CALCULATE EMPTY WEIGHT AND EMPTY CENTER OF GRAVITY LOCATION 5 7 25 3 5 7 26 PARKING MOORING 5 7 26 1 PARKING 5...

Page 81: ...TENANCE MANUAL 5 7 1 1 5 7 1 RAISING THE AIRCRAFT TABLE OF CONTENTS GENERAL 5 7 1 2 RAISING THE NOSE 5 7 1 2 RAISING THE AIRCRAFT FROM THE FUSELAGE 5 7 1 4 RAISING THE AIRCRAFT FROM THE MAIN LANDING G...

Page 82: ...Bracket CAUTION Do not jack the aircraft outside or in an open hangar with winds in excess of 10 knots NOTE Raise airplane no more than required for the maintenance being performed Parts Required No p...

Page 83: ...MAINTENANCE MANUAL 5 7 1 3 d Remove downward load on horizontal stabilizer e Ensure aircraft is firmly supported and will not fall before working under it Figure 5 7 1 1 Lifting front of aircraft PUS...

Page 84: ...ar with force sufficient to raise the nose wheel c Place a padded sawhorse under forward fuselage as indicated in Figure 5 7 1 2 d Remove download on horizontal stabilizer e Lift up gently on the inbo...

Page 85: ...5 RAISING THE AIRCRAFT FROM THE MAIN LANDING GEAR a Place chocks under opposite main wheel and nose wheel b Insert Vashon Aircraft Axle Jack Adapter c Lift aircraft up by jacking up on the adapter d E...

Page 86: ...AIRCRAFT FROM THE WING a Place chocks under main wheels b Lift up gently on the forward wing spar at a rib intersection inboard of the inboard alerion bracket c Put jack under the lifting point and un...

Page 87: ...1 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 1 7 Figure 5 7 1 3 Lifting the aircraft by its wings LIFT ALONG SPAR AT RIB JUNCTION INBOARD OF THIS POINT LIFT ALONG SPAR AT RIB JUNCTION INBO...

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Page 89: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 2 1 5 7 2 WINDSCREEN TABLE OF CONTENTS GENERAL 5 7 2 2 REMOVAL 5 7 2 2 INSTALLATION 5 7 2 9 REPAIRS AND ALTERATIONS 5 7 2 10...

Page 90: ...selage through screws and washers and are drilled to allow for thermal expansion and shrinkage It is sealed with a combination of foam weather stripping and silicon sealant REMOVAL Required Tools No s...

Page 91: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 2 3 a Protect surrounding areas with tape Figure 5 7 2 1 Protect surrounding areas...

Page 92: ...vision 2 5 7 2 4 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL b Cut silicone seal with a sharp edge This will prevent the windscreen from sticking to airframe during removal Figure 5 7 2 2 Cut existin...

Page 93: ...Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 2 5 c Remove COM coax cable from position along the side rail leading up to the wing Figure 5 7 2 3 Remove COM coax cable from installed...

Page 94: ...Date 11 15 19 Revision 2 5 7 2 6 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL d Drill out the windscreen base fairing rivets Figure 5 7 2 4 Drill out windscreen base fairing rivets...

Page 95: ...n 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 2 7 e Unscrew and remove the windscreen attach brackets that help to secure the windscreen Figure 5 7 2 5 Unscrew windscreen attach b...

Page 96: ...VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL f Unscrew the upper windscreen fairing from the wing Figure 5 7 2 6 Unscrew the upper windscreen fairing from the wing g Carefully remove the entire winds...

Page 97: ...en is the reverse of removal Please ensure surfaces are clean and free of residual silicone sealant before resealing windshield with silicon See Section 5 2 for torque specifications NOTE Do not overt...

Page 98: ...or alterations as outlined as outlined in ASTM F2483 FAR 43 or in this manual are authorized at this time To obtain engineering approvals for any major repairs or alterations please contact Vashon Air...

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Page 100: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 3 1 5 7 3 FUSELAGE TABLE OF CONTENTS GENERAL 5 7 3 2 INSPECTION 5 7 3 3 REPAIRS AND ALTERATIONS 5 7 3 9...

Page 101: ...ust be carefully scrutinized and evaluated in order to ensure that there is no loss in load carrying capacity The majority of the structural parts in the fuselage are produced from sheets of inherentl...

Page 102: ...vel of Maintenance Line Maintenance Certification Required Please see Table 5 4 3 in Section 5 4 1 ACCESS COVER REMOVAL a Remove EFIS screen by unfastening the four bolts disconnecting the EFIS harnes...

Page 103: ...3 Removal of the panel into the avionics bay on the passenger side c Remove access panel on the rear bulkhead of the baggage compartment and access hole covers on the floor of the fuselage Set aside F...

Page 104: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 3 5 Figure 5 7 3 5 Seat removal...

Page 105: ...UAL e Remove seat hinges control access panels and seat access panel covers as shown below Set aside Figure 5 7 3 6 Cabin access panel removals f Remove the main landing gear access panel and both acc...

Page 106: ...nel access panel removals g Remove the access hole covers near the epennage on pilot and passenger sides of the plane and on the bottom of the aircraft Figure 5 7 3 8 Rear outer fuselage access hole c...

Page 107: ...or wear security of attachment binding interference 3 INSTALLATION a Installation of the components are the reverse of their removal DOORS Required Tools No special tools are required for this operati...

Page 108: ...can occur 2 INSTALLATION a Installation of the door is the reverse of its removal REPAIRS AND ALTERATIONS No major repair or alterations as outlined in ASTM F2483 FAR 43 or in this manual are authoriz...

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Page 110: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 4 1 5 7 4 WINGS TABLE OF CONTENTS GENERAL 5 7 4 2 REMOVAL 5 7 4 4 INSTALLATION 5 7 4 12 REPAIRS AND ALTERATIONS 5 7 4 12...

Page 111: ...tributes such a large percentage of the load carrying capability of the wing dents cracks or other defects in the skin must be carefully scrutinized and evaluated in order to ensure that there is no l...

Page 112: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 4 3 Figure 5 7 4 1 Wing structure with skin hidden...

Page 113: ...red No parts are required at this time Level of Maintenance Heavy Maintenance Certification Required Please see Table 5 4 3 in Section 5 4 1 REMOVAL CAUTION Before removing the wing chock the wheels a...

Page 114: ...c Remove all access panels from the bottom skin of the wing Remove the aileron pushrod access panels located just aft of the aft door jambs Figure 5 7 4 3 Aileron pushrod access panels covers Figure 5...

Page 115: ...of the spar in the cabin Cover all exposed ends of tubing to prevent dirt or debris from entering the fuel system Figure 5 7 4 5 Fuel line disconnect Follow the same operation for disconnecting the pi...

Page 116: ...MAINTENANCE MANUAL 5 7 4 7 Figure 5 7 4 7 Aileron torque tube disconnect Use same procedure on opposite wing NOTE The flaps and ailerons may be removed from the wings at this point See Section 5 7 6 g...

Page 117: ...FT RANGER R7 MAINTENANCE MANUAL Figure 5 7 4 8 Electrical harness disconnect h Disconnect the com radio antenna cable from the antenna and then push the connector out through the opening in the spar w...

Page 118: ...Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 4 9 Figure 5 7 4 9 Antenna cable disconnect as shown from above the wing i Remove the screws that attach the wing lower skin to the upper...

