VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL-REV 3

Please report any service difficulties or any other issue relating to flight 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. 1.3 PILOT/OWNER SERVICING AND MAINTENANCE This manual identifies servicing and maintenance actions which can be performed by the owner who holds a pilot certificate but who may not have received any specific authorized training in the maintenance of the Vashon Aircraft RANGER R7™. The maintenance actions authorized in Section Date: 11-15-19 Section Revision: 2 1-3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL-REV 3 this manual comply with the intent of FAA 14 CFR Part 43.3 with regard to preventive maintenance. 1.4 PREVENTIVE MAINTENANCE This manual identifies the Ranger’s preventive maintenance tasks, which are to be accomplished by qualified personnel, and include the actions for the 100-hour inspection and the annual condition inspection. 1.5 CORRECTIVE MAINTENANCE AND ALTERATIONS This manual identifies the line maintenance, minor 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 maintenance tasks that require a certified airframe and powerplant mechanic and the approval of Vashon Aircraft to perform. No major repairs, or major alterations, as outlined in ASTM F2483 Sections 7 through 9, or in this maintenance manual, are authorized by this manual at this time for the Ranger aircraft. Any major repairs, or major alterations, as outlined in ASTM F2483 Sections 7 through 9 can only be performed by Vashon Aircraft or only as provided by Vashon Aircraft’s approved engineering data. Section Revision: 2 Section Date: 11-15-19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL-REV 3 1-4 CHANGE OF ADDRESS/OWNERSHIP FORM Aircraft Serial Number: RANGER R7- Aircraft Registration Number: 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/Province Postal Code Country Country TELEPHONE NUMBER(S) TELEPHONE NUMBER(S) SIGNATURE DATE FOR VASHON AIRCRAFT USE ONLY Change of Ownership/Address Log Number: Date Received: Section Date: 11-15-19 Section Revision: 2 1-5 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL-REV 3 CONTINUED OPERATIONAL SAFETY REPORTING FORM NAME (Last, 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 OF SAFETY OF FLIGHT ISSUE OR SIGNIFICANT SERVICE DIFFICULTY: SIGNATURE DATE FOR VASHON AIRCRAFT USE ONLY COS Log Number: Date Received: Section Revision: 2 Section Date: 11-15-19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL-REV 3 1-6 Section Date: 11-15-19 Section Revision: 2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL-REV 3 2- i SECTION 2 REFERENCE DOCUMENTS Section Revision: 2 Section Date: 11-15-19 2-ii VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 Section Date: 11-15-19 Section Revision: 2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 2-1 2. REFERENCE DOCUMENTS ASTM F2483 Standard Practice for 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 Operational Safety Monitoring of a Light Sport Aircraft 14 CFR Part 43 Maintenance, Preventive Maintenance, Rebuilding, and Alteration Section Revision: 2 Section Date: 11-15-19 2-2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 Section Revision: 2 Section Date: 11-15-19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 3- i SECTION 3 TERMINOLOGY Section Revision: 2 Section Date: 11-15-19 3-ii VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 Section Revision: 2 Section Date: 11-15-19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 3-1 3. TERMINOLOGY 3.1 DEFINITIONS 3.1.1 Annual Condition Inspection – detailed inspection accomplished once a year on an LSA in accordance with instructions provided in the maintenance manual supplied with the aircraft. The purpose of the inspection is to look for any wear, corrosion, or damage that would cause an aircraft to not be in a condition for safe operation. 3.1.2 A&P – airframe and powerplant mechanic as defined by 14 CFR Part 65 in the U.S. or equivalent certification in other countries. 3.1.3 FAA – United States Federal Aviation Administration. 3.1.4 Heavy Maintenance – any maintenance, inspection, repair, or alteration which requires specialized training, equipment, or facilities that a manufacturer has designated 3.1.5 Line Maintenance – any repair, maintenance, scheduled checks, servicing, inspections, or alterations not considered heavy maintenance that are approved by the manufacturer and in specified in the 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 F2244 for powered parachutes, Specification F2245 for airplanes, and Specification F2352 for gyroplanes. 3.1.7 LSA Repairman Inspection – U.S. FAA-certificated repairman (light sport aircraft) with an inspection rating as defined by 14 CFR Part 65, authorized to perform the annual condition inspection on experimental light sport aircraft or an equivalent rating issued by other civil aviation authorities. 3.1.8 LSA Repairman Maintenance – U.S. FAA-certificated repairman (light sport aircraft) with a maintenance rating as defined by 14 CFR Part 65, authorized to perform line maintenance on aircraft certificated as special light sport aircraft. Authorized to perform the annual condition/100-h inspection on a light sport aircraft, or an equivalent rating issued by other civil aviation authorities. 3.1.9 Maintenance Manual(s) – manual provided by the manufacturer or supplier of a light sport aircraft that specifies all maintenance, repairs, and alterations authorized by the manufacturer. Section Revision: 2 Section Date: 11-15-19 3-2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 3.1.10 Major Repair, Alteration, or Maintenance – any repair, alteration, or maintenance for which instructions to complete the task are excluded from the maintenance manuals(s) supplied to the consumer are considered major. 3.1.11 Manufacturer – any entity engaged in the production of a light sport aircraft or component used on a light sport aircraft. 3.1.12 Minor Repair, Alteration, or Maintenance – any repair, alteration, or maintenance for which instructions provided for in the maintenance manual(s) supplied to the consumer of the product are considered minor. 3.1.13 Overhaul – maintenance, inspection, repair, or alterations that are only to be accomplished 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 overhaul the product originally produced by that manufacturer. 3.1.15 Repair Facility – facility specifically authorized by the aircraft or component manufacturer to repair the product originally produced by that manufacturer. 3.1.16 14 CFR – Code of Federal Regulations Title 14 Aeronautics and Space also known as the “FARs” or Federal Aviation Regulations. 3.1.17 100-h Inspection – same as an annual condition inspection, except the interval of inspection is 100 h of operation instead of 12 calendar months. This inspection is utilized when the light sport aircraft is being used for commercial operations such as flight instruction or rental, or both. 3.2 ACRONYMS 3.2.1 POH – pilot operating handbook 3.2.2 LSA – light sport aircraft 3.2.2 EFIS – electronic flight instrument system 3.2.X PFD – primary flight display Section Revision: 2 Section Date: 11-15-19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 4-i SECTION 4 SIGNIFICANCE AND USE Section Date: 11-15-19 Section Revision: 2 4-ii VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 Section Revision: 2 Section Date: 11-15-19 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 4-1 4. 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 maintenance, repairs, and alterations on the Vashon Aircraft model RANGER R7™. Section Date: 11-15-19 Section Revision: 2 4-2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5-i SECTION 5 AIRCRAFT MAINTENANCE MANUAL Section Date: 04-18-25 Section Revision: 3 5-ii VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL-REV 3 Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5-1 5. AIRCRAFT MAINTENANCE MANUAL TABLE OF CONTENTS 5.1 FORMAT & GUIDANCE FOR THE USE OF THIS MANUAL 5.1-1 5.2 GENERAL SPECIFICATIONS, TORQUES, DATA, AND FORMS 5.2-3 5.3 PERIODIC AND CONDITION INSPECTION REQUIREMENTS 5.3-1 5.4 MAINTENANCE OVERVIEW, SERVICING OF FLUIDS, AND PERSONNEL AUTHORIZATION 5.4-6 5.5 REPAIR OVERVIEW 5.5-5 5.6 ALTERATIONS OVERVIEW 5.6-1 5.7 MAINTENANCE, REPAIRS, AND ALTERATION TASKS 5.7-1 5.7.1 RAISING THE AIRCRAFT 5.7.1-1 5.7.2 WINDSCREEN 5.7.2-1 5.7.3 FUSELAGE 5.7.3-1 5.7.4 WINGS 5.7.4-1 5.7.5 EMPENNAGE 5.7.5-1 5.7.6 FLIGHT CONTROLS 5.7.6-1 5.7.7 LANDING GEAR 5.7.7-1 5.7.8 WHEEL AND BRAKE ASSEMBLIES 5.7.8-1 5.7.9 ENGINE COWL 5.7.9-1 5.7.10 ENGINE 5.7.10-7 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 5.7.15-6 5.7.16 PROPELLER 5.7.16-1 5.7.17 UTILITY SYSTEMS 5.7.17-1 5.7.18 INSTRUMENTS AN D AVIONICS SYSTEMS 5.7.18-1 5.7.19 ENGINE CONTROLS 5.7.19-1 5.7.20 ELECTRICAL POWER SYSTEMS 5.7.20-1 5.7.21 ELECTRICAL SYSTEMS 5.7.21-1 5.7.22 SEATS 5.7.22-1 5.7.23 HOSES AND LINES 5.7.23-1 5.7.24 LEVELING 5.7.24-1 5.7.25 WEIGHING 5.7.25-1 5.7.26 PARKING & MOORING 5.7.26-1 5.7.27 PAINTING AND COATINGS 5.7.27-1 5.8 MAJOR REPAIRS AND ALTERATIONS 5.8-1 5.8.1 ALTERATIONS GENERAL 5.8-2 5.8.2 EVALUATION TO ASTM STANDARD WITH PRODUCTION ACCEPTANCE SPECIFICATIONS 5.8-3 5.8.3 ALTERATION AFFADAVIT 5.8-4 5.8.4 WRITTEN INSTRUCTIONS AND DIAGRAMS FOR CERTIFICATION 5.8-5 5.8.5 OWNER INFORMATION ON ALTERATION DOCUMEN TATION FOR AI RCRAFT RECORDS 5.8-6 Section Date: 04-18-25 Section Revision: 3 5-2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.9 OVERHAUL 5.9-1 5.9.1 AUTHORIZATION TO PERFORM OVERHAULS 5.9-1 APPENDIX A 1 Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.1-1 5.1 FORMAT & GUIDANCE FOR THE USE OF THIS MANUAL 1. GENERAL Vashon Aircraft, Inc. prepared this aircraft maintenance manual. It contains the information that a trained mechanic will need to maintain the aircraft in an airworthy condition. The Aircraft Maintenance Manual was prepared to meet the ASTM F2483 Standard Specification requirements. The format of the manual is designed to be familiar to aircraft mechanics. This maintenance manual does not list part numbers and cannot be used for ordering replacement parts. The wiring schematics that have been included in the manual are for general information purposes only. 