Rans S-7S COURIER User manual

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

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/01/2014
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AFTER PRINTING THE S-7S MANUAL.
HOW DO I ASSEMBLE THE MANUAL?
1. Obtain three 2" wide 3-ring binders.
2. Place the TEXT, PARTS and FIGURES manuals in separate binders. Every page has a
section number then a page number within that section. (Example: parts page 006-02)
Parts pages have an exploded view and a parts listing. NOTE: The PARTS manual
pages will need to rotate to allow easier viewing. Refer to pages at beginning of PARTS
manual.
3. Separate the sections with the tab inserts listed below.
4. Cut out on solid lines, fold on dotted line, and slip in the labels to corresponding sections.
Tabs are designed for 1-1/4 ” Insertable Tabs.
00 - GENERAL
00 - GENERAL
01 – FUSELAGE
SYSTEMS
01 – FUSELAGE
SYSTEMS
02 – CONTROL
SYSTEMS
02 – CONTROL
SYSTEMS
03 - ENGINE
03 - ENGINE
04 - INSTRUMENT
PITOT/STATIC
04 - INSTRUMENT
PITOT/STATIC
05 - WINGS
05 - WINGS
06 - BOOT COWL &
PANEL
06 - BOOT COWL &
PANEL
07 - WINDSHIELD &
DOORS
07 - WINDSHIELD &
DOORS
08 – COVERING
08 – COVERING
09 –SEAT BELTS &
INTERIOR
09 - SEAT BELTS &
INTERIOR
10 – OPTIONS
10 - OPTIONS
11 – RIGGING
11 - RIGGING
12 – WEIGHT &
BALANCE
12 - WEIGHT &
BALANCE
13 - OPERATIONS
13 - OPERATIONS

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00 - GENERAL
00 - GENERAL
01 – FUSELAGE
SYSTEMS
01 – FUSELAGE
SYSTEMS
02 – CONTROL
SYSTEMS
02 – CONTROL
SYSTEMS
03 - ENGINE
03 - ENGINE
04 - INSTRUMENT
PITOT/STATIC
04 - INSTRUMENT
PITOT/STATIC
05 - WINGS
05 - WINGS
06 - BOOT COWL &
PANEL
06 - BOOT COWL &
PANEL
07 - WINDSHIELD &
DOORS
07 - WINDSHIELD &
DOORS
08 – COVERING
08 – COVERING
09 –SEAT BELTS &
INTERIOR
09 - SEAT BELTS &
INTERIOR
10 – OPTIONS
10 - OPTIONS
11 – RIGGING
11 - RIGGING
12 – WEIGHT &
BALANCE
12 - WEIGHT &
BALANCE
13 - OPERATIONS
13 - OPERATIONS
00 - GENERAL
00 - GENERAL
01 – FUSELAGE
SYSTEMS
01 – FUSELAGE
SYSTEMS
02 – CONTROL
SYSTEMS
02 – CONTROL
SYSTEMS
03 - ENGINE
03 - ENGINE
04 - INSTRUMENT
PITOT/STATIC
04 - INSTRUMENT
PITOT/STATIC
05 - WINGS
05 - WINGS
06 - BOOT COWL &
PANEL
06 - BOOT COWL &
PANEL
07 - WINDSHIELD &
DOORS
07 - WINDSHIELD &
DOORS
08 – COVERING
08 – COVERING
09 –SEAT BELTS &
INTERIOR
09 - SEAT BELTS &
INTERIOR
10 – OPTIONS
10 - OPTIONS
11 – RIGGING
11 - RIGGING
12 – WEIGHT &
BALANCE
12 - WEIGHT &
BALANCE
13 - OPERATIONS
13 - OPERATIONS

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/01/2014
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Labels for the exterior spine of each manual may be made from self-stick labels. The
format below may be used.
RANS
S-7S
COURIER
TEXT
MANUAL
RANS
S-7S
COURIER
PARTS
MANUAL
RANS
S-7S
COURIER
FIGURES
MANUAL

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/01/2014
00-04
RANS Designs
4600 Highway 183 Alternate
Hays, KS 67601
Technical Support
[phone]
[e-mail]
Parts Department
[phone]
[e-mail]
When calling Technical Support or Parts Department please have the following ready:
•Aircraft Model
•Serial Number
•Engine Model
•Parts Number Needed (Parts Department Only)
•Your Aircraft Assembly Manuals
NOTE: Please make your questions precise and to the point, so that we may
assist as many customers as possible.

