MAULE Super Rocket M-7-235C Maintenance Manual
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MAULE Super Rocket M-7-235C Maintenance Manual

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FOR
MAULE
M-7-235C
Super Rocket
P/N: TLC-M-7-235C
PERFORMANCE THAT COUNTS!
Page 1 of 37
Rev. D Dated 6-5-19
2099 Georgia Hwy 133 South ~ Moultrie, GA 31788
Tel: 229-985-2045 ~ Fax: 229-890-2402/985-2048
PC:
SMM
www.mauleairinc.com

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Summary of Contents for MAULE Super Rocket M-7-235C

  • Page 1 MAULE M-7-235C Super Rocket P/N: TLC-M-7-235C PERFORMANCE THAT COUNTS! Page 1 of 37 Rev. D Dated 6-5-19 2099 Georgia Hwy 133 South ~ Moultrie, GA 31788 Tel: 229-985-2045 ~ Fax: 229-890-2402/985-2048 www.mauleairinc.com...

  • Page 2: Warranty

    The Maule M-7 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-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

    Lift Struts..............… Fuselage..............…..…… 21 Movable Surfaces and Controls........…… 22 Landing Gear, Wheels and Brakes.......…...…. 23 Hoisting Wheel Views……………………………………… Parking Brake Control Adjustment……………………….. Maule SFS P8 Tailwheel…………………………………... 27 Power Plant System..…........…...… 30 Fuel System....…......………..… 31 Electrical System....…........…… 32 Electrical Schematic…14V… ………. 34 (s/n 25001C-25044C) Electrical Schematic…14V…...

  • Page 4: Log Of Revisions

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C LOG OF REVISIONS Rev. Description Date page(s) Added Log of revision page iii. 3, 4 Added special maintenance procedures for floatplanes based in 07/19/99 coastal areas or an otherwise corrosive atmosphere. Revised the inspection procedure concerning the horizontal stabilizer strut lower attach stub tubes.

  • Page 5: Section I - General Data

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C 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. Fi- berglass wing tips.

  • Page 6: Fluid Capacities And Specification

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C DESIGN SPECIFICATIONS: (Cont’d) Wings: Airfoil Modified USA 35-B Chord 63 inches Incidence +30 minutes 1.2 degrees Dihedral Sweepback None Areas: 165.6 sq.ft. Wing, Aileron and Flaps 14.2 sq.ft. Ailerons (total) 23.9 sq. ft.

  • Page 7: General Maintenance

    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 sepa- rate dissimilar metals with primers and coatings during manufacture, but there are some loca- tions (such as rivets in wing skins) where this is impossible.
  • Page 8 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C 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 wa- ter on textile materials.

  • Page 9: Inspection Guides

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C 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 60297-9, Initial Revision or later.
  • Page 10 MECH INSP 8. Check general condition of Maule tailwheel, leaf springs and spring attachment. Leaf springs should have 45° angle with no weight on the wheel. Check all bolts and nuts holding the tail springs to the fuselage. Tighten nuts, if needed, so that there is no play or side movement in the springs or their attachment.
  • Page 11 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C MECH INSP 4. Inspect all control cables, pulleys, fairings and electrical connections and wires for security and chafing. 5. Open zippers in headliner and inspect all control cables, pulleys, fairleads and electrical connections and wires for security and chafing.
  • Page 12 NOTE: Check top side of rear elevator horn and cable and bottom side of forward elevator horn and cable if yellow color-coding paint is visible. If missing, paint per Maule Service Bulletin No. 30. 12. CAUTION: At inspection hole in tail, visually check the pivoting action at the control cable attachment points over the full range of rudder and elevator travel.
  • Page 13 15. Lubricate door hinges and latches and seat tracks. CAUTION: Carefully inspect all door hinge bolts and nuts for condition and security. If using elastic nuts on door hinges, they must be replaced with castle nuts and cotter pins. Refer to Maule Service Letter No. 61.

  • Page 14: Periodic Maintenance For Me406/406Hm Elt

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C Periodic Maintenance for ME406/406HM ELT for the US In the United States, minimum maintenance requirements for ELTs are stated in FAR 91.207 para- graph (d): (d) Each emergency locator transmitter required by paragraph (a) of this section must be inspected...

  • Page 15: Weighing Procedure

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C ELT Battery replacement: If replacing the battery pack, order replacement kit 455-0012 which contains the battery pack (452-6499), replacement gasket, hardware and labels. A spare label showing the expiration date is included in the replacement kit. This label should be mounted in the same location as the former expiration date label.
  • Page 16 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C PROCEDURE: 1. Place each of the wheels on a scale with the tailwheel elevated to place the airplane in approximately the flight attitude. 2. Place a level on the leveling mark and leveling lug on the bottom of the right wing near the root.