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. 2. LAYOUT OF THE MANUAL This maintenance manual is divided into chapters. The chapter numbers appear at the foot of each page. Each chapter contains its own table of contents. Where the systems are complex, the table of contents will be found in the sub chapter. 3. WARNINGS, CAUTION, AND NOTES WARNING AN OPERATING PROCEDURE, PRACTICE, OR A CONDITION, WHICH, IF NOT CORRECTLY FOLLOWED OR REMEDIED, COULD RESULT IN SERIOUS PERSONAL INJURY OR LOSS OF LIFE. CAUTION An operating procedure, practice, or a condition, which, if not strictly Observed or corrected, could result in destruction of, or damage to equipment. NOTE An operating procedure, practice, or condition, which is important to emphasize. 4. REVISION SERVICE The Maintenance Manual will be made available to aircraft owners and repair shops via Vashon Aircraft’s webpage. Section Date: 04-18-25 Section Revision: 3 5.1-2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 Revisions may also be obtained by submitting a request to: Vashon Aircraft™ 19825 141ST PL NE Woodinville, WA 98072 USA Tel: +1 425 527 9940 Email:support@vashonaircraft.com Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.2-3 5.2 GENERAL SPECIFICATIONS, TORQUES, DATA, AND FORMS TABLE OF CONTENTS 1. GENERAL 5.2-4 2. EQUIPMENT LIST 5.2-8 3. PURCHASE PARTS SOURCE LISTS 5.2-8 4. ENGINE SPECIFICATIONS AND DATA 5.2-9 5. WEIGHT AND BALANCE DATA 5.2-10 6. TIRE INFLATION 5.2-10 7. APPROVED OILS AND CAPACITIES 5.2-10 8. RECOMMENDED FASTENER TORQUES 5.2-10 8.1 Definitions 5.2-10 8.2 Torquing Requirement 5.2-10 8.3 Use of Torque Wrenches and Adaptors 5.2-11 8.4 Torquing Patterns 5.2-12 8.5 Specific Torque Requirements 5.2-13 8.6 General Torque Values (Given in in-lbs) 5.2-14 9. GENERAL SAFETY INFORMATION 5.2-16 10. FLIGHT SAFETY AND SERVICE DIFFICULTY REPORTING INSTRUCTIONS 5.2-17 Section Date: 04-18-25 Section Revision: 3 5.2-4 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 1. GENERAL The location of any point on the aircraft is identified in a three-axis grid as follows (refer to Figure 5.2.1): • FS – Fuselage Station is a horizontal reference designation starting 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 970mm/31.189in below the door sill. • BL – Buttock Line is a horizontal reference designation starting at the airplane centerline. When the aircraft is viewed from above, the letters “L” and “R” indicate whether the point is to the left or the right of the centerline. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.2-5 Figure 5.2.1 Vashon Ranger datums and dimensions . Section Date: 04-18-25 Section Revision: 3 5.2-6 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 (1) MAIN DIMENSIONS Span 9.00 m/29.53 ft Length 6.64 m/21.77 ft Height (ground attitude) 2.66 m/8.74 ft Propeller Ground Clearance* 312 mm/12.3 in Design Gross Weight (wheels) 600 kg/1323 lb Design Gross Weight (floats) 650 kg/1433 lb *With 70 inch diameter propeller and 6.00-6 tires. (2) WINGS Type 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) 0.97 m2/10.46 ft2 (5) HORIZONTAL STABILIZER AND ELEVATORS Airfoil Section NACA 63A015 Span 3.18 m2/10.44 ft2 Chord 812.8 mm/32.000 in Dihedral 0° Area (horiz. stab. & elevators) 2.59 m2/27.83 ft2 Aspect Ratio 3.91 (6) VERTICAL STABILIZER AND RUDDER Airfoil Section NACA 63A015 - modified Span (dist. above fuse ref. plane) 1.37 m/4.50 ft2 Mean Aerodynamic Chord 978 mm/38.496 in Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.2-7 Area (vert stab & rudder) 1.38 m2/14.88 ft2 Aspect Ratio 2.72 (7) LANDING GEAR Wheel Track (main to main) 2.15 m/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° ± 1.0° Trailing Edge DN 15.0° ± 2.0° (b) Flaps Take-Off Position 20.0° ± 2.0° Landing Position 40.0° ± 2.0° (c) Elevators Trailing Edge UP 22.8° Trailing Edge DN 19.0° (d) Elevator Trim Tab Trailing Edge UP 27.0° ± 2.0° Trailing Edge DN 23.0° ± 2.0° (e) Rudder Trailing Edge LEFT 32.0° Trailing Edge RIGHT 32.0° Section Date: 04-18-25 Section Revision: 3 5.2-8 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 2. EQUIPMENT LIST This section provides a list of components and equipment that the operator is likely to change on the aircraft. Description Ref. In AMM 6.00-6, main wheel and tires 5.7.8 6.00-6 nose wheel and tire 5.7.8 CATTO two-bladed 70”x48” propeller 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. 3. PURCHASE PARTS SOURCE LISTS Consumable or Frequently Replaced Items. For oil, see Table 1. Description Part Number (Reference purpose) Source Engine Oil Filter TEMPEST OIL FILTER AA48162 Aircraft Parts Store Air Filter CONTINENTAL 657514 Aircraft Parts Store Air Filter (alternate) TEMPEST AEROGUARD AA10-7150 Aircraft Parts Store Fuel Filter RUSSELL PERFORMANCE 650133 Aircraft Parts Store or Auto Parts Store Brake Pad Lining MATCO MFG WHLM66-106 Aircraft Parts Store Brake Pad Lining Rivets MATCO MFG MSC4-6 Aircraft Parts Store Spark Plugs See Table 5.7.5 Aircraft Parts Store Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.2-9 4. ENGINE SPECIFICATIONS AND DATA Engine Model O-200-D Number of Cylinders 4 Bore & Stroke 4.062 in x 3.875 in Compression Ratio 8.5:1 Piston Displacement 201 in3 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 240° F Maximum Cylinder Head Temperature 525°F Engine Weight – Dry w/o Accessories 168.53 lb. Engine Weight—Dry w/ Accessories 205 lbs. Oil Sump Capacity 5 quarts Recommended TBO 2000 hours or 12 years Refer to Continental Motor’s Engine Operator’s Manual for the operating limits. Section Date: 04-18-25 Section Revision: 3 5.2-10 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5. WEIGHT AND BALANCE DATA Refer to RANGER R7™ Pilot’s Operating Handbook, Section 6 for the most current Weight and Balance Data. 6. TIRE INFLATION Refer to section 5.4 part 3 of this manual for the tire inflation data. 7. APPROVED OILS AND CAPACITIES Refer to the POH or section 5.4 part 3 SERVICING OF FLUIDS of this manual for the approved oil and capacity data. 8. RECOMMENDED FASTENER TORQUES General Torque Values: This chapter gives the requirements for torquing the fasteners. No lubricating or anti-seize compounds are to be applied to threaded fasteners except when specified. At the time of installation, the threads must be clean and free of corrosion, paint or any products other than those applied by the fastener’s manufacturer. 8.1 Definitions Running Torque: The average torque developed after the fastener is at 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 to create the desired axial load on the bolt/nut assembly (also called tightening torque or installation torque). Prevailing Torque: the driving torque required to overcome friction in a threaded fastening application. Standard maintenance practice dictates that mechanics add this value to the specified torque. Prevailing Torque is the driving torque required to overcome friction in a threaded fastening application. Standard maintenance practice dictates that mechanics add this value to the specified torque. 8.2 Torquing Requirement Whenever possible, the nut shall be turned during torquing. Where it is necessary to tighten the fastener assembly from the head, the installation torque shall be the maximum torque (accounting for prevailing torque if applicable) indicated in part 0 of this section plus 10 percent. NOTE This is only applicable for fasteners greater than 3/16” in diameter. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.2-11 When nuts are to be secured to fasteners by means of cotter pins or lock wire, the low side of the specified torque range shall be approached for tightening. If necessary, tightening shall be continued until the next slot aligns with the hole. Nuts shall not be loosened to obtain the required alignment. Maximum torque shall not be exceeded. Threaded fasteners which have been torqued above the maximum value specified 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 rotation (360°) maximum and retightened to the specified value; the bolt, screw or stud must not be allowed to rotate. 8.3 Use of Torque Wrenches and Adaptors All final torquing shall be carried out with certified torque wrenches or torque screwdrivers. When adaptors or extensions are used on manually operated torque wrenches, they shall be used as shown in Figure 5.2.2 and the dial reading required shall be calculated from the following formula: 𝐷𝑖𝑎𝑙 𝑅𝑒𝑎𝑑𝑖𝑛𝑔 = 𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑒𝑑 𝑇𝑜𝑟𝑞𝑢𝑒 × 𝐿 𝐿 + 𝐴 Figure 5.2.1.1.1.1 Torque wrench with extension. Section Date: 04-18-25 Section Revision: 3 5.2-12 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 Dimensions 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 in Figure must be followed when torquing fasteners. Figure 5.2.3 Torquing patterns. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.2-13 8.5 Specific Torque Requirements NOTE These values do not account for prevailing torque. Prevailing Torque is the driving torque required to overcome friction in a threaded fastening application. Standard maintenance practice dictates that mechanics add this value to the specified torque. For example, a random sample of new and used AN365-4, and -5 nuts shows that the torque required to turn AN4 (1/4") nuts varied 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 Maximum Dry Torque Inch Pounds Catto CPX-01 Propeller Bolts (see reference for torquing procedure) 5.7.16 300 Propeller Extension Bolts (see reference for torquing procedure) 5.7.16 360 Spark Plugs 5.7.15 300 360 Front Wheel Axle Nut 5.7.8 160 190 Engine to Engine Mount Bolts 5.7.11 180 190 Brake Caliper Bolts 5.7.8 100 Brake Rotor Bolts 5.7.8 100 Wheel Half Bolts and Locknuts 5.7.8 100 Nose Wheel Breakout Force 5.7.7 See 5.7.7 Rudder Pedal Attach Bolts 5.7.6 15-18 Section Date: 04-18-25 Section Revision: 3 5.2-14 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 8.6 General Torque Values (Given in in-lbs) NOTE These values do not account for prevailing torque. Prevailing Torque is the driving torque required to overcome friction in a threaded fastening application. Standard maintenance practice dictates that mechanics add this value to the specified torque. For example, a random sample of new and used AN365-4, and -5 nuts shows that the torque required to turn AN4 (1/4") nuts varied 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. ALL TORQUE VALUES (Inch Pounds) BOLTS – STEEL TENSION BOLTS – STEEL TENSION BOLTS – ALUMINUM AN3 THRU AN20 AN42 THRU AN 49 AN73 THRU AN81 AN173 THRU AN186 MS20033 THRU NS20046 MS20073 MS20074 AN509 MS24694 AN525 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 AN20D AN173DD THRU AN186DD MS20033 THRU NS20046 AN509D AN525D MS24694DD MS20739D MS24694DD NUTS - STEEL NUTS - STEEL NUTS - ALUMINUM TENSION SHEAR TENSION SHEAR TENSION SHEAR AN363 AN365 NAS1021 MS21045 MS20365 MS20500 NAS679 AN364 MS20364 NAS1022 NAS1024- 1030 NAS1067- 1068 NAS680-687 NAS696-698 AN363 AN365 NAS1021 MS21045 MS20365 MS20500 NAS679 AN364 MS20364 NAS1022 AN365D NAS1021D AN364D NAS1022D THREAD SIZE (FINE) MIN. MAX. MIN. MAX. MIN. MAX. MIN. MAX. MIN. MAX. MIN. MAX. 10-32 20 25 12 15 25 30 15 20 10 15 5 10 ¼-28 50 70 30 40 80 100 50 60 30 45 15 30 5/16-24 100 140 60 85 120 145 70 90 40 65 25 40 3/8-24 160 190 95 190 200 250 120 150 75 110 45 70 7/16-20 450 500 270 300 520 630 300 400 180 280 110 170 Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.2-15 THREAD SIZE (COARSE) MIN. MAX. MIN. MAX. 8-32 12 15 7 9 10-24 20 25 12 15 ¼-20 40 50 25 30 5/16-18 80 90 48 55 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 screwdrivers. Section Date: 04-18-25 Section Revision: 3 5.2-16 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 9. GENERAL SAFETY INFORMATION There are many hazards inherently present when performing any maintenance task on this aircraft. To minimize the risk to both yourself and others, begin by thinking through each task that is to be performed before starting any work. Think of ways to avoid these hazards and remember that many accidents happen because of carelessness. Be sure to also use the right tool for the task at hand and to use the proper personal protective equipment. Such equipment may include, but is not limited to: • Eye protection – safety glasses, goggles, and face shield • Gloves • Hearing protection – ear plugs of muffs • Apron • Protective footwear with non-slip soles You should also keep on hand a suitable fire extinguisher, absorbent material to contain spills, an eyewash bottle, and a general-purpose first aid kit. It is also advisable to have on hand the material safety data sheet (MSDS) for all products and chemicals that will be used during the servicing of the aircraft. Some other general rules to follow are: • Never leave the ignition switch or the master switch turned on when the engine is not running. Doing so could allow the engine to fire if the propeller were rotated by hand 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 be lethal yet almost invisible. Remove hats when running the engine to keep them from being removed by the propeller slipstream. • Remove any loose clothing, such as neckties and scarves. Tuck in your shirt and secure any long hair to prevent them from becoming tangled in power tools. • Remove all jewelry. Not only can items such as rings, watches, and necklaces become caught in rotating tools, they can also conduct electricity and may cause a short circuit. This could result in burns or damage to electrical circuits. • Disconnect the negative lead from the battery when doing any electrical work that does not involve troubleshooting the electrical systems. This will reduce the risk of a short circuit or even a fire. • Aviation gasoline is also highly flammable. When working with the fuel system, always work in a well-ventilated environment. Any nearby source of ignition such as sparks or an open flame can result in a fire or explosion. Keep all ignition sources away. Always ground the airframe to a suitable earth ground during fueling/defueling operations to reduce the risk of a static discharge ignition source. • When working with the landing gear, always support the aircraft properly with jacks. Do not work underneath the aircraft unless it is properly supported. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.2-17 10.FLIGHT SAFETY AND SERVICE DIFFICULTY REPORTING INSTRUCTIONS This form is to be used for the owner/operator of the aircraft to provide information to Vashon Aircraft, of any safety of flight or service difficulty experienced with the aircraft in accordance with ASTM F2295. Additional forms may be obtained by writing or calling Vashon Aircraft’s customer service department at +1 425 527 9940. It is the responsibility of the owner/operator to notify Vashon 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 USA Tel: +1 425 527 9940 Email:support@vashonaircraft.com --------------------------------------------------------- --------------------------------------------------- VASHON AIRCRAFT CONTINUED OPERATIONAL SAFETY REPORTING FORM Print or type all entries NAME (Last, First and Middle) AIRCRAFT MODEL ORGANIZATION (if applicable) AIRCRAFT SERIAL NUMBER ADDRESS (Number, street, city, state, and postal code) AIRCRAFT REGISTRATION NUMBER PRIMARY TELEPHONE NUMBER ALTERNATE TELEPHONE NUMBER E-MAIL ADDRESS (optional) DESCRIPTION OF SAFETY OF FLIGHT ISSUE OR SIGNIFICANT SERVICE DIFFICULTY (Describe in detail. Use additional pages if necessary.) SIGNATURE DATE Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.3-1 5.3 PERIODIC AND CONDITION INSPECTION REQUIREMENTS TABLE OF CONTENTS 1. GENERAL 5.3-2 2. CONDITION INSPECTION TASKS 5.3-4 3. PERIODIC INSPECTION TASKS 5.3-5 Section Date: 04-18-25 Section Revision: 3 5.3-2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 1. GENERAL This section is intended to serve as a guide for a certified airframe and powerplant mechanic to perform routine maintenance on the aircraft. It is the responsibility of the owner and/or the operator to maintain the aircraft in an airworthy condition and ensure that the airplane is inspected as specified in Parts 43 and 91 of the Federal Aviation Regulations. This inspection guide is not intended to replace the good judgement of a certified airframe and powerplant mechanic. The guide will refer to service information provided by other vendors, such as the manufacturer of the engine. The persons performing the maintenance on the aircraft must ensure that they have the latest editions of these publications. This guide will not refer to revision levels of vendor publications. This guide will be applicable to the aircraft in the configuration it left Vashon Aircraft when it was first delivered, and it may not cover modifications made to the aircraft subsequently. 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, panels, fairings, or cowlings. Visual Inspection criteria will normally consist of, but are not limited to the following criteria: (A)Moving Parts Proper operation, correct alignment, security, sealing, cleanliness, lubrication, adjustment, tension, travel, condition, binding, excessive wear, cracking, corrosion, deformation, and any other apparent damage. (B)Metal Parts Security, condition of finish, cleanliness, dents, distortion, fatigue cracks, cracked welds, corrosion, and any other apparent damage. (C)Non-Metal Parts Security, condition, cleanliness, wear, cracking, deformation, heat deterioration, fluid saturation, and any other apparent damage. (D)Fuel and Hydraulic Oil Lines and Hoses Cracks, dents, kinks, loss of flexibility, deterioration, obstruction, chafing, improper bend radius, cleanliness, security, and any other apparent damage. (E)Electrical Wiring Cleanliness, loose, corroded, or broken terminals, chafed, broken, or worn insulation, security, heat deterioration, and any other apparent damage. (F)Bolts and Nuts Fretting, wear, damage, stretch, proper torque and safety wiring. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.3-3 (G)Filters and Screens Filters and screens shall be removed, cleaned, inspected for contamination, or replaced as applicable. (H)Fuel Tank Areas Evidence of leaks Inspection forms in Appendix A may be used as a guidance to perform the visual inspection. (2) Operational Inspection An operational inspection is a check intended to determine that a component or system is fulfilling its intended purpose. The 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 more functions of a component perform within specified limits. The functional inspection is a comparative examination of a component or system against a specific standard. NOTE The operational and functional checks involve operating the engine and taxiing the aircraft. Therefore, whoever performs this check must be familiar with the aircraft and its systems and the risks and dangers of operating an aircraft on the ground. During the check, observe engine temperature limitations. Section Date: 04-18-25 Section Revision: 3 5.3-4 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 2. CONDITION INSPECTION TASKS If the aircraft is registered in the United States, ASTM F2483 requires that all LSA category airplanes must undergo a complete inspection at least once every 12 calendar months. An authorized maintenance person, as described 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 Report is to be signed-off in the logbook/maintenance record. The inspection items to be covered in the condition inspection are identical to the 100-hour Inspection items. The inspection interval to the next condition inspection may not exceed twelve calendar months. Refer to Appendix A of this manual for the inspection forms. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.3-5 3. PERIODIC INSPECTION TASKS If the aircraft is operated commercially (for hire) in the United States, it must also have an inspection every 100 flight hours. 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 accomplished. Additionally, the time the interval was exceeded must be included as flight hours in the next 100-hour interval. Inspection tolerances cannot be accumulated. Refer to Appendix A of this manual for the inspection forms. Section Date: 04-18-25 Section Revision: 3 5.4-6 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.4 MAINTENANCE OVERVIEW, SERVICING OF FLUIDS, AND PERSONNEL AUTHORIZATION TABLE OF CONTENTS 1. 100 HOUR INSPECTION 5.4-7 2. CONDITION INSPECTION 5.4-7 3. SERVICING OF FLUIDS 5.4-7 4. REPLACEMENT INTERVALS 5.4-11 5. AUTHORIZATION TO PERFORM LINE MAINTENANCE, REPAIRS, ALTERATIONS, & INSPECTIONS 5.4-1 6. FAA AUTHORIZATION FOR PILOT/OWNER TO PERFORM LINE MAINTENANCE TASKS 5.4-4 Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.4-7 1. 100 HOUR INSPECTION Refer to APPENDIX A of this manual for 100 Hour Inspection requirements. 2. CONDITION INSPECTION Refer to APPENDIX A of this manual for Condition Inspection requirements. 3. SERVICING OF FLUIDS This information gives the general servicing procedures and maintenance practices that are to be used when servicing the airplane. For additional detailed information concerning unit servicing of the various airplane systems and components, refer to the applicable chapters. For electrical wiring diagrams, please contact Vashon. The interval specified in Appendix A are considered adequate to meet average requirements under normal operating conditions. However, it is advisable to shorten the service and maintenance intervals when operating under abnormal environmental conditions, such as high humidity and moisture, saltwater environments, dusty atmospheric conditions, extreme temperature ranges, unimproved airport facilities, or other unusual operating requirements. In saltwater areas, special care should be taken to keep the engine, accessories, and airframe clean to help prevent oxidation. CAUTION The operation of the airplane can be seriously impaired if unapproved or contaminated fuel, oil, fluids, lubricants or materials are used. Adherence to instructions, cautions, and warnings can avoid injury to personnel and damage to the airplane or associated equipment. Mixing of various brands, types, and weights of materials should be avoided. Specified lubricants will meet requirements for extreme hot or cold temperature operations. Use of substitutes or other lubricants may cause a malfunction when operating in extreme temperature conditions or may cause excessive wear due to improper lubrication. Section Date: 04-18-25 Section Revision: 3 5.4-8 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 Table 1 Fuel, oil, brake fluid, and tire pressures. Item Specifications Capacity Fuel Aviation Grade 100/100LL 28.1 US Gallons Total 27.6 US Gallons Usable Oil (See note below) Average Ambient Temperature SAE J-1899* ashless- dispersant oil grades 5 Quarts Above 40°F SAE 40 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 operated on non-dispersant mineral (non-detergent) oil (SAE J-1966) during the first 25 hours of operation. For further information, refer to the Continental Motors Service Manual. CAUTION Use only oils conforming to Continental Motors Specification SAE J-1899 after break-in period. For further information, refer to the Continental Motors Service Manual. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.4-9 Table 2 Lubrication chart. LUBRICATION CHART ITEM SUGGESTED SPEC ENGINE Engine Oil Appropriate for temperature See Table 1 Spark Plug Thread Lubricant Champion Aerospace #2612 Oil Fittings with Pipe Threads Loctite 567 COCKPIT Hydraulic Fluid (Brake) Any Brand MIL-H-5606 Control Stick Pivot Points & Torque Tube Bearings LPS 2 MIL-C-16173E GRADE 3 CLASS I Elevator Pushrod Bearings LPS 2 MIL-C-16173E GRADE 3 CLASS I Elevator Torque Tube Bearings LPS 2 MIL-C-16173E GRADE 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 Rudder Pedal, Brake Pedal, and Master Cylinder Pivot Points LPS 2 MIL-C-16173E GRADE 3 CLASS I Door Latch Mechanism LPS 2 MIL-C-16173E GRADE 3 CLASS I Fuel Fittings with Pipe Threads EZ TURN Lubricant on NPT threads only MIL-G-6032D FUSELAGE Fuel Fittings with Pipe Threads EZ TURN Lubricant on NPT threads only MIL-G-6032D LANDING GEAR Nose Wheel Swivel Aeroshell 5 MIL-G-3545C Wheel Bearings Aeroshell 22 MIL-G-81322E EMPENNAGE Elevator Pushrod Bearings LPS 2 MIL-C-16173E GRADE 3 CLASS I Elevator Hinge Bearings LPS 2 MIL-C-16173E GRADE 3 CLASS I Section Date: 04-18-25 Section Revision: 3 5.4-10 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 Trim Tab Hinge Pin LPS 2 MIL-C-16173E GRADE 3 CLASS I Rudder Hinge Bearings 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-C-16173E GRADE 3 CLASS I Rudder Hinge Bearings LPS 2 MIL-C-16173E GRADE 3 CLASS I Fuel Fittings with Pipe Threads EZ TURN Lubricant MIL-G-6032D Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.4-11 4. REPLACEMENT INTERVALS This section lists the components that Vashon Aircraft recommends be replaced at specified intervals. Whenever this is carried out, ensure that the following information is properly recorded in the airplane maintenance log: • Date of removal, installation, or overhaul of the component. • Time on the component since last overhaul (if appropriate). • Aircraft’s flight hours. (1) Replacement Times ITEM INTERVAL REPLACE OVERHAUL REF. 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 engine overhaul X 5.7.20 Refer to the latest revision of the manufacturer’s maintenance manual 4 Starter At engine overhaul X 5.7.20 Refer to the latest revision of the manufacturer’s maintenance manual 6 Induction Air Box 2000 Hours/engine overhaul, whichever comes first X 5.7.13 Refer to the latest revision of the manufacturer’s maintenance manual 7 Flexible Fuel Lines 12 years/engine overhaul, whichever comes first X 5.7.23 8 Flexible Oil System Lines 12 years/engine overhaul, whichever comes first X 5.7.23 Section Date: 04-18-25 Section Revision: 3 5.4-12 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 ITEM INTERVAL REPLACE OVERHAUL REF. IN THIS MANUAL NOTES 9 Emergency Locator Transmitter Batteries 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) 8 years Lithium, 4 years Alkaline X Refer to the latest revision of the manufacturer’s maintenance manual 11 Rubber Engine Mount Bushings At engine overhaul X 5.7.11 Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.4-1 5. AUTHORIZATION TO PERFORM LINE MAINTENANCE, REPAIRS, ALTERATIONS, & INSPECTIONS Table 3 shows the certifications required to perform line maintenance, repairs, alterations, and inspections on Vashon Aircraft RANGER R7™ aircraft, as defined by ASTM F2483 Section 3.1.12. Guidance for accomplishing such maintenance, repairs, alterations, and inspections is contained in this manual and is to be accomplished in accordance with the practices contained in FAA Advisory Circular 43.13. Table 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&P, OR REPAIR STATION A&P OR REPAIR STATION AIRCRAFT SHEET METAL Minor Repairs X Major Repairs X AIRCRAFT PAINTING Minor Repairs X Major Repairs X AIRCRAFT TASKS Rigging wings X Rigging Tail Brace Wires X Rigging Tail Control Surfaces X Jacking Aircraft X Condition Inspection X 100-Hour Inspection X Preventive Maintenance X Lubrication X PREPARATION For Storage X For Use X For Shipment X SYSTEM DIAGRAMS Electrical System X Avionics System X Avionics System - Intercom X Lighting X Brake System X Fuel System X Section Date: 04-18-25 Section Revision: 3 5.4-2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 DESCRIPTION OWNER/ OPERATOR OR ABOVE LSA REPAIRMAN- I, REPAIRMAN- M, A&P, OR REPAIR STATION LSA REPAIRMAN-M, A&P, OR REPAIR STATION A&P OR REPAIR STATION FLIGHT CONTROLS Aileron Controls X Elevator Controls X Flap Controls X Rudder 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 