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/01/2014
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RANS AIRCRAFT
TECHNICAL SUPPORT
RANS has taken care to provide clear, comprehensive, and straightforward instructions for
assembly, maintenance, and operation by reference to manuals alone. In the event a question
arises for which no answer seems apparent, feel free to contact RANS headquarters.
Physical and mailing address:...........RANS Designs
4600 Highway 183 Alternate
Hays, KS 67601
Voice: ...........................................................785-625-6346
Fax: ..............................................................785-625-2795
E-mail (General) ........................................[email protected]
E-mail (Aircraft Tech)............................ [email protected]
E-mail (Aircraft Parts) ...............................part[email protected]
Internet site:.................................................www.rans.com
Aircraft Technical Support:............................785-625-0069
Aircraft Parts Department:.............................785-625-6346
When calling for parts or technical assistance, have the aircraft model, serial number, engine
model number, and assembly manuals at hand.
Questions about propeller care and adjustment and about engine break-in, operation, and
maintenance should be directed to respective manufacturer’s or supplier’s technical
support personnel. Refer to manufacturer’s or supplier’s literature for instructions and
contact information.

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/01/2014
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RANS S-7S Courier
AIRCRAFT TOOL LIST
The following is a list of tools that will be helpful when assembling your RANS aircraft.
HAND TOOLS
Pliers Safety Wire Pliers
Needle Nose Pliers Linesman Pliers
Side Cutters Electrical Wire Stripers Aviation
Snips Pop Rivet Tool
Hammer Click Punch
Rubber Mallet* Ball Peen Hammer
Center Punch Drift Pin & Punch Set Screwdriver
Set Safety Glasses
Several Small Clamps (Stanley quick clamps work well) Wrench Set SAE & Metric
Socket Set – SAE & Metric Ruler & Tape Measure
2 or 4 ft. Level
Utility Knife Hole Saw*
Set of Drill Bits (sizes listed below)
Hack Saw
Fluting Pliers Scotch-Brite Pads
1/2” & 3/4" Uni-Bit® Step Drill
Digital Protractor*
Pop Grip Dimpler for 1/8” holes Files
Cleco Pliers Silver #40 Clecos
Copper #30 Clecos Gold #11 Clecos
POWER TOOLS
Electric Hand Drill Small Electric Grinder
Dremel* Bench Disk Sander*
Soldering Gun/Hot Knife Heat Gun*
CD/MP3 Player* Right Angle Drill and Bits
It is highly recommended to use a pneumatic riveter.
RANS uses these pneumatic riveters.
Marson V2 lightweight pneumatic riveter P/N 79014
MSC Industrial Supply Co. P/N 04053278
LUBRICANTS, ADHESIVES , TAPES & ETC
Small Can Lithium Grease Clear Silicone
WD40 Super Glue
Lubricating oil Loctite Blue Threadlocker
DOW 730 Sealant or similar 3M Super 77 Spray Adhesive
Thread Sealant 1/4” wide Double Stick Tape
Safety Wire Hi-Temp Silicone Seal (RED)
Clear Plastic Tape (anti-chafe) 1” Acrylic Foam Tape (2-sided)
Adhesive backed Velcro Masking Tape
White Lightning Bike Chain Lube or similar LORD Fusor 703 Prep/Cleaner
LORD Fusor 108B/109B Adhesive, Plunger & Mixer Tips

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/01/2014
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DRILL BIT SIZES
A full set of fractional drill bits ranging from 3/32" to 5/8" is strongly recommended. In addition to
these the following number bits will be required to assemble your S-7S Courier.
NUMBERED BITS FRACTIONAL BITS
#40 1/4”
#30 5/16"
#11 3/8"
#28 1/2"
#21 & 10-32 TAP 7/8"
*Not a necessary tool but helpful