  • Page 17: Rigging Procedures

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C 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 18 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C 5. AILERONS: Adjust the ailerons to streamline position by placing a straight edge on the bottom of the wing chordwise at the inboard end of the aileron. Then adjust the turnbuckles in the aileron system so the control wheels are centered and there is a gap of zero to ¼...

  • Page 19: Lubrication

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C 9. ELEVATOR TRIM: Elevator trim tab movement is 12° ± 2° up, 38° ± 2° down. If adjustment is needed, it may be done at the turnbuckles located just aft of the trim control. Proper cable tension is 15 to 25 lbs.

  • Page 20: Fabric Repairs

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C 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. Trim the damaged area to a rectangular or circular shape.

  • Page 21: Major Component Parts

    The aft fuselage section is covered with Ceconite fabric and standard dope and paint finish as per Maule Specification S-17. Later models are finished with polyurethane or acrylic urethane paint in accordance with Maule Specifications S-40 or S-41, respectively. This fabric need not be pulled or punch tested.

  • Page 22: Movable Surfaces And Controls

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C MOVABLE SURFACES AND CONTROL 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 23: Landing Gear, Wheels And Brakes

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C LANDING GEAR, WHEELS AND BRAKES MAIN LANDING GEAR: The main landing gear consists of separate left and right side heat-treated (7075-T651) alu- minum spring legs, which are bolted to a square tube truss in the bottom of the fuselage struc- ture.
  • Page 24 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C 24/37 Rev. D...
  • Page 25 18. Reinstall 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 26 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C Leak in system Inspect all attachments and fittings in brake sys- tem. Air in system A springy, rubber action of the pedal indicates air in the system. An excessive amount of air in system will allow the pedal to continue traveling under normal pressure.

  • Page 27: Maule Sfs P8 Tailwheel

    MAINTENANCE MANUAL M-7-235C MAULE SFS-P8B TAILWHEEL The Maule SFS-P8B is a Full Swivel Steerable Tailwheel. See Fig. 1 for detailed break- down. If shimmy of the tailwheel becomes a problem, it should be lubricated and adjusted as fol- lows: A. DISASSEMBLY 1.
  • Page 28 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C 4. Carefully slide the fork spindle through the friction ring and bearings until the friction washer is bottomed against the springs. Make sure that all parts stay in place. 5. Assemble lock ring (73B), arm (6) (with lock pin (13AB) and spring (14) installed), shield (36), and pins (60AB) together as a unit.

  • Page 29: Power Plant System

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C 7. Thread on nut (A1) and torque to 15-20 foot pounds. Fork should rotate by hand, but with some drag, which is normal and caused by the friction washer. 8. Install cap (74B) with soft mallet. Check wheel rotation. There must be no play in the bearings.
  • Page 30 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C An extremely close visual inspection of the engine mount should be made to periodically check for cracks, dents, weld failures, etc., of the mount tubular members as well as the gen- eral condition of the mount. At regular intervals, the attaching bolts at the engine should be checked for tightness (required torque value of 37.5-41.5 ft.

  • Page 31: Fuel System

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C FUEL SYSTEM Two (2), 23.8 gallon (or 21.5-gallon) main fuel tanks, mounted in the inboard end of the wings, have front and rear outlets. The fuel lines running from these tanks terminate at the fuel selector valve on the left side kick panel.
  • Page 32 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C This battery is considered fully charged at a hydrometer specific gravity reading of 1.265. A low charge would be 1.225 or lower. Operating with a low charge will shorten the life of the battery and can be prevented by recharging or operating with the electrical equipment turned off until the battery has been sufficiently recharged.

  • Page 33: Electrical Schematic

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C Electrical Schematic (14V) (For s/n 25001C-25044C) 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-7-235C Electrical Schematic (14V) (For s/n 25044C & up) 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 35: Electrical Schematic

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C Electrical Schematic The wire numbering system has been designed to ease tracing a faulty wire. The cir- (28 Volt) cuit tracing code is as shown below in the schematic. Wires are plainly labeled near each end.
  • Page 36 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C Old Style Door Latch Assembly (New improved Door Latch Assemblies are now available and are being installed in present production. Order Part No. 1395X for new improved Door Latch Assembly) 36/37 Rev. D...

  • Page 37: Airworthiness Limitations Section

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-7-235C Airworthiness Limitations Section The airframe does not have mandatory life limits or overhaul requirements. See Textron Ly- coming Operator's Manual, p/n 60297-9, Initial Revision or later and the Hartzell Owner’s Manual and Logbook, p/n 7998-115N, Revision 14 or later or McCauley Owner’s Manual, p/n MPC-11, Initial Revision or later for the constant speed prop for their airworthiness limitations.

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