Page 119: ...ame procedure for passenger side bolts j Remove the screws that attach the aft edge of the wing upper skin to the forward edge of the upper aft fuselage skin and remove the bolts attaching the rear sp...

Page 120: ...support each side of the wing at or near the tie down bolt location while the third person removes the attaching hardware k Remove the bolts attaching the front spar to the fuselage Figure 5 7 4 12 F...

Page 121: ...ace the wing so as not to dent or damage the wing skins INSTALLATION Required Tools No special tools are required for this operation Parts Required No parts are required at this time Level of Maintena...

Page 122: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 4 13 Vashon Aircraft 19825 141ST PL NE Woodinville WA 98072 USA Tel 1 425 527 9940 Email support vashonaircraft com...

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Page 124: ...T RANGER R7 MAINTENANCE MANUAL 5 7 5 1 5 7 5 EMPENNAGE TABLE OF CONTENTS GENERAL 5 7 5 2 FUSELAGE INSPECTION 5 7 5 3 TAIL SURFACES INSPECTION 5 7 5 4 VERTICAL STABILIZER 5 7 5 5 HORIZONTAL STABILIZER...

Page 125: ...arrying capacity The majority of the structural parts in the empennage are produced from sheets of inherently corrosion resistant 6061 T6 aluminum using a CNC turret punch press The machine cut flat p...

Page 126: ...or this operation Parts Required No parts are required at this time Level of Maintenance Line Maintenance Certification Required Please see Table 5 4 3 in Section 5 4 Figure 5 7 5 2 Empennage fairing...

Page 127: ...looseness or wear of the elevator pushrod rod end bearings g Instillation of fairings is the reverse of removal h Safety wire the 2X hinge pins TAIL SURFACES INSPECTION Required Tools No special tools...

Page 128: ...are required at this time Level of Maintenance Heavy Maintenance Certification Required Please see Table 5 4 3 in Section 5 4 NOTE Vertical stabilizer and rudder can be removed as one unit 1 REMOVAL...

Page 129: ...removal d Place the vertical stabilizer on any flat surface that is covered or padded such that the skin will not become dented or damaged 2 INSTALLATION a Installation of the vertical stabilizer is t...

Page 130: ...uselage side skin remove the four bolts attaching the horizontal stabilizer front spar to the upper aft fuselage bulkhead Figure 5 7 5 5 Horizontal stabilizer front spar detachment b Remove the four b...

Page 131: ...izer is the reverse of removal Please see Section 5 2 for torque specification and torque seal all bolts REPAIRS AND ALTERATIONS No major repair or alterations as outlined as outlined in ASTM F2483 FA...

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Page 133: ...AINTENANCE MANUAL 5 7 6 1 5 7 6 FLIGHT CONTROLS TABLE OF CONTENTS GENERAL 5 7 6 2 TROUBLESHOOTING 5 7 6 3 AILERON REMOVAL 5 7 6 4 FLAP REMOVAL 5 7 6 8 RUDDER 5 7 6 11 ELEVATORS 5 7 6 13 RUDDER PEDAL A...

Page 134: ...pilot and passenger The flaps are actuated electrically via a linear actuator mounted in the wing directly above the passenger seat The actuator is attached to the center arm of a torque tube assembly...

Page 135: ...rod end bearings worn and loose Replace pushrod rod end bearings Worn holes in control stick torque tube arm bellcrank or idler where pushrod rod end bearings are attached Replace worn out components...

Page 136: ...rate AoA AoA system does not work AoA port clogged Check that AoA port is clear AoA tube broken or not attached at pitot static aoa head or ADAHRS Check AoA tube for proper installation AoA functional...

Page 137: ...IRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 6 5 Figure 5 7 6 2 Access hole location for aileron pushrod Figure 5 7 6 3 Pushrod removal b Remove the hinge bolts and washers while firmly holding the ailero...

Page 138: ...Date 11 15 19 Revision 2 5 7 6 6 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL Figure 5 7 6 4 Removal of aileron hinge bolts c Carefully remove the aileron from the wing...

Page 139: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 6 7 2 INSTALLATION a Installation of the ailerons is the reverse of its removal Figure 5 7 6 5 Aileron installation...

Page 140: ...s found by positioning the trailing edge of the ailerons 1 8 below the trailing edge of the wing tip NOTE In addition to ensuring proper assembly check spring back and that the ailerons are free and c...

Page 141: ...NGER R7 MAINTENANCE MANUAL 5 7 6 9 Figure 5 7 6 6 Flap access hole location a Through the access hole shown above remove the bolt that fastens the flap pushrod to the torque tube Figure 5 7 6 7 Flap p...

Page 142: ...6 10 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL b Unfasten the safety wire and remove the flap hinge pin Figure 5 7 6 8 Flap hinge pin removal c Lower flaps carefully to remove 2 INSTALLATION Figur...

Page 143: ...ailing edge with the aileron trailing edge in the neutral position d Connect the flap actuator rod end to the flap nose rib by installing the actuator bolt with Locktite 601 or equivalent Make sure th...

Page 144: ...the cotter pins from the rudder cable attach bolts Disconnect the rudder cables from the rudder horn Figure 5 7 6 10 Rudder cable detachment b Remove the bolt from the lower mid and upper rudder hinge...

Page 145: ...d or damaged 2 INSTALLATION a Installation of the rudder is the reverse of removal Please see Section 5 2 for torque specification and torque seal all bolts b In addition to proper assembly and fasten...

Page 146: ...removing the vertical stabilizer or rudder 1 REMOVAL a Remove the bolt attaching elevator pushrod to the elevator horns Figure 5 7 6 12 Elevator pushrod detachment b Disconnect the trim motor wire con...

Page 147: ...is covered or padded such that the skin will not become dented or damaged f Remove the bolts from the opposite side elevator and separate from the horizontal stabilizer using the same procedure as ste...

Page 148: ...ages The pedal position can be adjusted forward and aft through removing a pin on the track rail and sliding it to the proper position REMOVAL Required Tools No special tools are required for this ope...

Page 149: ...ble disconnect e Remove EFIS screen by unfastening the four bolts disconnecting the EFIS harnesses and setting screens aside f Remove rudder cable anchor as shown below This may include removing the e...

Page 150: ...MANUAL Figure 5 7 6 15 Rudder cable anchor removal g From the pilot and passenger side unfasten the rudder pedal brackets underneath the dashboard that holds the rudder adjustment tubes Figure 5 7 6 1...

Page 151: ...ION a Installation is the reverse of its removal Please see part 6 section 5 7 8 for brake installations See section 5 2 part 8 5 for the rudder attachment bolts for specific torque specifications REP...

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Page 153: ...MAINTENANCE MANUAL 5 7 7 1 5 7 7 LANDING GEAR TABLE OF CONTENTS GENERAL 5 7 7 2 TROUBLESHOOTING 5 7 7 3 MAIN LANDING GEAR 5 7 7 4 MAIN LANDING GEAR AXLE SUBASSEMBLY 5 7 7 8 NOSE LANDING GEAR 5 7 7 10...

Page 154: ...heet and are bolted directly to the fuselage structure Both main wheels are fitted with hydraulically operated disc brakes actuated by pressing toe brakes at each crew position The nose landing gear l...

Page 155: ...er washer stack orientation and properly lubricated nose wheel swivel Replace bushings as needed Tighten nose swivel to proper breakout force See part 6 of this section Uneven rotation Ensure nose whe...

Page 156: ...MAIN LANDING GEAR Figure 5 7 7 3 Main landing gear arrangement Required Tools No special tools are required for this operation Parts Required No parts are required at this time Level of Maintenance H...