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/01/2014
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RANS Designs
RECOMMENDED AVIONICS LIST – S-7S
Comm Radios
GARMIN GTR 200
Transponder
GARMIN GTX 335
Encoder
AMERI-KING AK-350
GPS GARMIN AERA 660
ELT ACK Technologies E-04
Push to Talk Switch
RADIO SHACK #275-644 Pushbutton Switch
Local Avionic shops can wire your avionic harnesses for you.
Switches, circuit breakers, and other electrical parts are also available from RANS.
Contact RANS Parts Department for pricing.
RED Illuminated Master Switch
KSES0017
Non-illuminated Switch
KSES0016
Panel Post Lights
KSES0018
Electrical Buss Bar
AMW 636
W58 Circuit Breakers
1 amp
KSES0010
2 amp
KSES001
4 amp
KSES0014
5 amp
KSES001
10 amp
KSES0013
15 amp
KSES001
1

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/01/2014
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S-7S COURIER - GENERAL INFORMATION
INTRODUCTION
As the builder of the S-7S COURIER kit you are considered the manufacturer by law.
The rules state that you must build 51% of the total. In essence, we are your parts
supplier. You have the final say in regard to every single item that goes into your project.
The responsibility of making a safe aircraft is on your shoulders. It is by your hand this
box of parts becomes an aircraft. Set up your quality assurance and construction activity
according to the level of risk you are willing to take. The manual provided is to be
thought of as a suggested guidebook. Use the book, but learn to think things through.
This will minimize errors and reduce build time.
BEFORE BEGINNING ASSEMBLY
TAKE INVENTORY:
You must complete an inventory within 60 days of
receiving your kit.
We check and re-check and are 99.9% certain that if we say we shipped it, we did. The
first task in building your kit is to inventory the parts using the packing list provided. It is
your job to keep all parts organized and accounted for. We cannot provide missing parts
cost free after 60 days. Use the supplied pack list to verify that everything that we
packed is in the box. The fast way to inventory is to use the Priority Number that appears
on the Part Number labels, these will match the pack list in numeric order. Go through
the list item by item. If anything is not there that should be, please contact our parts
department immediately. HINT: Use sections of plywood from the packing crate to
fabricate a part inventory board. As each part is inventoried and checked off on the pack
list, staple the bag to the board. This allows for quick identification and part selection
during assembly. We fabricate “A” Frame stands to support the plywood. Refer to
FIGURE 0-01. Plywood can also be attached to shop walls.
IMPORTANT: When hanging the parts on the board, use the aircraft section
designator of the part number to organize the parts. For an explanation of the part
number and the meaning of the letters in the prefix refer to ENGINEERING DEPT.
DRAWING NUMBERING SYSTEM.

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/01/2014
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ENGINEERING DEPT. DRAWING NUMBERING SYSTEM
RANS TYPICALLY DESIGNATES PARTS BY EIGHT VARIABLES. THIS SYSTEM CONSISTS OF
LETTERS AND NUMBERS. THE FOLLOWING IS A BREAK DOWN OF THIS SYSTEM.
X1X2XX3XXXX4
1CLASSIFICATION 2DWG TYPE 3AIRCRAFT SECTION 4ID NUMBER
K = KIT
A = ASSEMBLY
AC = AIRCRAFT
0 - 9999
I = INSTALLATION
AL = AILERON
P = PART
AV = AVIONICS
S = SUPPLIERS
BS = BRAKE SYSTEM
V = VIEW
CS = CONTROL SYSTEM
CV = COVERING
CW = COWLING
DR = DOOR
EL = ELEVATOR
EM = EMPENNAGE
ES = ELECTRICAL SYSTEM
EX = EXHAUST
FL = FLAP
FS = FUEL SYSTEM
FU = FUSELAGE
FW = FIREWALL
HS = HORIZ. STAB
HW = HARDWARE (NOT MS, AN...)
IN = INTERIOR
IP = INSTRUMENT PANEL
JS = JURY STRUT
LS = LIFT STRUT
MG = MAIN GEAR
NG = NOSE GEAR
PL = PLACARDS
PR = PROPELLER/SPINNER
PT = PITOT/STATIC SYSTEM
PW = POWER PLANT
RD = RUDDER
ST = SEAT/HARNESS
SY = SYSTEM
TG = TAIL GEAR
TR = TRIM TAB
VS = VERT. STAB.
WI = WING
WS = WINDSHIELD
E

