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MAULE Starcraft Turbo-Prop MT-7-420 Maintenance Manual

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FOR
MAULE
MT-7-420
Starcraft Turbo-Prop
P/N: TLC-MT-7-420
PERFORMANCE THAT COUNTS!
2099 Georgia Hwy 133 South ~ Moultrie, GA 31788
Tel: 229-985-2045 ~ Fax: 229-890-2402 ~ www.mauleairinc.com
9/02

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Summary of Contents for MAULE Starcraft Turbo-Prop MT-7-420

  • Page 1 MAULE MT-7-420 Starcraft Turbo-Prop P/N: TLC-MT-7-420 PERFORMANCE THAT COUNTS! 2099 Georgia Hwy 133 South ~ Moultrie, GA 31788 Tel: 229-985-2045 ~ Fax: 229-890-2402 ~ www.mauleairinc.com 9/02...
  • Page 2 The Maule MT-7 is 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 MT-7. Its sturdy construction means you will not have to pamper it to enjoy long years of trouble-free service.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION I........................1 GENERAL DATA .....................1 GENERAL DESCRIPTION: ................1 DESIGN SPECIFICATIONS: ................1 FLUID CAPACITIES AND SPECIFICATIONS: ..........2 SECTION II........................5 GENERAL MAINTENANCE..................5 CLEANING AND CARE OF AIRCRAFT ............5 INSPECTION GUIDES ..................6 RIGGING PROCEDURES ................17 LUBRICATION....................19 FABRIC REPAIRS: ..................19 SECTION III.......................21 MAJOR COMPONENT PARTS ................21 WINGS:......................21 LIFT STRUTS: ....................21...
  • Page 4 LOG OF REVISIONS Description Date Page(s) Added statement for Service Letter #74. Differentiated between 06/05/19 old AN and new NAS bolts. 9/02...

  • Page 5: Section I

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 SECTION I GENERAL DATA GENERAL DESCRIPTION: Type: Five place high wing cabin monoplane. Engine Installation: Single tractor engine in nose of fuselage. Wing: Strut braced, two spar, metal covered, modified USA 35-B airfoil. Fiberglass wing tips.

  • Page 6: Fluid Capacities And Specifications

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 Areas: a. Wing, Aileron and Flaps 165.6 sq. ft. b. Ailerons (total) 14.2 sq. ft. Flaps (total) 23.9 sq. ft. d. Horizontal Stabilizer 18.1 sq. ft. e. Elevators (including tab) 14.1 sq. ft.
  • Page 7 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 Emergency Mil-G-5572F, Aviation Gasoline, all grades (aircraft boost pump on; maximum of 6 hours operation per overhaul period of turbine through an engine operat- ing range of idle to 90% maximum SHP.) CAUTION: MIL-G-5572 fuel containing tricresylphosphate (TCP) additive shall NOT be used.
  • Page 8 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 Approved Oils: Mixing of approved oils in 250 series engines is permitted only within a given group number. An oil may be mixed with any other oil in its group. For example, an oil in Group 23 may be mixed with another brand of oil in Group 23.

  • Page 9: Section Ii

    Salt water and chemicals act as an electrolyte between dissimilar metals and can start a strong corrosive action over a short period of time. Maule makes every effort to separate dissimilar metals with primers and coatings during manufacture, but there are some locations (such as rivets in wing skins) where this is impossible.

  • Page 10: Inspection Guides

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 blocking them. Accumulated water can be dangerous, so check behind the baggage compart- ment frequently. Interior: Cont’d Textile upholstery may be cleaned using a vacuum cleaner. Grease and oil spots on the upholstery should be treated with a spot remover or dry cleaning fluid. Do not use soap and water on textile materials.
  • Page 11 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 CAUTION: If airplane is subject to excessive stress, i.e., heavy loads, adverse wind conditions, rough landings, etc., take special care in examining wing skins for any cracks. If any are found, repair before further flight in accordance with AC 43:13 and factory drawings.
  • Page 12 CAUTION: This aircraft was equipped with sealed struts when manufactured, however, if these struts were replaced in field with unsealed struts, comply with Maule Service Bulletin No. 11 as required. (New sealed struts are identified by two weld spots located at upper end.
  • Page 13 Long Island City, NY Tucker, GA NOTE: Maule Service Bulletin No. 9 covers corrosive resistant parts replacement and is particularly recommended for airplanes operating in a potentially corrosive environment. Compliance to this SB provides for larger stainless steel turnbuckles and corrosion resis- tant steel fasteners and attachment details for the elevator cables.
  • Page 14 19. Check and clean vacuum system regulator valve filter and intake filter. 20. Check the pitot static system for leaks. 21. Ensure that all applicable Airworthiness Directives and Maule Service Letters and Bulletins that are mandatory have been complied with.
  • Page 15 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 vanes for foreign object damage. Clean compressor with chemical wash solution if operating in a 3-37 smoggy area (as required). Inspect the compressor scroll for cracks or breaks at the anti-ice valve and customer bleed ports. If cracks or breaks are de- tected, check engine for possible vibration causes.
  • Page 16 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 Inspect the outer combustion case for condition. Inspect the 3-230 weld joints of cases that do not have the brazed screen rein- forcement in the armpit area. 3-232 Clean the burner drain valve.
  • Page 17 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 3-105 Purge air from the filter bowl area of the single element pump. 3-108 Inspect and clean the fuel nozzle. Item 8, Table III-10 Inspect and clean the No. 1 bearing oil pressure reducer.
  • Page 18 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 Inspect and clean filter Engine oil element using ultra- Follow procedures in Oil Fil- 100 hr max. filter sonic cleaner with ter, para 3-168. perchloroethylene. When changing from Engine Refer to Approved Oils, para...
  • Page 19 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 Power tur- Follow procedures in Inspec- bine sup- Inspect and clean in- tion and Cleaning of Power ternal carbonaceous port scav- 300 hr max. Turbine Support Scavenge enge oil deposits. Oil Strut, para 3-166.
  • Page 20 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 Check balance the propeller. If the aircraft propeller strikes an object causing damage to the propeller blades requiring blade replacement and overhaul of the propeller assembly, remove the engine and send it to a designated overhaul facility for inspection.