Page 157: ...Figure 5 7 7 4 Landing gear removal overview 1 REMOVAL a Raise the aircraft by placing one stand aft of the nose gear bracket and one under the main bulk head aft of the baggage compartment window see...

Page 158: ...the brake line from the fuselage c Drill out hole into skin shown below and remove both nuts as shown Alternatively the bottom panel can be partially removed by drilling out the rivets on the desired...

Page 159: ...bolts 4X Remove landing gear and shims if needed Figure 5 7 7 8 Lower landing gear bolt removal NOTE Each landing gear has its own shim shim stack Ensure that each shim shim stack documented and or k...

Page 160: ...values and torque seal bolts b Verify that all the hardware is installed properly reconnect the brake lines and tighten the fittings and lower the aircraft to the ground c Service the brakes if neede...

Page 161: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 7 9 1 REMOVAL Figure 5 7 7 9 Main landing gear axle assembly removal...

Page 162: ...re there are no cracks or grooves b Inspect the landing gear and fuselage attachment points for cracks damage and oversized holes c Replace unserviceable parts as required 3 CLEANING a Clean with degr...

Page 163: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 7 11 Figure 5 7 7 10 Nose landing gear arrangement 1 REMOVAL Figure 5 7 7 11 Nose landing gear removal...

Page 164: ...spect the landing gear and fuselage attachment points for cracks damage and oversized holes b Replace or repair affected parts 3 INSTALLATION a Installation of the nose landing gear is the reverse of...

Page 165: ...faces b Check for excess wear and or elongation in nose pivot hole and wheel axle hole c Check nose pivot spindle for excess wear and or damage 3 INSTALLATION a Grease nose leg pivot spindle and nose...

Page 166: ...e location and pull sideways to pivot nose fork d Tighten nose fork pivot nut until it takes 15 20lb 26lbs for new assembly before break in to break free from the axle location e Installation is compl...

Page 167: ...epair or alterations as outlined in ASTM F2483 FAR 43 or in this manual are authorized at this time To obtain engineering approvals for any major repairs or alterations please contact Vashon Aircraft...

Page 168: ...Date 11 15 19 Revision 2 5 7 7 16 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 169: ...ENANCE MANUAL 5 7 8 1 5 7 8 WHEEL AND BRAKE ASSEMBLIES TABLE OF CONTENTS GENERAL 5 7 8 2 TROUBLESHOOTING 5 7 8 3 MAIN WHEELS 5 7 8 4 NOSE WHEEL 5 7 8 9 BRAKE CALIPERS 5 7 8 12 MASTER CYLINDER REMOVAL...

Page 170: ...side left brake pilot side right brake passenger side left brake and passenger side right brake The master cylinders push hydraulic fluid to the calipers where pistons are displaced and force the brak...

Page 171: ...hydraulic system thaw ice first Bent or cracked toque plate Replace Corroded anchor bolts and or torque plate bushings Clean and lubricate or replace Warped brake disc inspect by laying a straight edg...

Page 172: ...d by bent bolts or over torquing bolts Check and replace bolts Incorrect lining and or disc Replace with correct parts Defective caliper Rebuild caliper Rapid disc and lining wear Excessive rusting sc...

Page 173: ...moval inspection and assembly procedure are outlined below For more information on the removal inspection and assembly of the brake and wheel assemblies please see the manufacturer s manual 1 MAIN WHE...

Page 174: ...IR PRESSURE HAS BEEN RELEASED WARNING INJURY CAN RESULT WHEN ATTEMPTING TO SEPARATE WHEEL HALVES WITH THE TUBE INFLATED a Deflate the tire b Break the tire bead loose from the wheel c Remove the brake...

Page 175: ...Tube Visually inspect the tires inside and outside for cuts uneven or excessive wear and penetration by foreign objects Visually inspect the inner tube for wear cuts or cracks Pay close attention to...

Page 176: ...r distortion Minimum disc thickness is 0 167 in Inspect for rust Light rust may be acceptable but heavier rust may need removal See Matco Manual for definitions and more information e Bearings Clean a...

Page 177: ...reverse order of its removal while repacking the bearings Tighten axle nut while moving wheel back and forth to seat bearing Tighten until rubber bearing seal is stationary but wheel can rotate freely...

Page 178: ...of Maintenance Heavy Maintenance Certification Required Please see Table 5 4 3 in Section 5 4 1 NOSE WHEEL REMOVAL a Remove nose wheel axle bolt washers and nut b Slide wheel out of nose wheel fork R...

Page 179: ...ead loose from the wheel c Remove the 6 bolts fastening the hub and wheel halves together and pull them apart Note be careful not to damage the inner tube valve stem Figure 5 7 8 6 Nose wheel disassem...

Page 180: ...wheel axle c Fasten nose wheel axle bolt with washers 2X and nut Torque axle bolt until wheel will only rotate 2 5 turns or less when spun from tire roughly 190 220 in lbs Torque other bolts to the s...

Page 181: ...iper and the remaining two bolts to finish the removal of the brake from the landing gear 2 INSPECTION a Inspect the brake linings for loose rivets cracks and uneven wear b The minimum lining thicknes...

Page 182: ...sure that all bolts on the brake caliber assembly are torqued to the specifications outlined in Section 5 2 and that the cotter pin is on the wheel axle nut Torque seal bolts MASTER CYLINDER REMOVAL A...

Page 183: ...on 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 8 15 Figure 5 7 8 8 Brake master cylinders 1 REMOVAL a Drain hydraulic fluid from system and disconnect brake lines from 90 brass fi...

Page 184: ...ter pins and bolts holding the master cylinders to the pedals 2 INSPECTION a Inspect master cylinder for signs of leaks cracks or any other damage b Inspect all fittings for signs of leaks cracks or a...

Page 185: ...uts finger tight and lock the nuts with cotter pins c Connect brake lines to 90 fittings d After installation of the master cylinder carefully fill brake system from the brake calipers and ensure no a...

Page 186: ...the brake reservoir making sure that it is a minimum of full REPAIRS AND ALTERATIONS No major repair or alterations as outlined in ASTM F2483 FAR 43 or in this manual are authorized at this time To ob...

Page 187: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 8 19 INTENTIONALLY LEFT BLANK...

Page 188: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 9 1 5 7 9 ENGINE COWL TABLE OF CONTENTS GENERAL 5 7 9 2 ENGINE COWL 5 7 9 2 REPAIRS AND ALTERATIONS 5 7 9 6...

Page 189: ...tant resins ENGINE COWL Required Tools No special tools are required for this operation Parts Required No parts are required at this time Level of Maintenance Line Maintenance Certification Required P...

Page 190: ...g top cowl pins b Unfasten and remove the cowl side hinge pin on both sides Unfasten the top screws 3X each side from the cowl attach plates on both sides Figure 5 7 9 2 Top cowl side hinge pin and co...

Page 191: ...ON AIRCRAFT RANGER R7 MAINTENANCE MANUAL Figure 5 7 9 4 Top cowl removal d Unfasten the screws 6X on the bottom aft of the lower cowling Figure 5 7 9 5 Bottom cowl screw removal e Remove both hinge pi...

Page 192: ...IRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 9 5 Figure 5 7 9 6 Lower cowl hinge pin removal f Carefully remove the lower cowling Figure 5 7 9 7 Lower cowl removal 2 INSPECTION a Inspect the cowl for loos...