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/01/2014
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IMPORTANT: PLEASE READ FIRST
PLEASE READ: We highly recommend that you completely read the manual cover to
cover before beginning assembly of your aircraft. This will help to eliminate costly
mistakes and considerably speed up your build time. As you read through the Assembly
Manual, follow along in the Parts and Figure Drawings Manual. Study each and every
parts and figure drawing. The Assembly, Parts, and Figure Drawing manuals will parallel
each other; however, at times the Assembly manual will use parts from two or more
pages of the Parts manual. PLEASE NOTE: Unless otherwise noted, all figure and
exploded view drawings are NOT to scale.
GET ORGANIZED!Prepare your workshop; be certain that what comes in the door will
be able to go out!
KEEP IT CLEAN: Wash your hands, tools, and work tables. You will notice most of the
parts are labeled with part numbers. These labels are easily removed with a cloth
dampened with acetone or lacquer thinner. CAUTION: Do no allow Acetone, lacquer
thinner, Loctite or fuel to come in contact with the Lexan glazing. These and some other
solvents will destroy the Lexan.
STEEL PREPARATION: Even though every care is taken to assure a safe arrival of
your aircraft, thoroughly inspect the fuselage as well as all other parts for the following:
unclosed welds, nicks, and dents. If you locate any suspect areas with excessive dents
or scratches call our Tech-Staff for information on damage tolerance. All Welded steel
parts will require primer and top coating. We recommend a good two part epoxy primer.
Be sure the primer and paint you choose will not be affected by the urethane adhesive
used to bond the fabric to the airframe. Final painting of certain components will be done
after trial assembly. Include these components when designing your paint scheme. If
you assemble the aircraft in a humid environment it is best to prime everything first.
ASSEMBLY SEQUENCING: We have tried to format the manual in a step by step order
as to how to assemble your aircraft. However, there is truly no “one” order in which to
follow, as long as the check- lists in the covering section are met prior to covering. If you
should choose to build your wings first rather then the fuselage, it is acceptable to do so.
NOTE:It is not necessary to trial fit wings and tail surfaces to the fuselage frame
except for the rudder and elevator fit up described in section 1. It is total acceptable
to complete building of the components and than to final install them. Refer to the
assembly sequence flow chart at the end of this section.
DEBURRING: Many parts will need to be deburred. This is an IMPORTANT step and
must be performed. Assembly of parts with burrs can cause stress risers and eventual
part failure. Various tools can be used. A deburring tool is nice but a 1/2" drill bit can do
a good job on most holes. Radius and smooth sharp corners with files or fine grit
sanders and grinders. Edges of certain parts also need deburring...a good file works
here.

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/01/2014
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CLECOS: These are temporary fasteners that will be used to hold things together while
fitting and drilling. A pair of pliers is also required to install and remove the clecos. The
cleco's are color coded as to hole size.
Silver #40
Copper #30
Gold #11
To use, simply set cleco in the special pliers, squeeze closed, insert into the hole and
release. (Reverse for removal). You will find the clecos to be extremely useful throughout
assembly.
ROD ENDS: When installing rod ends and similar hardware, be certain at least ten
threads are engaged, unless directed otherwise within the text.
CAUTION: Rod Ends must be engaged a minimum of 10 complete turns.
RIVETS: Your kit is supplied with various sizes of aluminum and stainless steel pop
rivets. Even though we are careful, there is always the chance of the packages being
mis-labeled. So before riveting, be sure to double check that you have the correct
aluminum or stainless steel pop rivet for the particular section you are working on.
MARKERS: Throughout the manual, you are instructed to mark on various parts. Use
flairs or any type of felt tip marker. Avoid using pencils. The graphite in the lead will
cause the aluminum to corrode.
ENGINE WARRANTY: Rotax engines have a six- month warranty from the time of first
use. There are however time constraints on this warranty. Please read the following
pages on warranty extensions very closely. If there are any questions on engine
warranty, please contact the factory.
AN & RIVET CHARTS: All bolts and rivets furnished with the kit are labeled as to their
size. In the event they become mixed or you question the size or length of a particular
bolt or rivet, we have included an AN bolt chart and a rivet chart.