Assembly X Air Filter X Exhaust System X Oil Cooler X Oil Filter and Oil Change X Alternator X Magnetos X Carburetor X Starter X Propeller - Spinner X FUSELAGE Cowling Removal X Cowling Repair X Firewall Components X Fuel Lines, Fittings, and Parts X Fuel Shut-Off Valve X Fuel Filter X Fuel Pump X Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.4-3 DESCRIPTION OWNER/ OPERATOR OR ABOVE LSA REPAIRMAN- I, REPAIRMAN- M, A&P, OR REPAIR STATION LSA REPAIRMAN-M, A&P, OR REPAIR STATION A&P OR REPAIR STATION Fuel Flow Transducer X Fuel Drain X Seatback Assembly X Seat Belt/Shoulder Harness X Brake Master Cylinder X 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 Module X AFS Power Module X Alternator Fuse Replacement X EFIS Display (Removal) X Com Radio (Removal) X Intercom (Removal) X Auto Pilot Control (Removal) X Transponder (Removal) X Landing Gear Installation X Wheels and Tires X Tire Inflation X Brake Assembly X Nose Wheel Friction X Pitch Trim Motor X MISCELLANEOUS Placards and Data Plates X Section Date: 04-18-25 Section Revision: 3 5.4-4 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 6. FAA AUTHORIZATION FOR PILOT/OWNER TO PERFORM LINE 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 and who is the holder of an FAA Sport Pilot, Recreational Pilot, Privat e Pilot, Commercial, or Airline Transport Pilot Certificate Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.5-5 5.5 REPAIR OVERVIEW TABLE OF CONTENTS 1. GENERAL 5.5-6 2. NON-STRUCTURAL SHEET METAL REPAIRS 5.5-6 3. NON-STRUCTURAL COMPOSITE MATERIAL REPAIRS 5.5-6 Section Date: 04-18-25 Section Revision: 3 5.5-6 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 1. GENERAL This section describes the process and method of repairing non-structural metal or composite components. 2. NON-STRUCTURAL SHEET METAL REPAIRS 1.1 Level of Certification Non-structural sheet metal repairs are to be accomplished by: a certificated LSA Repairman; Maintenance Rated and FAA certified LSA Pilot/Owner, or a suitably qualified and experienced FAA certified A&P Mechanic. 1.2 Authorized Non-Structural Sheet Metal Repairs Damage to non-structural sheet metal parts may be repaired using the techniques of FAA Aircraft Circular 43.13, Chapter 4, Section 4. At this time repairs to primary or secondary structures by others than Vashon Aircraft are not authorized. Description, by electronic photos or 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. 3. NON-STRUCTURAL COMPOSITE MATERIAL REPAIRS 2.1 Level of Certification Non-structural composite material repairs are to be accomplished by: a certificated LSA Repairman; Maintenance Rated and FAA certified LSA Pilot/Owner, or a suitably qualified and experienced FAA certified A&P Mechanic. 2.2 Authorized Non-Structural Composite Material Repairs Damage to non-structural composite material parts may be repaired using the techniques of FAA Aircraft Circular 43.13, Chapter 3, Section 1. At this time repairs to primary or secondary structures by others than Vashon Aircraft are not authorized. Description, by electronic photos or 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. Section Revision: 3 Section Date: 04-18-25 5.6-1 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.6 ALTERATIONS OVERVIEW TABLE OF CONTENTS 1. COMPLIANCE WITH MANUFACTURER’S SERVICE DIRECTIVE 5.6-2 2. MAJOR REPAIRS AND/OR ALTERATIONS 5.6-2 Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.6-2 1. COMPLIANCE WITH MANUFACTURER’S SERVICE DIRECTIVE When service directives are issued, they will be in the form described in Chapter 7.2 of this manual. These will be issued to the owner/operator in the most current Vashon Aircraft database and will be in the form of safety alerts, service bulletins, and notifications. 2. 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 can be made to Customer Support at Vashon Aircraft or through a form on the company website. The latest revisions of all applicable service documents released by Vashon Aircraft do not require an MRA form. These documents, which include service alerts, service bulletins, notifications, and service instructions, are considered appendices to this maintenance manual. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7-1 5.7 MAINTENANCE, REPAIRS, AND ALTERATION TASKS TABLE OF CONTENTS 5.7.1 RAISING THE AIRCRAFT 5.7.1-1 1. GENERAL 5.7.1-2 2. RAISING THE NOSE 5.7.1-2 3. RAISING THE AIRCRAFT FROM THE FUSELAGE 5.7.1-4 4. RAISING THE AIRCRAFT FROM THE MAIN LANDING GEAR 5.7.1-5 5. RAISING THE AIRCRAFT FROM THE WING 5.7.1-6 5.7.2 WINDSCREEN 5.7.2-1 1. GENERAL 5.7.2-2 2. REMOVAL 5.7.2-2 3. INSTALLATION 5.7.2-9 4. REPAIRS AND ALTERATIONS 5.7.2-10 5.7.3 FUSELAGE 5.7.3-1 1. GENERAL 5.7.3-2 2. INSPECTION 5.7.3-3 3. DOORS 5.7.3-8 4. REPAIRS AND ALTERATIONS 5.7.3-9 5.7.4 WINGS 5.7.4-1 1. GENERAL 5.7.4-2 2. REMOVAL 5.7.4-4 3. INSTALLATION 5.7.4-12 4. REPAIRS AND ALTERATIONS 5.7.4-12 5.7.5 EMPENNAGE 5.7.5-1 1. GENERAL 5.7.5-2 2. FUSELAGE INSPECTION 5.7.5-3 3. TAIL SURFACES INSPECTION 5.7.5-4 4. VERTICAL STABILIZER 5.7.5-5 5. HORIZONTAL STABILIZER 5.7.5-6 6. REPAIRS AND ALTERATIONS 5.7.5-8 5.7.6 FLIGHT CONTROLS 5.7.6-1 1. GENERAL 5.7.6-2 2. TROUBLESHOOTING 5.7.6-3 3. AILERON REMOVAL 5.7.6-4 4. FLAP REMOVAL 5.7.6-9 5. RUDDER 5.7.6-14 6. ELEVATORS 5.7.6-16 7. RUDDER PEDAL AND LINKAGE 5.7.6-21 8. REPAIRS AND ALTERATIONS 5.7.6-24 5.7.7 LANDING GEAR 5.7.7-1 1. GENERAL 5.7.7-2 2. TROUBLESHOOTING 5.7.7-4 Section Date: 04-18-25 Section Revision: 3 5.7-2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 3. MAIN LANDING GEAR 5.7.7-5 4. MAIN LANDING GEAR AXLE SU BASSEMBLY 5.7.7-9 5. NOSE LANDING GEAR 5.7.7-11 6. NOSE FORK 5.7.7-13 7. REPAIRS AND ALTERATIONS 5.7.7-16 5.7.8 WHEEL AND BRAKE ASSEMBLIES 5.7.8-1 1. GENERAL 5.7.8-2 2. TROUBLESHOOTING 5.7.8-3 3. MAIN WHEELS 5.7.8-4 4. NOSE WHEEL 5.7.8-9 5. BRAKE CALIPERS 5.7.8-13 6. MASTER CYLINDER REMOVAL AND INSPECTION 5.7.8-15 7. REPAIRS AND ALTERATIONS 5.7.8-19 5.7.9 ENGINE COWL 5.7.9-1 1. GENERAL 5.7.9-2 2. ENGINE COWL 5.7.9-2 3. REPAIRS AND ALTERATIONS 5.7.9-6 5.7.10 ENGINE 5.7.10-7 1. GENERAL 5.7.10-8 2. ENGINE SERVICING 5.7.10-8 3. TROUBLESHOOTING 5.7.10-8 4. OIL SYSTEM SERVICING 5.7.10-12 5. REPAIRS AND ALTERATIONS 5.7.10-17 5.7.11 ENGINE MOUNT 5.7.11-1 1. GENERAL 5.7.11-2 2. INSPECTION 5.7.11-3 3. REPAIRS AND ALTERATIONS 5.7.11-3 5.7.12 FUEL SYSTEM 5.7.12-1 1. GENERAL 5.7.12-2 2. TROUBLESHOOTING 5.7.12-3 3. DRAINING FUEL 5.7.12-4 4. REPLACING WING TANK FUEL SUMPS 5.7.12-6 5. REPLACING FUEL TAN KS 5.7.12-6 6. REPLACING FUEL FILTERS 5.7.12-10 7. REPAIRS AND ALTERATIONS 5.7.12-12 5.7.13 INDUCTION SYSTEM 5.7.13-1 1. GENERAL 5.7.13-2 2. REPLACING AIR FILTER 5.7.13-2 3. CARBURETOR HEAT 5.7.13-4 4. REPAIRS AND ALTERATIONS 5.7.13-6 5.7.14 EXHAUST SYSTEM 5.7.14-1 1. GENERAL 5.7.14-2 2. ENGINE EXHAUST 5.7.14-2 3. REPAIRS AND ALTERATIONS 5.7.14-4 5.7.15 POWERPLANT – IGNITION 5.7.15-6 Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7-3 1. SPARK PLUGS 5.7.15-7 2. MAGN ETOS 5.7.15-11 3. REPAIRS AND ALTERATIONS 5.7.15-13 5.7.16 PROPELLER 5.7.16-1 1. GENERAL 5.7.16-2 2. TROUBLESHOOTING 5.7.16-3 3. REMOVAL, INSPECTION, AND INSTALLATION 5.7.16-3 4. REPAIRS AND ALTERATIONS 5.7.16-12 5.7.17 UTILITY SYSTEMS 5.7.17-1 1. GENERAL 5.7.17-2 2. REPAIRS AND ALTERATIONS 5.7.17-2 5.7.18 INSTRUMENTS AND AVIONICS SYSTEMS 5.7.18-1 1. GENERAL 5.7.18-2 2. AVIONICS REMOVAL 5.7.18-17 3. REPAIRS AND ALTERATIONS 5.7.18-20 5.7.19 ENGINE CONTROLS 5.7.19-1 1. GENERAL 5.7.19-2 2. THROTTLE 5.7.19-2 3. MIXTURE CONTROL 5.7.19-5 4. REPAIRS AND ALTERATIONS 5.7.19-9 5.7.20 ELECTRICAL POWER SYSTEMS 5.7.20-1 1. GENERAL 5.7.20-2 2. TROUBLESHOOTING 5.7.20-3 3. STARTER 5.7.20-4 4. ALTERNATOR 5.7.20-7 5. BATTERY 5.7.20-9 6. REPAIRS AND ALTERATIONS 5.7.20-11 5.7.21 ELECTRICAL SYSTEMS 5.7.21-1 1. LANDING LIGHTS 5.7.21-7 2. NAVIGATION AND ANTI-COLLISION LIGHTS 5.7.21-9 3. CABIN LIGHTING 5.7.21-10 4. ELT EMERGENCY SYSTEM 5.7.21-10 5. REPAIRS AND ALTERATIONS 5.7.21-11 5.7.22 SEATS 5.7.22-1 1. GENERAL 5.7.22-2 2. SEAT BACKREST REMOVAL 5.7.22-3 3. REPAIRS AND ALTERATIONS 5.7.22-3 5.7.23 HOSES AND LINES 5.7.23-1 5.7.24 LEVELING 5.7.24-1 1. GENERAL 5.7.24-2 2. PREPARATION 5.7.24-2 3. LONGITUDINAL LEVELING 5.7.24-2 4. LATERAL LEVELING 5.7.24-3 Section Date: 04-18-25 Section Revision: 3 5.7-4 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.25 WEIGHING 5.7.25-1 1. GENERAL 5.7.25-2 2. PREPARATION 5.7.25-2 3. MEASURING WHEEL LOCATIONS 5.7.25-3 4. WEIGHING THE AIRCRAFT 5.7.25-3 5. CALCULATE EMPTY WEIGHT AND EMPTY CENTER OF GRAVITY LOCATION 5.7.25-3 5.7.26 PARKING & MOORING 5.7.26-1 1. PARKING 5.7.26-2 2. MOORING 5.7.26-2 3. STORAGE 5.7.26-5 5.7.27 PAINTING AND COATINGS 5.7.27-1 1. GENERAL 5.7.27-2 2. PAINTING 5.7.27-2 Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.1-1 5.7.1 RAISING THE AIRCRAFT TABLE OF CONTENTS 1. GENERAL 5.7.1-2 2. RAISING THE NOSE 5.7.1-2 3. RAISING THE AIRCRAFT FROM THE FUSELAGE 5.7.1-4 4. RAISING THE AIRCRAFT FROM THE MAIN LANDING GEAR 5.7.1-5 5. RAISING THE AIRCRAFT FROM THE WING 5.7.1-6 Section Date: 04-18-25 Section Revision: 3 5.7.1-2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 1. GENERAL Tools Required: Depending on the procedure used, the following tools outlined in Table 4 may be required. Table 4 Tools required for jacking up the aircraft. Description P/N or Spec Supplier Purpose Floor Jack - Any Source Jack Main Wheels Padded Wooden Sawhorse or Bench - Any Source Place Under Fwd Fuselage Wing Jack - Any Source Jack From Wing Axle-Jack Adapter 710013 Vashon Jack from Axle 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 parts are required at this time. Level of Maintenance: Line maintenance. Certification Required: Please see Table 3 in Section 5.4. 