Page 193: ...RS AND ALTERATIONS No major repair or alterations as outlined as outlined in ASTM F2483 FAR 43 or in this manual are authorized at this time To obtain engineering approvals for any major repairs or al...

Page 194: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 9 7 INTENTIONALLY LEFT BLANK...

Page 195: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 10 1 5 7 10 ENGINE TABLE OF CONTENTS GENERAL 5 7 11 2 INSPECTION 5 7 11 3 REPAIRS AND ALTERATIONS 5 7 11 3...

Page 196: ...valve on the carburetor that stops the supply of fuel to the engine The mixture control should always be used to stop the engine ENGINE SERVICING Refer to publications by Continental Motors in conjunc...

Page 197: ...ing procedure with more priming Excess priming puffs of black smoke Clear cylinders by turning propeller several revolutions with ignition switch OFF and throttle wide open Engine hot vapor lock in fu...

Page 198: ...neto distributor block Overhaul magneto Check for very fine cracks in block 5 7 15 Worn cam lobe Overhaul engine Defective valve lifter Remove and test hydraulic unit Replace if worn Scored valve stem...

Page 199: ...lean filter check for obstruction in fuel flow transducer clean carburetor screen 5 7 13 5 7 12 5 7 23 Worn cylinders pistons and or piston rings Overhaul engine Low oil pressure Low oil supply Replen...

Page 200: ...limb Avoid prolonged high power operation at low airspeed Lean fuel air mixture Refer to Continental Motors overhaul manual OIL SYSTEM SERVICING The oil system is integrated into the engine except for...

Page 201: ...7 10 1 Oil filter secured by safety wire f Close the oil drain making sure it is sealed g Fill the engine with an approved oil See Chapter 5 4 for specifications and amount h Verify oil quantity with...

Page 202: ...gine and determine the trouble k Visually check inside of cowling for any obvious leaks and correct them as necessary 4 2 OIL COOLER Required Tools No special tools are required for this operation Par...

Page 203: ...and dispose of any oil that may leak from the tubes and cooler b Remove the through bolts and carefully remove the oil cooler c Disconnect the hoses from the oil cooler elbows d Remove the elbows fro...

Page 204: ...r and install bolts and washers through the long spacer tubes between the oil cooler webs with washers c Torque the bolts nuts as outlined in Section 5 2 d Attach the oil hoses to the elbows on the oi...

Page 205: ...epairs or alterations as outlined in ASTM F2483 FAR 43 or in this manual are authorized at this time To obtain engineering approvals for any major repairs or alterations please contact Vashon Aircraft...

Page 206: ...Date 11 15 19 Revision 2 5 7 10 12 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 207: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 11 1 5 7 11 ENGINE MOUNT TABLE OF CONTENTS GENERAL 5 7 11 2 INSPECTION 5 7 11 3 REPAIRS AND ALTERATIONS 5 7 11 3...

Page 208: ...N AIRCRAFT RANGER R7 MAINTENANCE MANUAL GENERAL The structure of the engine mount is made of high strength steel and the engine is attached to the mount through rubber mounts that help reduce vibratio...

Page 209: ...stortion and security REPAIRS AND ALTERATIONS No major repair or alterations as outlined in ASTM F2483 FAR 43 or in this manual are authorized at this time To obtain engineering approvals for any majo...

Page 210: ...Date 11 15 19 Revision 2 5 7 11 4 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 211: ...ANCE MANUAL 5 7 12 1 5 7 12 FUEL SYSTEM TABLE OF CONTENTS GENERAL 5 7 12 2 TROUBLESHOOTING 5 7 12 3 DRAINING FUEL 5 7 12 4 REPLACING FUEL TANKS 5 7 12 6 REPLACING WING TANK FUEL SUMPS 5 7 12 6 REPLACI...

Page 212: ...ward from the pitot static aoa mast to discharge clear of the leading edge of the wing The vent line discharge is shielded to prevent in flight obstruction of the vent opening due to bird insect debri...

Page 213: ...ges Fuel Level High with Fuel Starvation into the Engine Clogged Vent Tube Clog in Fuel System Verify vent screens and fuel lines are clear of debris Fuel Levels Erratic or Not Moving Over Time Fuel s...

Page 214: ...ing the fuel line from the carburetor is recommended CAUTION Observe all precautions related to fueling and de fueling the aircraft In particular the following are highlighted Connect grounding wire t...

Page 215: ...has been drained and then the aircraft has been re fueled the engine must be run on the ground for enough time to purge the system of air prior to flight 2 DRAINING FUEL FROM FUEL LINE INTO CARBURETO...

Page 216: ...install in the reverse order of its removal REPLACING FUEL TANKS Required Tools No special tools are required for this operation Parts Required No parts are required at this time Level of Maintenance...

Page 217: ...2 3 Disconnecting fuel lines in cockpit c Use access panels on the underside of the wing to disconnect the fuel line fuel vent line and wiring connector for each side of the tank Figure 5 7 12 4 Disco...

Page 218: ...EL FILTERS Required Tools No special tools are required for this operation Parts Required No parts are required at this time Level of Maintenance Line Maintenance Certification Required Please see Tab...

Page 219: ...the fuel filter to remove the inline fuel filter Contain any residual fuel that may drain from the fuel lines d Replace the filter if needed Installation is the reverse of its removal 2 CARBURETOR INL...

Page 220: ...mber d Install the hex plug REPAIRS AND ALTERATIONS No major repairs or alterations as outlined in ASTM F2483 FAR 43 or in this manual are authorized at this time To obtain engineering approvals for a...

Page 221: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 12 11 INTENTIONALLY LEFT BLANK...

Page 222: ...te 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 13 1 5 7 13 INDUCTION SYSTEM TABLE OF CONTENTS GENERAL 5 7 13 2 REPLACING AIR FILTER 5 7 13 2 CARBURETOR HEAT 5 7 13 3 REPAIRS AND ALTERATI...

Page 223: ...rument panel and is discuss further in Section 5 7 19 and 5 7 13 CAUTION Ground operations with the carburetor heat control in the hot position must be limited because it allows air to bypass the filt...

Page 224: ...er b If a new filter is required contact Vashon Aircraft 2 INSPECTION a Inspect the filter for any damage such as tears or large holes b Clean the filter by blowing compressed air on the aft side of t...

Page 225: ...tion Parts Required No parts are required at this time Level of Maintenance Line Maintenance Certification Required Please see Table 5 4 3 in Section 5 4 NOTE Please see Section 5 7 13 for the carbure...

Page 226: ...tops at both extents of its travel However there should not be more than 1 8 cushion between the knob and the panel nut when the knob is fully closed pushed in 2 CARBURETOR HEAT CABLE ROUTING a Route...

Page 227: ...ing and through the carburetor heat valve arm c Place the washer and castle nut on the stud 4 INSPECTION a Ensure no visible damage and loose parts b Ensure full range of motion is achieved when the l...

Page 228: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 13 7 Vashon Aircraft 19825 141ST PL NE Woodinville WA 98072 USA Tel 1 425 527 9940 Email support vashonaircraft com...

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Page 230: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 14 1 5 7 14 EXHAUST SYSTEM TABLE OF CONTENTS GENERAL 5 7 14 2 ENGINE EXHAUST 5 7 14 2 REPAIRS AND ALTERATIONS 5 7 14 4...