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ORIENTATION: Throughout the Manual, you will be asked to refer to specific stations of
the fuselage. Station One (S-1) is the first structural member starting at the nose of the
plane. Progressing towards the tail, we pass all stations. Refer to FIGURE 00-03.
When a left hand side part is called out, this means the plane’s left or your left if you
were sitting in the cockpit looking forward.
SERIAL NUMBER: Refer to FIGURE 00-02 for the serial number location. Please
record your serial number and have it handy whenever you call into the factory for
assistance.
HAVE FUN: A RANS aircraft is almost as much fun to build as it is to fly and with a little
care and planning, your ship could be a show-stopper...Send us and the magazine's
pictures of your work in progress or your finished plane.
Send your completion photos to EAA Sport Planes, Experimenter, or Kit Planes. They
love to see completed kit planes.
Don’t be shy, SHOW IT OFF!!
AS ALWAYS, WE ARE HERE TO HELP!
GIVE US A CALL IF YOU RUN INTO A PROBLEM.

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/01/2014
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S-7S ASSEMBLY FLOW CHART – GENERAL
For a general overview refer to the following chart. For more detailed information refer to
ASSEMBLY FLOW CHARTS – DETAILED. Note: The headings in the general chart
refer to headings in the detailed flow charts.
S-7S FUSELAGE
PRE-COVERING ASSEMBLY
S-7S TAIL SURFACES
PRE-COVERING ASSEMBLY
S-7S TAIL SURFACES
FINAL ASSEMBLY &
INSTALLATION
S-7S WINGS
PRE-COVERING ASSEMBLY
S-7S WINGS
FINAL ASSEMBLY &
INSTALLATION
S-7S FUSELAGE
FINAL ASSEMBLY

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/01/2014
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S-7S ASSEMBLY FLOW CHART – DETAILED
Note: The headings in the detailed flow charts on the following pages refer to text
manual headings.
S-7S FUSELAGE – PRE-COVERING ASSEMBLY
Refer to Section 1 and complete the following items:
•RUDDER SYSTEM ASSEMBLY AND INSTALLATION
oRUDDER FIT UP
•PREP AND PRIME FUSELAGE FRAME AND RUDDER FRAME
•FUSELAGE FORMER INSTALLATION
oVERTICAL STABILIZER FORMER
oFUSELAGE SIDE FORMER
oFUSELAGE BOTTOM FORMER
oRIB VERTICAL STABILIZER
•MAIN GEAR ASSEMBLY AND INSTALLATION
oMAIN GEAR FIT UP
•FLOORBOARD INSTALLATION
oFIT UP
•RUDDER SYSTEM ASSEMBLY AND INSTALLATION
oPRE-COVERING ASSEMBLY
•DOORFRAME BATTERY ACCESS PANEL INSTALLATION
Refer to Section 4 and complete the following items:
•BATTERY BOX ASSEMBLY AND INSTALLATION
oBATTERY BOX AND GROUND CABLE
•ELT AND COMMUNICATION ANTENNA INSTALLATION
oANTENNA MOUNT PLATES

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Refer to Section 8 and complete the following items:
•BAGGAGE COMPARTMENT ASSEMBLY AND INSTALLATION
•SEAT BELT ASSEMBLY AND INSTALLATION
AFTER PRIMING OF FUSELAGE FRAME/ BEFORE COVERING
COVERING (Refer to Section 7)
PAINTING (Manual does not provide guidance for painting)

