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MAULE Vintage M-4-180V Maintenance Manual

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FOR
MAULE
M-4-180V
Vintage Rocket
P/N: TLC-M-4-180V
PERFORMANCE THAT COUNTS!
2099 Georgia Hwy 133 South ~ Moultrie, GA 31788
Rev A: 04/13/16
PC: SMM
Tel: 229-985-2045 ~ Fax: 229-890-2402/985-2048 ~ www.mauleairinc.com

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Summary of Contents for MAULE Vintage M-4-180V

  • Page 1 MAULE M-4-180V Vintage Rocket P/N: TLC-M-4-180V PERFORMANCE THAT COUNTS! 2099 Georgia Hwy 133 South ~ Moultrie, GA 31788 Rev A: 04/13/16 PC: SMM Tel: 229-985-2045 ~ Fax: 229-890-2402/985-2048 ~ www.mauleairinc.com...

  • Page 2: Warranty

    The Maule M-4 was designed and built to give you the airplane you have always wanted. It is fast, comfortable, and easy to fly, yet no light airplane is safer than the Maule M-4. Its sturdy construction means you will not have to pamper it to enjoy long years of trouble-free service.

  • Page 3: Table Of Contents

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V TABLE OF CONTENTS ITEM PAGE Foreword..............…... 2 Warranty....…..........….… 2 Table of Contents…............3 Log of Revisions….............….. 4 GENERAL DATA SECTION I - General Description............….. 5 Design Specification...........….. 5 Fluid Capacities and Specification......…. 6...

  • Page 4: Log Of Revisions

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V LOG OF REVISIONS REV. TO PAGES DESCRIPTION DATE 6, 17, 21, 22 Changed oleo strut oil to API GL-4 or GL-5 gear oil. 04/13/16 Rev. A 4/13/16...

  • Page 5: Section I - General Data

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V SECTION I GENERAL DATA GENERAL DESCRIPTION: Type: Two place high wing cabin monoplane. Engine Installation: Single tractor Lycoming O-360-C1F or O-360-C4F engine in nose of fuselage. Propeller for O- 360-C1F: Hartzell Constant Speed HC-C2YR-1BF/F7666A (76”) and for O-360-C4F (or O-360- C1F modified for fixed pitch): Sensenich Fixed Pitch 76EM8S5-0-56 (76”) or 76EM8S8-0-56 (76”)

  • Page 6: Fluid Capacities And Specification

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V DESIGN SPECIFICATIONS: (Cont’d) Wings: Airfoil Modified USA 35-B Chord 63 inches Incidence +30 minutes Dihedral 3 inches Sweepback None Areas: Wing, Aileron and Flaps 157.9 sq.ft. Ailerons (total) 12.6 sq.ft. Flaps (total) 22.8 sq. ft.

  • Page 7: General Maintenance

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V SECTION II GENERAL MAINTENANCE CLEANING AND CARE OF AIRCRAFT Keeping the performance, speed and durability that was built into your aircraft at the factory requires more than casual attention. The accumulation of dirt and oil on the outside and debris inside does affect these factors and can be a fire hazard as well.
  • Page 8 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V INTERIOR CLEANING (Cont’d) For best results, stains, especially those caused by grease or paint, should be removed from upholstery as soon as possible or they may become “set”" and hard or impossible to remove. "Set" stains should be removed carefully with a clean cloth dampened in denatured alcohol.

  • Page 9: Inspection Guides

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V INSPECTION GUIDES At 25 Hour Total Time: Perform 50 Hour Inspection as described below: At 50 Hour Total Time and every 50 hours thereafter: A. POWER PLANT MECH INSP 1. Perform appropriate inspection as called for in the Textron Lycoming Operator's Manual, p/n 60297-12, Revision No.
  • Page 10 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V 8. Drain sumps of fuel tanks. 9. Check tires for inflation and cuts. At 100 Hours Total Time and every 100 Hours thereafter, perform the 50 hour inspection plus the following: A. POWER PLANT...
  • Page 11 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V 5. Open zippers in headliner and inspect all control cables, pulleys, fairleads and electrical connections and wires for security and chafing. 6. Remove wing root fairings and inspect control cables, fairleads, fuel lines and connections, and electrical wires and connections for security, chafing and leaks.
  • Page 12 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V Rev. A 4/13/16...
  • Page 13 20. Check and clean vacuum system regulator valve filter and intake filter. 21. Check the pitot static system for leaks. 22. Ensure that all applicable Airworthiness Directives and Maule Service Letters and Bulletins that are mandatory have been complied with.

  • Page 14: Weighing Procedure

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V WEIGHING PROCEDURE DETAILED CALCULATIONS OF EMPTY WEIGHT AND EMPTY WEIGHT CENTER OF GRAVITY: PROCEDURE: Place each of the wheels on a scale with the tailwheel elevated to place the airplane in approximately the flight attitude.

  • Page 15: Rigging Procedures

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V WEIGHTING PROCEDURES: (Cont'd) The above empty weight includes unusable fuel of 27.6 lbs. at 24 inches and 8 quarts of oil at minus 36.5 inches, plus all items of equipment as marked on the accompanying Equipment Lists.
  • Page 16 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V To check the dihedral angle at the front spar, proceed as follows: Stretch a string along the top of the wing above the front spar, from wing tip to wing tip, and draw it tight. Check the dimension vertically from the top of the spar at root end fitting.