Page 231: ...from stainless steel tubing and contains heat exchangers for both the carb heat and cabin heat functions Figure 5 7 14 1 Exhaust system heat muffs not shown ENGINE EXHAUST Required Tools No special t...

Page 232: ...buretor and Cabin Heat shrouds can be removed by unfastening the screws shown below Figure 5 7 14 2 Exhaust heat muff removal d Remove exhaust by disconnecting the springs hanging the exhaust tubing t...

Page 233: ...SIDE THE COWL THIS MAY TRAVEL THROUGH THE FIREWALL AND INTO THE COCKPIT CARBON MONOXIDE MAY RESULT IN DEATH NEVER OPERATE THE AIRCRAFT WITH ANY CRACKS IN THE EXHAUST SYSTEM 3 INSTALLATION a Install th...

Page 234: ...R R7 MAINTENANCE MANUAL 5 7 14 5 To obtain engineering approvals for any major repairs or alterations please contact Vashon Aircraft at Vashon Aircraft 19825 141ST PL NE Woodinville WA 98072 USA Tel 1...

Page 235: ...Date 11 15 19 Revision 2 5 7 14 6 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 236: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 15 1 5 7 15 POWERPLANT IGNITION TABLE OF CONTENTS SPARK PLUGS 5 7 15 2 MAGNETOS 5 7 15 3 REPAIRS AND ALTERATIONS 5 7 15 5...

Page 237: ...ny foreign material lodged between electrodes or around the insulator that could be conductive Clean as needed b Check the electrode gap For the correct electrode gap please see Continental Maintenanc...

Page 238: ...tinental magnetos that supply electricity to the spark plugs through the ignition cables The magnetos are wired in a way such that the firing order of the engine is 1 3 2 4 The right magneto supplies...

Page 239: ...s No special tools are required for this operation Parts Required No parts are required at this time Level of Maintenance Heavy Maintenance Certification Required Please see Table 5 4 3 in Section 5 4...

Page 240: ...INSTALLATION a Install the magnetos as per Continental s Standard Practice Maintenance Manual REPAIRS AND ALTERATIONS No major repair or alterations as outlined as outlined in ASTM F2483 FAR 43 or in...

Page 241: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 15 1 INTENTIONALLY LEFT BLANK...

Page 242: ...1 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 16 1 5 7 16 PROPELLER TABLE OF CONTENTS GENERAL 5 7 16 2 TROUBLESHOOTING 5 7 16 2 REMOVAL INSPECTION AND INSTALLATION 5 7 16 3 REPAIRS AND ALTE...

Page 243: ...peller as a tow bar to move the aircraft Figure 5 7 16 1 Propeller overview This section is prepared to give an outline of the removal and installation For the more information on the removal inspecti...

Page 244: ...his section REMOVAL INSPECTION AND INSTALLATION Required Tools No special tools are required for this operation Parts Required No parts are required at this time Level of Maintenance Heavy Maintenance...

Page 245: ...t the propeller to ensure that it does not fall d Once torque is released remove all bolts with the crush plate and the adapter plate 2 PROPELLER INSPECTION Defer to propeller manufacturers detailed i...

Page 246: ...ly Bubbled or Separated surface lamination c Oversize or elongated hub bore or bolt holes d If there is any major visual damage due to impact e Obvious damage or wear beyond economical repair h Inspec...

Page 247: ...inner rear bulkhead and engine flange for fretting If the fretting is severe and cannot be dressed out with emery cloth and re anodized for aluminum parts only then the parts must be replaced Clean th...

Page 248: ...ed alcohol the surfaces of both propeller hub faces and mounting flange and the front and rear surfaces of the spinner backing plate ENSURE both surfaces are free of contaminants b Make sure that the...

Page 249: ...ach prop extension to crankshaft Note the 12 O CLOCK position Figure 5 7 16 4 Propeller extension alignment e Torque the extension bolts with washers to 10 ft lb in a star bolt pattern then to 20 ft l...

Page 250: ...7 MAINTENANCE MANUAL 5 7 16 9 Figure 5 7 16 5 Rear spinner bulkhead alignment g After installing spinner bulkhead install propeller Position the blades at the 2 and 8 o clock position referencing the...

Page 251: ...ON AIRCRAFT RANGER R7 MAINTENANCE MANUAL Figure 5 7 16 6 Propeller alignment h Install crush plate forward bulkhead washers and bolts on to prop Note alignment marks on forward and aft bulkheads made...

Page 252: ...urs of operation and then again at 10 to 15 hours l It is mandatory to recheck the bolt torque every 50 hours or 6 months whichever comes first If there are any significant changes in environmental co...

Page 253: ...epairs or alterations as outlined in ASTM F2483 FAR 43 or in this manual are authorized at this time To obtain engineering approvals for any major repairs or alterations please contact Vashon Aircraft...

Page 254: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 16 13 INTENTIONALLY LEFT BLANK...

Page 255: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 17 1 5 7 17 UTILITY SYSTEMS TABLE OF CONTENTS GENERAL 5 7 17 2 REPAIRS AND ALTERATIONS 5 7 17 2...

Page 256: ...he air either out the bottom of the cowling with the rest of the engine cooling air or into the cabin through an opening in the firewall To select cabin heat the control on the lower part of the cente...

Page 257: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 17 3 INTENTIONALLY LEFT BLANK...

Page 258: ...FIS 5 7 18 4 SV ADAHRS 200 201 5 7 18 4 SV EMS 220 5 7 18 5 SV BAT 320 5 7 18 6 COM SYSTEM 5 7 18 6 SV COM C25 5 7 18 6 NAVIGATION SYSTEM 5 7 18 8 SV XPNDR 261 5 7 18 8 SV GPS 2020 5 7 18 8 SV ADASB 4...

Page 259: ...FD information Engine Monitoring GPS moving map with procedure and en route charts two axis approach capable Autopilot Mode S Transponder with 2020 compliant ADS B Out capability ADS B Traffic and Wea...

Page 260: ...ndary X SV INTERCOM 2S Intercom X NAV SYSTEM STANDARD OPTIONAL SV XPNDR 261 Mode S Transponder X SV GPS 2020 GPS Antenna Receiver Module primary X SV GPS 2020 GPS Antenna Receiver Module secondary X S...

Page 261: ...EFIS as shown in Figure 5 7 18 2 As an option a second SV D1000 EFIS may be installed Figure 5 7 18 2 SV D1000 EFIS SV ADAHRS 200 201 The primary ADAHRS is the SV ADAHRS 200 as shown in Figure 5 7 18...

Page 262: ...trument system utilizes a separate Engine Monitoring Module to connect to all engine and fuel system probes See Figure 5 7 18 4 This module is mounted on the cabin side of the firewall above the rudde...

Page 263: ...ent panel and the firewall Figure 5 7 18 5 SV BAT 320 COM SYSTEM No major repair or alterations as outlined in ASTM F2483 FAR 43 or in this manual are authorized at this time To obtain engineering app...

Page 264: ...7 Figure 5 7 18 6 SV COM C25 1 1 SV INTERCOM 2S The SV INTERCOM 2S connects all the audio devices in the instrument panel It provides dual stereo headset connections and dual radio outputs as well as...

Page 265: ...0 Email support vashonaircraft com SV XPNDR 261 A remote mounted Mode S transponder with control and annunciation appearing on the SkyView displays See Figure 5 7 18 8 The transponder module is mounte...

Page 266: ...9 Figure 5 7 18 9 SV GPS 2020 SV ADASB 470 A remote mounted receiver for ADS B IN information that utilizes an externally mounted antenna See Figure 5 7 18 10 The ADS B receiver is mounted on the shel...