2. RAISING THE NOSE This method is recommended to service the nose wheels and/or nose gear leg unless required otherwise. (a) Place chocks under main wheels. (b) Push down on inboard third of horizontal stabilizer front spar with force sufficient to raise the nose wheel. (c) Place a padded sawhorse under forward fuselage as indicated in Figure 5.7.1.1. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 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 the front of aircraft. PUSH DOWN ON SPAR SAWHORSE POSITIONED AFT OF EXHAUST Section Date: 04-18-25 Section Revision: 3 5.7.1-4 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 3. RAISING THE AIRCRAFT FROM THE FUSELAGE This method is recommended to lift the aircraft from the ground unless required otherwise. (a) Place chocks under main wheels. (b) Push down on inboard third of horizontal stabilizer front spar 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 inboard third of horizontal stabilizer front spar. (f) Place a padded sawhorse beneath first bulkhead behind the baggage area window and unload the stabilizer. (g) Ensure aircraft is firmly supported and will not fall before working under it. Figure 5.7.1.2 Lifting the aircraft up from front and rear. PUSH UP ON SPAR Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.1-5 4. 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 around bolts as shown in figure 5.7.1.3. (c) Lift aircraft up by jacking up on the adapter using a floor jack. (d) Ensure aircraft is firmly supported and will not fall before working under it. Figure 5.7.1.3: Lifting the aircraft using Axle-Jack Adapter Section Date: 04-18-25 Section Revision: 3 5.7.1-6 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5. RAISING THE 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 unload the wing. (d) Ensure aircraft is firmly supported and will not fall before working on it. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.1-7 Figure 5.7.1.4 Lifting the aircraft by its wings. LIFT ALONG SPAR AT RIB JUNCTION INBOARD OF THIS POINT LIFT ALONG SPAR AT RIB JUNCTION INBOARD OF THIS POINT Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL - REV 3 5.7.2-1 5.7.2 WINDSCREEN TABLE OF CONTENTS 1. GENERAL 5.7.2-2 2. REMOVAL 5.7.2-2 3. INSTALLATION 5.7.2-9 4. REPAIRS AND ALTERATIONS 5.7.2-10 Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.2-2 1. GENERAL The windscreen is made from clear acrylic and is manufactured through a thermoforming process. It is attached to the fuselage 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. 2. REMOVAL Required Tools: 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 3 in Section 5.4. (1) REMOVAL Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL - REV 3 5.7.2-3 (a) Protect surrounding areas with tape. Figure 5.7.2.1 Protect surrounding areas. Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.2-4 (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 existing silicone seal. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL - REV 3 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 position. Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.2-6 (d) Drill out the windscreen base fairing rivets. Figure 5.7.2.4 Drill out windscreen base fairing rivets. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL - REV 3 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 brackets. Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.2-8 (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 windscreen assembly from the airframe. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL - REV 3 5.7.2-9 Figure 5.7.2.7 Windscreen assembly removal. (h) Remove any residual silicone sealant left on the mating surfaces. 3. INSTALLATION (a) Installation of the windscreen 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 overtighten the threaded fasteners securing the windscreen into place. This could cause the brittle plastic to crack. (b) Use only approved rivets for riveting the windscreen base fairing back into place. Contact Vashon Aircraft for Approval. Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.2-10 4. REPAIRS 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 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 Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL - REV 3 5.7.2-11 Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL - REV 3 5.7.3-1 5.7.3 FUSELAGE TABLE OF CONTENTS 1. GENERAL 5.7.3-2 2. INSPECTION 5.7.3-3 3. REPAIRS AND ALTERATIONS 5.7.3-9 Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.3-2 1. GENERAL The fuselage structure is of monocoque design in which the outer skin carries the major part of the load. Bulkheads and stiffeners are present but primarily for the purpose of stabilizing the outer skin such that it can carry greater loads than if it were not supported. Because the outer skin contributes such a large percentage of the load carrying capability of the fuselage, dents, cracks, or other defects in the skin must 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 inherently corrosion resistant 6061-T6 aluminum using a CNC turret punch press. The machine cut “flat patterns” which require forming are either hydropress formed over dedicated “formblocks” or bent using a press-brake machine. The predominant method for joining parts is with blind rivets although solid rivets and threaded fasteners (screws and/or bolts and nuts) are used where the fasteners either must be removable or where high shear-strength fasteners are required. Figure 5.7.3.1 Fuselage structure with skin hidden . Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL - REV 3 5.7.3-3 2. INSPECTION 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 Table 3 in Section 5.4. (1) ACCESS COVER REMOVAL (a) Remove EFIS screen by unfastening the four bolts, disconnecting the EFIS harnesses, and setting both screens aside. Figure 5.7.3.2 EFIS screen removal for avionics bay inspection. (b) Remove the panel into the avionics bay on the passenger side by unfastening the 10 screws, as shown below. Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.3-4 Figure 5.7.3.3 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. Figure 5.7.3.4 Baggage compartment access panel removals. (d) Remove pilot and passenger seats. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL - REV 3 5.7.3-5 Figure 5.7.3.5 Seat removal. Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.3-6 (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 access panels that cover the central tunnel through the cabin of the fuselage. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL - REV 3 5.7.3-7 Figure 5.7.3.7 Main landing gear and tunnel 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 cover removals. (2) INSPECTION (a) Visually inspect outer surface for damage, dents, missing/loose rivets, scratches in finish. Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.3-8 (b) Visually inspect interior of fuselage of structure for cleanliness, damage, missing/loose rivets, and corrosion. (c) Visually inspect flight control linkage for wear, security of attachment, binding/interference. (3) INSTALLATION (a) Installation of the components are the reverse of their removal. 3. DOORS 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 Table 3 in Section 5.4. (1) DOOR REMOVAL (a) Unfasten the two hinges that connects the door to the fuselage. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL - REV 3 5.7.3-9 Figure 5.7.3.9 Door removal. (b) Turn door handle to the open position and remove the door carefully. Place on a padded surface so no denting, or scratching can occur. (2) INSTALLATION (a) Installation of the door is the reverse of its removal. 4. 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 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:support@vashonaircraft.com Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.3-10 Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL - REV 3 5.7.4-1 5.7.4 WINGS TABLE OF CONTENTS 1. GENERAL 5.7.4-2 2. REMOVAL 5.7.4-4 3. INSTALLATION 5.7.4-12 4. REPAIRS AND ALTERATIONS 5.7.4-12 Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.4-2 1. GENERAL The wing has two spars - a main spar, located at approximately 25% of the wing chord, and a rear spar located at approximately 75% of the wing chord. The main spar carries the majority of the wing bending loads and is comprised of a c-channel shear web with upper and lower spar caps both comprised of four aluminum bars of varying length. The spar assembly is held together with solid driven aluminum rivets. The two main fuel tanks are in the inboard leading edge of the wing and are removable. The wing incorporates plain wing flaps inboard of the ailerons and both the flaps and ailerons are mounted off the rear spar. Wing main ribs and leading-edge ribs provide support to the skins which form two closed cells to carry the majority of the torsional loads on the wing. Because the outer skin contributes 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 loss in load carrying capacity. An LED landing light is installed in the outboard leading edge of each wing and combination position/strobe light units are mounted at the tip of each wing. A combination pitot/static/angle of attack head is mounted to a mast located approximately 1/3 out on the left wing. The fuel system vent line is also attached to the mast. The majority of the structural parts in the wing are produced from sheets of inherently corrosion resistant 6061-T6 aluminum using a CNC turret punch press. The machine cut “flat patterns” are either hydropress formed over dedicated “formblocks” or bent using a press-brake machine. The predominant method for joining parts is with blind rivets although solid rivets and threaded fasteners (screws and/or bolts and nuts) are used in places where fasteners must be removable or where high shear strength fasteners are required. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL - REV 3 5.7.4-3 Figure 5.7.4.1 Wing structure with skin hidden. Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.4-4 2. REMOVAL Required Tools: 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 3 in Section 5.4. (1) REMOVAL CAUTION Before removing the wing, chock the wheels. (a) Remove the windscreen attach fairing and windscreen. Please see Section 0 for the removal procedure. Figure 5.7.4.2 Windscreen fairing and windscreen removal. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL - REV 3 5.7.4-5 (b) Remove ailerons and flaps, see Section 5.7.6 for more details. (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 5.7.4.4 Aileron pushrod access panel located inside the cabin. (d) Drain the wing fuel tanks and the fuel lines that attaches to the header tank. Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.4-6 (e) Disconnect the fuel and vent lines at the forward side 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 pilot-side fuel line. Figure 5.7.4.6 Header tank vent line disconnect. (f) Disconnect the aileron pushrods from the aileron torque tube arms. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL - REV 3 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) Disconnect electrical connectors in the rear spar. Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.4-8 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 web and secure the loose cable with a tie-wrap. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL - REV 3 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 door jambs. Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.4-10 Figure 5.7.4.10 Door frame screw removal. Use same 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 spar to the fuselage. Figure 5.7.4.11 Aft edge skin and rear spar bolt removal. Use same procedure for pilot-side rear spar bolts. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL - REV 3 5.7.4-11 CAUTION To accomplish removal and installation of the wing, at least three people will be required. Use one person to 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 Front spar bolt removal. Use same procedure for pilot-side bolts. (l) Remove the wing from the fuselage. This will require two to three people. Figure 5.7.4.13 Wing removal procedure from the fuselage. Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.4-12 Figure 5.7.4.14 Side-view of wing removal procedure. (m) Place the wing horizontally on padded sawhorses or on pads placed directly on the floor. If using padded sawhorses, the wing may be placed with either the top or bottom surface resting on the pads. If using pads on the floor, the wing must be placed with the bottom surface resting on the pads. In any case, position the pads and place the wing so as not to dent or damage the wing skins. 3. 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. Certification Required: Please see Table 3 in Section 5.4. (a) Installation of the wing is the reverse of removal. Please see Section 5.2 for torque specification and torque seal all bolts. 4. REPAIRS 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 alterations, please contact Vashon Aircraft at: Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL - REV 3 5.7.4-13 Vashon Aircraft™ 19825 141ST PL NE Woodinville, WA 98072 USA Tel: +1 425 527 9940 Email:support@vashonaircraft.com Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.4-14 Section Revision: 3 Section Date: 04-18-25 5.7.5-1 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.5 EMPENNAGE TABLE OF CONTENTS 1. GENERAL 5.7.5-2 2. FUSELAGE INSPECTION 5.7.5-3 3. TAIL SURFACES INSPECTION 5.7.5-4 4. VERTICAL STABILIZER 5.7.5-5 5. HORIZONTAL STABILIZER 5.7.5-6 6. REPAIRS AND ALTERATIONS 5.7.5-8 Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.5-2 1. GENERAL The structure of the horizontal stabilizer, elevators, vertical stabilizer, and rudder is of monocoque design in which the outer skin carries the majority of the load. Ribs and stiffeners are present but primarily for the purpose of stabilizing the outer skin such that it can carry greater loads than if it were not supported. Because the outer skin contributes such a large percentage of the load carrying capability of the fuselage, dents, cracks, or other defects in the skin must be carefully scrutinized and evaluated in order to ensure t hat there is no loss in load carrying 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 patterns” are either hydropress formed over dedicated “formblocks” or bent using a press-brake machine. The predominant method for joining parts is with blind rivets although solid rivets and threaded fasteners (screws and/or bolts and nuts) are used in places where fasteners must be removable or where high shear strength fasteners are required. The aircraft is trimmed in flight by changing the position of a tab on the left elevator. The tab is actuated by an electric servo mounted within the counterbalance arm of the left elevator. The servo is operated via a rocker switch located on the control stick. Figure 5.7.5.1 Empennage structure with skin hidden. Section Revision: 3 Section Date: 04-18-25 5.7.5-3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 FUSELAGE INSPECTION 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 Table 3 in Section 5.4. Figure 5.7.5.2 Empennage fairing removal. (1) INSPECTION (a) Remove empennage fairing by unfastening screws and removing the hinge pin located under the trailing edge of the elevator. Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.5-4 (b) Remove (4X) aft fuselage side skin inspection panels below horizontal stabilizer. (c) Visually inspect the aft fuselage skins for dents, damage, corrosion, and loose or missing rivets. (d) Visually inspect the upper aft fuselage bulkhead and fuselage rear bulkhead for damage, corrosion, or fretting. (e) Visually inspect the rudder cables for wear or corrosion. Check for proper cotter pin installation in the bolts attaching the rudder cables to the rudder horn. (f) Check the elevator pushrod for cracks, corrosion, and freedom of movement. Check for 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. 2. TAIL SURFACES INSPECTION 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 Table 3 in Section 5.4. (1) INSPECTION (a) Inspect all tail surface skins for dents, damage, corrosion, and loose or missing rivets. (b) Check that the rudder and elevators move freely from stop-to-stop with no binding or interference. (c) Check that the trim tab does not have excessive play, no signs of wear or binding of the trim tab pushrod. Check for looseness or wear of the trim tab pushrod rod- end bearings. Check for proper safetying of the trim tab hinge pin. Section Revision: 3 Section Date: 04-18-25 5.7.5-5 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 3. VERTICAL STABILIZER Required Tools: 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 3 in Section 5.4. NOTE Vertical stabilizer and rudder can be removed as one unit. (1) REMOVAL (a) Remove vertical stabilizer top fairing. Figure 5.7.5.3 Empennage fairing removal. (b) Remove four bolts attaching the vertical stabilizer front spar to the horizontal stabilizer rear spar. Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.5-6 (c) Remove four bolts attaching the vertical stabilizer rear spar to the fuselage rear bulkhead and separate the vertical stabilizer assembly from the fuselage. Figure 5.7.5.4 Vertical stabilizer 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 the reverse of removal. Please see Section 5.2 for torque specification and torque seal all bolts. 4. HORIZONTAL STABILIZER Required Tools: No special tools are required for this operation. Parts Required: No parts are required at this time. Level of Maintenance: Heavy Maintenance. Section Revision: 3 Section Date: 04-18-25 5.7.5-7 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 Certification Required: Please see Table 3 in Section 5.4. NOTE It is not necessary to remove elevators for this disassembly. The vertical stabilizer and rudder must be removed to remove the horizontal stabilizer. (1) REMOVAL (a) Working through the opening in the aft fuselage 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 bolts attaching the horizontal stabilizer rear spar to the attach bars that are part of the horizontal stabilizer rear spar bulkhead assembly. Figure 5.7.5.6 Horizontal stabilizer rear spar detachment. (c) Separate the horizontal stabilizer from the fuselage by lifting the horizontal stabilizer straight up until the attach bars are fully disengaged. Section Date: 04-18-25 Section Revision: 3 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.5-8 (d) Place the horizontal 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 horizontal stabilizer is the reverse of removal. Please see Section 5.2 for torque specification and torque seal all bolts. 