  • Page 17: Lubrication

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V Check the rudder travel for 21° ±1° right and left. Adjustment, if needed, may be accomplished by backing on the locknuts on the rudder stops located on fuselage frame and screwing stop screw in or out, whichever is required.

  • Page 18: Towing

    Tailwheel fork • Control pulley bearings and control surface hinges TOWING Aircraft can be towed using a Maule tow bar p/n TB101 or equivalent as shown below. FABRIC REPAIRS: (Applicable to Polyurethane paint on Ceconite fabric only) REPAIRS: Small holes and damaged areas can easily be repaired without removing the existing paint topcoat.

  • Page 19: Major Component Parts

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V Lightly scuff sand with #320 or #400 wet/dry sandpaper approximately 2 inches around the repair area. Mix one part gray urethane primer (catalyst) with two (2) parts gray urethane primer (2:1 ratio - 2 parts paint/1 part catalyst), mixing a very small amount only for coating the sanded area around the repair.

  • Page 20: Lift Struts

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V LIFT STRUTS: The lift struts are streamlined tubes attached to the wing and fuselage by means of AN standard steel bolts. When inspecting the struts, check for nicks and dents and see that all bolts are snug (not tight).

  • Page 21: Landing Gear, Wheels And Brakes

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V ELEVATORS: The elevator has a chrome molybdenum (4130) internal structure covered with Ceconite fabric. Inspect for corrosion. Drain grommets should be kept open. The hinge attachments should be lubricated with light engine oil. Accumulations of dust and dirt on hinges should be removed.
  • Page 22 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V Pull out cylinder head and spring assembly. To remove spring take all nuts off of strut shaft and press piston upward to free bolts for removal. Remove bolts, and piston will come out of end of shaft.
  • Page 23 17. Replace brake calipers and hubcap. BRAKE CYLINDERS: The hydraulic brakes are actuated by two (2) master cylinders, Maule P/N 4046B, on the left side, and two (2) slave cylinders on the right side. Check hydraulic oil level in master brake cylinders, proper level is no closer than ¼ inch to top of cylinder.
  • Page 24 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V of hydraulic brake fluid. Actuate brake pedal full stroke with the bleeder valve open which will force fluid into the receptacle where a check can be made for escaping air bubbles. Continue to actuate pedal until no more air bubbles are observed.
  • Page 25 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V MAINTENANCE HINTS ON HYDRAULIC BRAKES: Excessive pedal travel: Probable cause Corrective Action Normal wear of brake pad at wheel If pad is worn thin, replace with new pad. Leak in system Inspect all attachments and fittings in brake system.

  • Page 26: Sfs P8B Tailwheel

    Use only the recommended hydraulic fluid. SFS-P8B TAILWHEEL A later Maule SFS-P8B Full Swivel Steerable Tailwheel may be installed on aircraft. See Fig. 1 for detailed breakdown. If shimmy of the tailwheel becomes a problem, it should be lubricated and adjusted as follows: A.
  • Page 27 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V and the three (3) springs (76B) in the three deeper holes in bracket (71B). Place friction ring assembly (72B-3) over the springs with the pin in the shallow hole in bracket (71B). Grease may be used to hold the foregoing parts in place. Do Not allow any grease on the friction washer surface of the friction ring assembly (72B-3).
  • Page 28 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V FIGURE 1 D. TAILWHEEL INSTALLATION Check all bolts and nuts holding the tail springs to the fuselage. They must be tight so that there is no play or side movement in the springs or their attachment.

  • Page 29: Power Plant System

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V be no looseness or play between the bracket (71B) and the spring. Install the connector springs, using the heavier spring on the right side. Install the springs so that the light spring is compressed approximately 112 to 3/4 inch.

  • Page 30: Fuel System

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V A periodic inspection of the cowling should be made checking for cracks, chafing, security of attachment, etc. Baffling should be checked for security and the rubber sealing extensions should be checked for wear and security. When the cowl is installed, these sealing extensions should lay up, forward or inboard, and provide a good seal against the cowl.

  • Page 31: Electrical System

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V The fuel line should be checked for cracks and chafing every 100 hours or annually and the gascolator should be cleaned at the same time. The auxiliary tank transfer pump strainers should be cleaned at the same interval. This is done by removing the pump bottom with a 5/8"...

  • Page 32: Electrical Schematic

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V Electrical Schematic The wire numbering system has been designed to ease tracing a faulty wire. The circuit tracing code is as shown below in the schematic. Wires are plainly labeled near each end.
  • Page 33 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V Electrical Schematic The wire numbering system has been designed to ease tracing a faulty wire. The circuit tracing code is as shown below in the schematic. Wires are plainly labeled near each end.
  • Page 34 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V Rev. A 4/13/16...

  • Page 35: Airworthiness Limitations

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-4-180V SECTION VI Airworthiness Limitations The Airworthiness Limitations section is FAA approved and specifies maintenance required under §§43.16 and 91.403 of the Federation Aviation Regulations unless an alternate program has been FAA approved. The airframe does not have mandatory life limits or overhaul requirements. See Textron Lycoming Operator's Manual, p/n 60297-12, Revision No.

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