Page 267: ...s or alterations please contact Vashon Aircraft at Vashon Aircraft 19825 141ST PL NE Woodinville WA 98072 USA Tel 1 425 527 9940 Email support vashonaircraft com SV 42 The autopilot consists of two SV...

Page 268: ...controller that eliminates the need to equip with relay decks for trim control The trim controller does not depend on the autopilot servos and continues to operate independently of them It has SkyVie...

Page 269: ...major repair or alterations as outlined in ASTM F2483 FAR 43 or in this manual are authorized at this time To obtain engineering approvals for any major repairs or alterations please contact Vashon Ai...

Page 270: ...the location of the various standard and optional antennas on the aircraft AVIONICS REMOVAL Required Tools No special tools are required for this operation Parts Required No parts are required at this...

Page 271: ...e and various avionic components are accessible c Components on the front panel can be removed by unfastening their screws 2 INSPECTION a Ensure wiring harnesses and connectors are secure Visually ins...

Page 272: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 18 15 Vashon Aircraft 19825 141ST PL NE Woodinville WA 98072 USA Tel 1 425 527 9940 Email support vashonaircraft com...

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Page 274: ...on 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 19 1 5 7 19 ENGINE CONTROLS TABLE OF CONTENTS GENERAL 5 7 19 2 THROTTLE 5 7 19 2 MIXTURE CONTROL 5 7 19 5 REPAIRS AND ALTERATIONS 5...

Page 275: ...t off valve on the carburetor that stops the supply of fuel to the engine THROTTLE Required Tools No special tools are required for this operation Parts Required No parts are required at this time Lev...

Page 276: ...19 3 should not be more than between the knob and the panel nut when the throttle is in the fully open position 2 THROTTLE CABLE ROUTING Figure 5 7 19 2 Throttle cable routing in front of the oil sump...

Page 277: ...able attachment to carburetor a The throttle cable is secured to the carburetor arm with a bolt through bushings washers and an all metal lock nut b The throttle travel can be adjusted by adjusting th...

Page 278: ...No parts are required at this time Level of Maintenance Heavy Maintenance Certification Required Please see Table 5 4 3 in Section 5 4 1 MIXTURE CONTROL CABLE TO CENTER CONSOLE ATTACHMENT Figure 5 7 1...

Page 279: ...Date 11 15 19 Revision 2 5 7 19 6 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 2 MIXTURE CABLE ROUTING Figure 5 7 19 6 Mixture cable attachment Can be used to adjust cable tension...

Page 280: ...p to the carburetor mixture arm b The mixture cable is secured to the oil sump via the two mounting points c The position of the cable housing in the mixture bracket affects the travel of the knob in...

Page 281: ...length at the swivel fitting affects the travel of the mixture control lever There should be enough travel in the lever that it reaches the stops on either extreme of its travel c The swivel nut shoul...

Page 282: ...y and the cable is held tightly by the clamp However it is important that the carburetor arm moves freely If an improper washer stack is used then the mixture control can clamp the bolt too tight and...

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Page 284: ...ON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 20 1 5 7 20 ELECTRICAL POWER SYSTEMS TABLE OF CONTENTS GENERAL 5 7 20 2 TROUBLESHOOTING 5 7 20 3 STARTER 5 7 20 4 ALTERNATOR 5 7 20 7 BATTERY 5 7 20 9 REPA...

Page 285: ...ipment A Sky Tec starter is used with a Plane Power alternator and a 12 Volt Lithium Iron Phosphate EarthX battery in the aircraft The following section will outline the power system from the alternat...

Page 286: ...Increase engine speed Very low battery Charge battery Bad battery shorted cell Replace battery Load exceeds alternator output Decrease load or increase engine RPM High Voltage Bad battery open Check c...

Page 287: ...el C12ST2 12 Volt High Torque starter with a built in electro mechanical pinion to actuate the gear Figure 5 7 20 1 Starter assembly Required Tools No special tools are required for this operation Par...

Page 288: ...lace starter solenoid Starter drive gear stays engaged for some length of time after the start button released Stuck starter solenoid Replace starter solenoid Repair or replace starter 3 REMOVAL Remov...

Page 289: ...INTENANCE MANUAL h Thoroughly clean the bearing bore Figure 5 7 20 2 Starter needle bearing removal 4 INSPECTION a Visually inspect the teeth of the starter gear and starter s housing for damage 5 INS...

Page 290: ...lternator as shown in Figure 5 7 20 3 Please see the manufacturer s manual for more information Figure 5 7 20 3 Alternator overview Required Tools No special tools are required for this operation Part...

Page 291: ...lb min do not exceed 220 in lb install cotter pin if needed b Turn on FIELD ENABLE switch with engine running at 1200 RPM Verify the voltage to be 14 2 0 3 volts from the alternator with EFIS or volt...

Page 292: ...No parts are required at this time Level of Maintenance Heavy Maintenance Certification Required Please see Table 5 4 3 in Section 5 4 1 REMOVAL a Remove the engine top cowl as described in Section 5...

Page 293: ...to a charger to restore charge charge with 1 5 amps for 20 30 minutes and then re check the voltage If the voltage is 12 8V or greater the battery should be ok and can be fully charged If the battery...

Page 294: ...repair or alterations as outlined in ASTM F2483 FAR 43 or this manual are authorized at this time To obtain engineering approvals for any major repairs or alterations please contact Vashon Aircraft a...

Page 295: ...Date 11 15 19 Revision 2 5 7 20 12 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 296: ...RANGER R7 MAINTENANCE MANUAL 5 7 21 1 5 7 21 ELECTRICAL SYSTEMS TABLE OF CONTENTS LANDING LIGHTS 5 7 21 7 NAVIGATION AND ANTI COLLISION LIGHTS 5 7 21 9 CABIN LIGHTING 5 7 21 10 ELT EMERGENCY SYSTEM 5...

Page 297: ...the avionics system see section 5 7 18 2 ELECTRICAL POWER SYSTEMS 1 GENERAL The aircraft uses a 12 volt DC electrical system with the power supplied by a 50 amp engine driven alternator and a 12 volt...

Page 298: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 21 3 2 SCHEMATICS Figure 5 7 21 1 Main bus power schematic...

Page 299: ...Date 11 15 19 Revision 2 5 7 21 4 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL Figure 5 7 21 2 General wiring schematic...

Page 300: ...n Ranger is equipped with Landing lights on each wing and LED anti collision lights on each wing tip Each landing light consists of two LED lights in an assembly In addition each anti collision light...

Page 301: ...Date 11 15 19 Revision 2 5 7 21 6 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 2 SCHEMATIC Figure 5 7 21 3 Wiring schematic for lighting system...

Page 302: ...h both lights are continuously on and PULSE in which one light is on while the other light is off and then off while the other is on Required Tools No special tools are required for this operation Par...

Page 303: ...opening 3 DISASSEMBLY a Using a 30 bit drill out the blind rivets holding the lens to the bracket being careful to not enlarge the hole in the lens or bracket b Remove the nuts washers bolts attachin...

Page 304: ...5 4 1 TROUBLESHOOTING PROBLEM PROBABLE CAUSE REMEDY Both anti collision lights do not work Tripped anti collision light electronic circuit breaker Reset electronic circuit breaker Loose wiring Check...