5. REPAIRS 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 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 Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.6-1 5.7.6 FLIGHT CONTROLS TABLE OF CONTENTS 1. GENERAL 5.7.6-2 2. TROUBLESHOOTING 5.7.6-3 3. AILERON REMOVAL 5.7.6-4 4. FLAP REMOVAL 5.7.6-9 5. RUDDER 5.7.6-14 6. YAW TRIM ADJUSTMENT 5.7.6-16 7. ELEVATORS 5.7.6-18 8. RUDDER PEDAL AND LINKAGE 5.7.6-21 9. REPAIRS AND ALTERATIONS 5.7.6-24 Section Date: 04-18-25 Section Revision: 3 5.7.6-2 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 1. GENERAL The aircraft has conventional ailerons and elevators that are operated with a stick and are mechanically actuated via systems of pushrods and bellcranks. The rudder is operated with overhead pivoting rudder pedals and is actuated via cables. Each set of rudder pedals is independently adjustable to accommodate variations in height and body proportions of both 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 while the flap pushrods are attached to arms at the ends of the torque tube assembly. Synchronization of the motion of the left and right flaps is assured by virtue of the torque tube. The flap actuator is controlled via a rocker switch located on the instrument panel. Flap position is displayed on the EFIS screen with the signal coming from a position potentiometer inside the flap linear actuator. Figure 5.7.6.1 Flight control system overview. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.6-3 The control surfaces of the aircraft must be rigged within the prescribed limits in order to maintain adequate margins of safety. This section specifies the procedures that must be used to rig the flight control surfaces. The flight controls consist of ailerons, rudder, elevators, and flaps. 2. TROUBLESHOOTING PROBLEM PROBABLE CAUSE REMEDY Control sticks are displaced when ailerons are in neutral Aileron pushrods improperly adjusted Adjust length of aileron pushrods Improper trailing edge down aileron travel Aileron pushrods improperly adjusted Adjust length of aileron pushrods Lost motion in control sticks Pushrod rod-end bearing bolts not tightened properly Check pushrod rod-end bearing bolts for proper length and proper nut & washer installation Pushrod 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 Excessive resistance to movement of control sticks Binding or interference between pushrods and structure or control system torque tubes or bellcranks Check system for proper pushrod lengths, neutral positions of torque tubes and bellcranks and adjust pushrod lengths as required Control system bearings not lubricated Lubricate control system bearings Full elevator travel cannot be achieved Elevator pushrods improperly adjusted Adjust length of elevator pushrods Trim tab does not move up or down when actuating the trim switch Loose wiring Secure wiring connections Broken switch Replace switch Inoperative electric servo Replace electric servo Flaps do not move up or down when actuating the flap switch Loose wiring Secure wiring connections Broken switch Replace switch Inoperative electric actuator Replace electric actuator Section Date: 04-18-25 Section Revision: 3 5.7.6-4 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 Flaps do not move in unison Flap torque tube bent/twisted Replace flap torque tube Flap pushrod broken or bent Replace flap pushrod AoA stall warning tone comes on well above stalling speed AoA not calibrated properly Calibrate AoA AoA stall warning tone comes on at a speed less than 5kt above stall AoA not calibrated properly Calibrate 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 functionality not enabled in EFIS Enable AoA in EFIS 3. AILERON REMOVAL Required Tools: 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 3 in Section 5.4. (1) REMOVAL (a) Using the access hole shown below, disconnect aileron pushrod by unfastening the bolt that connects it to the torque-tube plate. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.6-5 Figure 5.7.6.2 Access hole location for aileron pushrod. Access Hole for Aileron Pushrod Section Date: 04-18-25 Section Revision: 3 5.7.6-6 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 Figure 5.7.6.3 Pushrod removal. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.6-7 (b) Remove the hinge bolts and washers while firmly holding the aileron. Figure 5.7.6.4 Removal of aileron hinge bolts. (c) Carefully remove the aileron from the wing. Section Date: 04-18-25 Section Revision: 3 5.7.6-8 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 (2) INSTALLATION Figure 5.7.6.5 Aileron installation. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.6-9 (a) Installation of the ailerons is the reverse of its removal. (b) When adjusting the pushrod for the aileron, ensure that there is a slight spring-back on each aileron. This allows the torque tube to have slight play that reaches equilibrium during flight. (3) RIGGING (a) The neutral position of the ailerons is 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 correct. 4. FLAP REMOVAL Required Tools: 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 3 in Section 5.4. NOTE Add protective layer between fuselage and flap to prevent scratching. (1) REMOVAL Section Date: 04-18-25 Section Revision: 3 5.7.6-10 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 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 pushrod removal. Access Hole for Flap Pushrod Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.6-11 (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 Section Date: 04-18-25 Section Revision: 3 5.7.6-12 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.6-13 Figure 5.7.6.9 Flap installation. (a) Installation of the flaps are the reverse of their removal. NOTE It may be necessary to check the flap rigging depending on the parts that were removed. (3) RIGGING THE POSITION OF THE FLAPS (a) Position and secure the ailerons in the neutral position. Note: ailerons must be properly rigged before rigging flaps. (b) Position the flap switch to the “UP” position. (c) Adjust the flap actuator tube rod end to match the flap trailing edge with the aileron trailing edge in the neutral position. Section Date: 04-18-25 Section Revision: 3 5.7.6-14 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 (d) Connect the flap actuator rod end to the flap nose rib by installing the actuator bolt with Loctite 601 or equivalent. Make sure the flap actuator rod end does not bind on the flap actuator bolt. (e) Tighten the flap actuator tube rod end jam nut. (f) Repeat steps a-e for opposite side. NOTE Flaps should be assembled properly and have full range of movement with the correct amount of spring back. 5. RUDDER Required Tools: 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 3 in Section 5.4. (1) REMOVAL (a) Remove the cotter pins from the rudder cable attach bolts. Disconnect the rudder cables from the rudder horn. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.6-15 Figure 5.7.6.10 Rudder cable detachment. (b) Remove the bolt from the lower, mid, and upper rudder hinge brackets then separate the rudder assembly from the vertical stabilizer (as shown below). Section Date: 04-18-25 Section Revision: 3 5.7.6-16 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 Figure 5.7.6.11 Rudder removal. (c) Place the rudder 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 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 fastening of the rudder, ensure free and correct rudder control before completing the installation. 6. YAW TRIM ADJUSTMENT Required Tools: No special tools are required for this operation. Parts Required: No parts are required at this time. Section Revision: 3 Section Date: 04-18-25 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 5.7.6-17 Level of Maintenance: Moderate Maintenance. Certification Required: Please see Table 3 in Section 5.4 (a) Test directional trim by establishing level flight at 75% power. Then pilot must remove their feet from both rudder pedals and observe if the slip/skid ball does not remain centered in which case rudder trim adjustment is needed. (b) Trim adjustment is achieved by shortening or lengthening the anti-servo tab (AST) pushrod. If the pilot applied the right rudder to center the slip/skid ball the pushrod must be lengthened. If the pilot applied the left rudder to center the slip/skid ball the pushrod must be shortened. See Figure 5.7.6.12 for reference. (c) With both feet off the rudder pedals, If the slip/skid ball is completely outside the vertical lines defining where the ball is centered, the AST pushrod must be shortened/lengthened by 1-1.5 turns before testing again in-flight. If the slip/skid ball is approximately bisected by one of the vertical lines defining where the ball is centered, the AST pushrod must be shortened by 0.5-1 turns before testing again in-flight. Refer to figure below for location of AST pushrod. (d) Several flights may be required to achieve proper yaw trim. Proper yaw trim is confirmed when level flight with 75% power and no force applied to the rudder pedals results in a centered slip/skid ball. Section Date: 04-18-25 Section Revision: 3 5.7.6-18 VASHON AIRCRAFT RANGER R7 MAINTENANCE MANUAL- REV 3 Figure 5.7.6.12 Rudder AST Adjustment 7. ELEVATORS Required Tools: 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 3 in Section 5.4. NOTE Elevator removal is not necessary for horizontal stabilizer removal. Elevators will be remo