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/01/2014
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S-7S FUSELAGE – FINAL ASSEMBLY
Refer to Section 1 and complete the following items:
•MAIN GEAR ASSEMBLY AND INSTALLATION
oFINAL INSTALLATION
•GEAR LEG FAIRING ASSEMBLY AND INSTALLATION
oFAIRING FIT UP
oINSTALLATION
•TAIL WHEEL ASSEMBLY AND INSTALLATION
Refer to Section 2 and complete the following items:
•CONTROL STICK ASSEMBLY AND INSTALLATION
oTORQUE TUBE FIT UP
oFINAL ASSEMBLY AND INSTALLATION
•ELEVATOR PUSH PULL TUBE ASSEMBLY
Refer to flow plan section TAIL SURFACES FINAL ASSEMBLY AND INSTALLATION
•Complete all items listed.
Refer to Section 2 and complete the following items:
•FLAP LEVER ASSEMBLY AND INSTALLATION
Refer to Section 6 and complete the following items:
•BOOT COWL AND INSTRUMENT PANEL INSTALLATION
oBOOT COWL AND INSTRUMENT PANEL FIT UP
Refer to Section 1 and complete the following items:
•FLOORBOARD INSTALLATION
oINSTALLATION
•RUDDER PEDAL INSTALLATION
•FIREWALL ASSEMBLY AND INSTALLATION
oASSEMBLY
oINSTALLATION
•HYDRAULIC BRAKE INSTALLATION
AFTER COVERING AND PAINT OF FUSELAGE
•RUDDER SYSTEM ASSEMBLY AND INSTALLATION
oFINAL INSTALLATION

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Refer to Section 2 and complete the following items:
•THROTTLE LEVER INSTALLATION
•AILERON CABLE SYSTEM INSTALLATION FUSELAGE
Refer to Section 3 and complete the following items:
•FUEL LINE INSTALLATION – FUSELAGE
AFTER COVERING AND PAINT OF FUSELAGE
•ENGINE MOUNT AND ENGINE INSTALLATION
•MUFFLER/ HEATER WRAP ASSEMBLY AND INSTALLATION
•LUBRICATION SYSTEM ASSEMBLY AND INSTALLATION
AFTER ENGINE IS INSTALLED
•COOLING SYSTEM INSTALLATION
•FUEL LINE INSTALLATION FIREWALL FORWARD
Note: To complete the following items it is necessary to clamp the finished instrument panel to
the fuselage frame in its approximate position to allow for cable routing and connection. The
panel should be in an assembly status allowing it to remain in its position.
•CARB HEAT INSTALLATION
•THROTTLE CABLE AND CHOKE INSTALLATION
•HEATER INSTALLATION
Refer to Section 9 and complete the following items:
•CARBURETOR HEAT
•CABIN HEAT
•THROTTLE AND CHOKE
Refer to Section 1 and complete the following items:
•HYDRAULIC BRAKE INSTALLATION
oAFTER INSTRUMENT PANEL INSTALLATION
Refer to Section 9 and complete the following items:
•PARK BRAKE
Refer to Section 4 and complete the following items:
•BATTERY BOX ASSEMBLY AND INSTALLATION
oBATTERY
•INSTRUMENTS AND ELECTRICAL
Note: Complete all electrical wiring and check for correct function before installing the boot cowl.

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Refer to Section 6 and complete the following items:
•BOOT COWL AND INSTRUMENT PANEL INSTALLATION
oFINAL INSTALLATION
Refer to Section 3 and complete the following items:
•FUEL LINE INSTALLATION – FUSELAGE
AT BOOT COWL &INSTRUMENT PANEL INSTALLATION
Refer to Section 6 and complete the following items:
•SPINNER ASSEMBLY AND INSTALLATION
oASSEMBLY
•PROPELLER INSTALLATION
•COWLING ASSEMBLY AND INSTALLATION
oASSEMBLY
•DOOR ASSEMBLY – LEXAN AND TRIM
•DOOR LATCH AND DOOR INSTALLATION
•SPINNER ASSEMBLY AND INSTALLATION
oINSTALLATION
•COWLING ASSEMBLY AND INSTALLATION
oINSTALLATION
Refer to flow plan section WINGS - FINAL ASSEMBLY &INSTALLATION.
•Complete all items listed after and including WING INSTALLATION.
Refer to Section 6 and complete the following items:
•WINDSHIELD ASSEMBLY AND INSTALLATION
oFIT UP
oINSTALLATION
Refer to Section 3 and complete the following items:
•FUEL LINE INSTALLATION – FUSELAGE
AT WINDSHIELD INSTALLATION
AFTER INSTALLATION OF WINGS