Page 305: ...ector into the mounting pad then attach and fasten the light unit to its mounting bracket CABIN LIGHTING Backlighting of the switch panels com radio control panel and autopilot control panel is contro...

Page 306: ...repair or alterations as outlined in ASTM F2483 FAR 43 or this manual are authorized at this time To obtain engineering approvals for any major repairs or alterations please contact Vashon Aircraft a...

Page 307: ...Date 11 15 19 Revision 2 5 7 21 12 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 308: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 22 1 5 7 22 SEATS TABLE OF CONTENTS GENERAL 5 7 22 2 SEAT BACKREST REMOVAL 5 7 22 3 REPAIRS AND ALTERATIONS 5 7 22 3...

Page 309: ...nd the backrest The seat bottom cushion consists of a main cushion and a small booster cushion that can be removed or installed depending upon the sitting height of the pilot The backrest is designed...

Page 310: ...n Remove the pin It may be helpful to rotate the backrest back and forth while applying force to the pin The aircraft may be flown solo with the passenger seatback removed so long as any items that ma...

Page 311: ...Date 11 15 19 Revision 2 5 7 22 4 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 312: ...VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 23 1 5 7 23 HOSES AND LINES For replacement hoses please contact Vashon Aircraft 19825 141ST PL NE Woodinville WA 98072 USA Tel 1 425 527 9940 Email su...

Page 313: ...Date 11 15 19 Revision 2 5 7 23 2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 314: ...sion 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 24 1 5 7 24 LEVELING TABLE OF CONTENTS GENERAL 5 7 24 2 PREPARATION 5 7 24 2 LONGITUDINAL LEVELING 5 7 24 2 LATERAL LEVELING 5 7 2...

Page 315: ...the aircraft in a closed hangar where the wind will not affect the aircraft Also required will be a source of compressed air and a tire pressure gage LONGITUDINAL LEVELING Open the pilot side door an...

Page 316: ...t or near its forward edge as shown in Figure 5 7 24 2 Center the bubble by adding air to one main tire and or by letting air out of the other main tire Re check the longitudinal leveling of the aircr...

Page 317: ...Date 11 15 19 Revision 2 5 7 24 4 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 318: ...NGER R7 MAINTENANCE MANUAL 5 7 25 1 5 7 25 WEIGHING TABLE OF CONTENTS GENERAL 5 7 25 2 PREPARATION 5 7 25 2 MEASURING WHEEL LOCATIONS 5 7 25 3 WEIGHING THE AIRCRAFT 5 7 25 3 CALCULATE EMPTY WEIGHT AND...

Page 319: ...ving the factory the empty aircraft was weighed and the CG location was computed You will find this information in Section 6 of the Pilot s Operating Handbook POH If it should become necessary to re w...

Page 320: ...erpendicular to the line Enter this distance in Table 5 7 3 as D1 e Repeat for the right main wheel Enter this distance in Table 5 7 3 as D3 f Measure the distance aft from the center of the nose whee...

Page 321: ...AL b Enter the values for W1 W2 and W3 from Table 5 7 3 into Table 5 7 4 c Calculate the empty weight empty moment and empty arm as shown on Page 5 7 25 7 d Enter the values for Empty Weight Empty Mom...

Page 322: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 25 5 INTENTIONALLY LEFT BLANK...

Page 323: ...ighing Distance Measurement Diagram Table 5 7 3 Weight on Each Wheel Distance to Wing Leading Edge LEFT WHEEL NOSE WHEEL RIGHT WHEEL WEIGHT __________ lb W1 __________ lb W2 __________ lb W3 DISTANCE...

Page 324: ...D1 A1 ______ ______ ________ in lb W1 A1 M1 NOSE WHEEL __________ lb W2 100 _______ ________ inches D2 A2 ______ ______ ________ in lb W2 A2 M2 RIGHT WHEEL __________ lb W3 100 _______ ________ inche...

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Page 326: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 26 1 5 7 26 PARKING MOORING TABLE OF CONTENTS PARKING 5 7 26 2 MOORING 5 7 26 2 STORAGE 5 7 26 4...

Page 327: ...good practice is to position the propeller in an angled or horizontal position when parked d Chock the main wheels e There are threaded receptacles in the underside of each wing which are attached to...

Page 328: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 26 3 Figure 5 7 26 1 Wing Tie Down Figure 5 7 26 2 Tail Tie Down...

Page 329: ...rer s Service Letter c Fill the fuel tanks completely Check for water accumulating each week d Wipe the tires with a dry cloth and treat them with a tire protector spray Mark the tire positions and da...

Page 330: ...e to use unserviceable tires for prolonged storage e In severe weather it is advisable to use multiple mooring lines During gusty or high wind conditions mooring lines may require periodic tightening...

Page 331: ...rvice Refer to the latest edition of the engine manufacturer s Service Letter b Remove all covers tapes and tags from the aircraft c Reinstall the battery refer to Chapter 5 7 20 and the ELT batteries...

Page 332: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 26 7 INTENTIONALLY LEFT BLANK...

Page 333: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 7 27 1 5 7 27 PAINTING AND COATINGS TABLE OF CONTENTS GENERAL 5 7 27 2 PAINTING 5 7 27 2...

Page 334: ...topcoats index htm Required Tools HVLP spray gun 180 320 grit sandpaper and very fine red Scuff pads Parts Required No parts are required at this time Level of Maintenance Heavy Maintenance Certifica...

Page 335: ...AL a The final finish is a polyurethane paint from PPG b Mix the paint in accordance with the PPG s application guide c Spray the first coat with an HVLP gun with a 30 50 psi inlet pressure Allow the...

Page 336: ...Date 11 15 19 Revision 2 5 7 27 4 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 337: ...ENERAL 5 8 2 5 8 2 EVALUATION TO ASTM STANDARD WITH PRODUCTION ACCEPTANCE SPECIFICATIONS 5 8 4 5 8 3 ALTERATION AFFADAVIT 5 8 6 5 8 4 WRITTEN INSTRUCTIONS AND DIAGRAMS FOR CERTIFICATION 5 8 8 Ground a...

Page 338: ...No major alterations as outlined in ASTM F2483 FAR 43 or in this manual are authorized at this time To obtain engineering approvals for any major alterations please contact Vashon Aircraft at Vashon A...

Page 339: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 8 1 3 INTENTIONALLY LEFT BLANK...

Page 340: ...Date 11 15 19 Revision 2 5 8 4 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 8 2 EVALUATION TO ASTM STANDARD WITH PRODUCTION ACCEPTANCE SPECIFICATIONS No content available at this time...

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Page 342: ...Date 11 15 19 Revision 2 5 8 6 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 8 3 ALTERATION AFFADAVIT No content available at this time...

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Page 344: ...HON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 8 4 WRITTEN INSTRUCTIONS AND DIAGRAMS FOR CERTIFICATION No content available at this time Ground and Flight Test Program for Verification of Safe Operation...

Page 345: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 8 9 INTENTIONALLY LEFT BLANK...

Page 346: ...Date 11 15 19 Revision 2 5 8 10 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 8 5 OWNER INFORMATION ON ALTERATION DOCUMENTATION FOR AIRCRAFT RECORDS No content available at this time...

Page 347: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 8 11 INTENTIONALLY LEFT BLANK...

Page 348: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 9 1 OVERHAUL TABLE OF CONTENTS 5 9 1 AUTHORIZATION TO PERFORM OVERHAULS 5 9 2...