  • Page 21: Rigging Procedures

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 RIGGING PROCEDURES 1. LEVELING: Laterally: The airplane can be accurately leveled laterally using the front spar attach bolts. Turn these two bolts so that a flat on the head is "up". Fabricate two equal length spacers (1½...
  • Page 22 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 4. TAIL ASSEMBLY: With the airplane in level position, the stabilizers should be leveled at their rear spars. The hinge line should be straight from tip to tip. The vertical stabilizer should be plumb at the hinge.

  • Page 23: Lubrication

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 10. RUDDER TAB: This tab is interconnected with the aileron system to automatically coordinate rudder with aileron to reduce adverse yaw. The tab should normally be streamlined with the rudder when the aileron and rudder controls are centered.
  • Page 24 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 sanded area around the repair. Apply one coat (this may be brushed) to the sanded area slightly larger than the size of the patch to be applied. This application aids in total adhesion to the topcoat and offers a fresh chemical adhesion base for the repair patch.

  • Page 25: Section Iii

    The forward fuselage section is aluminum covered (2024-T3). The firewall is made of .018 galvanized sheet steel or stainless steel. The aft fuselage section is covered with Ceconite fabric and standard dope and paint fin- ish as per Maule Specification S-17. This fabric need not be pulled or punch tested. 9/02...

  • Page 26: Surfaces And Controls

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 SURFACES AND CONTROLS AILERONS AND FLAPS: The ailerons and flaps are aluminum alloy structures covered with 2024-T3. The aileron control system consists of a chain drive connecting the two control wheels and is attached to the necessary cables which are routed over pulleys through the fuselage and into the wing section to the aileron horns.

  • Page 27: Landing Gear, Wheels And Brakes

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 LANDING GEAR, WHEELS AND BRAKES MAIN LANDING GEAR: The main landing gear consists of separate left and right side heat-treated (7075-T651) aluminum spring legs which are bolted to a square tube truss in the bottom of the fuselage structure.
  • Page 28 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 Cleveland 10-54 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 29 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 A springy, rubber action of the pedal indicates Air in system air in the system. An excessive amount of air in system will allow the pedal to continue trav- eling under normal pressure. In either case, the system should be bled and refilled.

  • Page 30: Nosewheel And Nosewheel Oleo Strut

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 NOSEWHEEL AND NOSEWHEEL OLEO STRUT NOSEWHEEL: To remove nosewheel, raise it off the ground by holding the tail down. Remove one of the 5/16 inch elastic stop nuts on the axle at the outside fork cap and remove the through-stud.

  • Page 31: Fuel System

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 ENGINE MOUNT: The engine mount is a welded structure of chrome molybdenum steel (4130) tubing. The engine is attached to the mount by means of three (3) point suspension to three (3) mounting pads on the engine case.

  • Page 32: Electrical System

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 trol. Two (2) auxiliary wing tip fuel tanks, twenty-one (21) gallon capacity, are mounted in the second from the outboard wing bay. They are fuel transfer tanks and simply supply fuel to the main tank through a small vibrator pump.
  • Page 33 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 GENERATOR CONTROL SYSTEM: Overvoltage protection is incorporated in the generator control unit which will latch off regu- lator output after an overvoltage event. Reset of latch off caused by either overvoltage or shorten output is accomplished by momentary turn off of supply voltage, i.e., to reset to ON.

  • Page 34: Electrical Schematic

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 ELECTRICAL SCHEMATIC Sheet 1 of 3 The wire numbering system has been designed to ease tracing a faulty wire. The code is as shown below the schematic. Wires are plainly labeled near each end.

  • Page 35: Electrical Schematic

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 ELECTRICAL SCHEMATIC Sheet 2 of 3 28 Volt 9/02...

  • Page 36: Electrical Schematic

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 ELECTRICAL SCHEMATIC Sheet 3 of 3 28 Volt 9/02...

  • Page 37: Door Latch Procedure

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 DOOR LATCH PROCEDURE 9/02...

  • Page 38: Airworthiness Limitations Section

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL MT-7-420 AIRWORTHINESS LIMITATIONS SECTION The airframe does not have mandatory life limits or overhaul requirements. See Textron Ly- coming Operator's Manual, p/n 60297-12, Revision No. 60297-12-6 or later and the Hartzell Owner’s Manual and Logbook, p/n 115N, Revision 10 or later for the constant speed prop or the Sensenich Fixed-Pitch Metal Propellers Instructions For Use and Care dated 9/4/97 or later for their airworthi- ness limitations.

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