Page 349: ...ined in ASTM F2483 FAR 43 or in this manual are authorized at this time Overhauls can only be performed by Vashon Aircraft To obtain engineering approvals for any major repairs or alterations please c...

Page 350: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 5 9 3 INTENTIONALLY LEFT BLANK...

Page 351: ...0 Special 1 Review compliance with current Federal Aviation Regulations including visual inspection of Pilot s Operating Handbook Aircraft Logbook Registration Certificate Weight Balance Record Aircra...

Page 352: ...erform visual inspection of filter element for foreign particles 5 7 10 After first 25 hrs and every 50 hrs or 4 months 5 Oil Temperature Sensor Unit Check for leaks and security Continental Motors Dy...

Page 353: ...terminals for security and cleanliness 5 7 20 Continental Motors X 13 Ignition Harness and Insulators Visual inspection for high tension leaks and continuity Continental Motors X 14 Magnetos Check mag...

Page 354: ...pection for condition Continental Motors X 22 Throttle and Mixture Controls Visual inspection for operating condition Check travel from stop to stop Lubricate 5 7 19 X 23 Exhaust Stacks Connections Ga...

Page 355: ...n X 31 Cabin Heater Control Visual inspection 5 7 13 5 7 17 X 32 Alternator Visual inspection for condition and security Ensure alternator is in working condition 5 7 20 Continental Motors X 33 Starte...

Page 356: ...for nicks cracks or delamination Prop Mfgr s Manual X 3 Propeller Hub Visual inspection for damage and security Prop Mfgr s Manual X 4 Propeller Mounting Bolts Visual inspection for damage and securit...

Page 357: ...22 X 5 Seat Belts and Shoulder Harnesses Visual inspection for general condition and security of attachment X 6 Seat Backs Remove from cabin and set aside Visual inspection for dents wrinkles and gen...

Page 358: ...Verify freedom of movement and ensure full travel 5 7 13 X 15 Cabin Heat Control Verify freedom of movement and ensure full travel 5 7 17 X 16 Fuel and Vent Lines Visual inspection for leakage chafin...

Page 359: ...ubricate per Chapter 5 4 5 7 5 5 7 6 X 5 Elevators and Rudder Visual inspection for rotation from stop to stop without binding interference 5 7 6 X 6 Elevator and Rudder Hinge Points Visual inspection...

Page 360: ...1 Outer Surfaces Overall Visual inspection for damage dents missing loose rivets scratches in finish 5 7 4 X 2 Access Panels Remove and set aside 5 7 4 X 3 Wing Interior Spaces Visual inspection of st...

Page 361: ...ty of attachment X 11 Fuel Vent Outlet Visual inspection for damage obstruction 5 7 12 X 12 Pitot Static AoA Head Visual inspection for damage obstruction of all air pressure and fluid drain ports X 1...

Page 362: ...nt of the axle bracket to the gear leg 5 7 7 X 5 Main Landing Gear Legs Visual inspection for cracking delamination or other damage to the gear leg especially at around attach points 5 7 7 X 6 Main Wh...

Page 363: ...r Attach Bolts Visual inspection for security of installation signs of damage or distress to the bolts nuts or surrounding structure 5 7 7 X 14 Nose Landing Gear Leg Visual inspection for cracks espec...

Page 364: ...on 5 4 5 4 5 7 8 X 20 Nose Wheel Tire Inflate to proper pressure per section 5 4 5 4 X Return to Service Ref Interval Initials 100 Special 1 Install fuselage access panels and empennage fairing 5 7 3...

Page 365: ...40 with second push of switch DN verify position indication on EFIS Check that flaps go from 40 to 20 with first push of switch UP Check that flaps go from 20 to 0 with first push of switch UP Ensure...

Page 366: ...e increases when load is applied 11 Check the radio s for proper Comm operation and Nav operation if installed 12 Check the transponder for proper operation 13 Verify proper ELT operation 14 Set throt...

Page 367: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 6 i CHAPTER 6 TASK SPECIFIC TRAINING...

Page 368: ...Date 11 15 19 Revision 2 6 ii VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 369: ...L 6 1 TASK SPECIFIC TRAINING TABLE OF CONTENTS VASHON AIRCRAFT RANGER SPECIFIC TRAINING GENERAL 6 1 1 TYPE SPECIFIC TRAINING REQUIRED BY VASHON AIRCRAFT 6 2 3 6 2 1 CONTINENTAL O 200 FACTORY TECHNICAL...

Page 370: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 6 1 1 VASHON AIRCRAFT RANGER SPECIFIC TRAINING GENERAL No content available at this time...

Page 371: ...Date 11 15 19 Revision 2 6 1 2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 372: ...D BY VASHON AIRCRAFT 6 2 1 CONTINENTAL O 200 FACTORY TECHNICAL TRAINING http www continentalmotors aero services factory training aspx 6 2 2 EAA SPORT AIR SHEET METAL BASICS COURSE https www eaa org s...

Page 373: ...Date 11 15 19 Revision 2 6 2 4 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 374: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL 6 2 5 6 2 3 OVERHAUL MANUAL FOR LSA OR LSA COMPONENTS NO CONTENT AT THE TIME...

Page 375: ...Date 11 15 19 Revision 2 6 2 6 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 376: ...fer to component manufacturer s overhaul manual Carburetor Refer to component manufacturer s overhaul manual Carburetor Air Box Refer to component manufacturer s overhaul manual Starters Generators Al...

Page 377: ...Date 11 15 19 Revision 2 6 2 8 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 378: ...pair or alterations as outlined in ASTM F2483 FAR 43 or in this manual are authorized at this time To obtain engineering approvals for any major repairs or alterations please contact Vashon Aircraft a...

Page 379: ...Date 11 15 19 Revision 2 6 2 10 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 380: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL i CHAPTER 7 SAFETY DIRECTIVES COMPLIANCE...

Page 381: ...Date 11 15 19 Revision 2 ii VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 382: ...R R7 MAINTENANCE MANUAL 7 1 SAFETY DIRECTIVES COMPLIANCE TABLE OF CONTENTS SAFETY DIRECTIVES FOR CONTINUED AIRWORTHINESS 7 1 1 TYPES OF SAFETY DIRECTIVES 7 2 1 MANDATORY SAFETY DIRECTIVES 7 3 1 OBTAIN...

Page 383: ...Date 11 15 19 Revision 2 7 2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 384: ...ct Vashon Aircraft quality department via postal mail e mail fax or telephone If the problem relates to safety of flight or is a significant service issue use the form and procedures specified in sect...

Page 385: ...Date 11 15 19 Revision 2 7 1 2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 386: ...classified in three different categories SAFETY ALERT The safety alert is a directive that relates to safety of flight and requires immediate action SERVICE BULLETIN A service bulletin is a directive...

Page 387: ...Date 11 15 19 Revision 2 7 2 2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 388: ...safety directive requiring mandatory action has been issued it is the owner operator s responsibility to ensure that the directive is fully complied with to allow the continued safe operation of the a...

Page 389: ...Date 11 15 19 Revision 2 7 3 2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK...

Page 390: ...ANCE MANUAL 7 4 1 OBTAINING LATEST SAFETY OF FLIGHT INFORMATION To ensure that you have the latest safety of flight information please contact Vashon Aircraft 19825 141ST PL NE Woodinville WA 98072 US...

Page 391: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL FRONT COVER 1 INTENTIONALLY LEFT BLANK...

Page 392: ...Revision 2 Date 11 15 19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL REAR COVER 1...

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