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MAULE Star Rocket M-8-235 Maintenance Manual

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FOR
MAULE
M-8-235
Star Rocket
P/N: TLC-M-8-235
PERFORMANCE THAT COUNTS!
Page 1 of 39
Rev. B Dated 6-5-19
2099 Georgia Hwy 133 South ~ Moultrie, GA 31788
Tel: 229-985-2045 ~ Fax: 229-890-2402/985-2048
SMM
PC:
www.mauleairinc.com

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Summary of Contents for MAULE Star Rocket M-8-235

  • Page 1 MAULE M-8-235 Star Rocket P/N: TLC-M-8-235 PERFORMANCE THAT COUNTS! Page 1 of 39 Rev. B 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-8 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-8. Its sturdy construction means you will not have to pamper it to enjoy long years of trouble-free ser- vice.

  • Page 3: Table Of Contents

    Lift Struts..............… Fuselage..............…..…… 22 Movable Surfaces and Controls........…… 22 Landing Gear, Wheels and Brakes.......…...…. 24 Hoisting Wheel Views……………………………………… Parking Brake Control Adjustment……………………….. Maule SFS P8 Tailwheel…………………………………... 28 Power Plant System..…........…...… 31 Fuel System....…......………..… 32 Electrical System....…........…… 33 Electrical Schematic…14V.. ………….. 35 (Circa before 1999) Electrical Schematic…14V..

  • Page 4: Log Of Revisions

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 LOG OF REVISIONS Rev. Description Date page(s) Added Log of revision page 4. Baggage/Cargo Allowance changed to 125 lb. and 175 lb. Structural Limit. Areas corrected. Added Textron Lycoming, Hartzell and McCauley Manual p/n’s.

  • Page 5: Section I - General Data

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 SECTION I GENERAL DATA GENERAL DESCRIPTION: Type: Four/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-8-235 DESIGN SPECIFICATIONS: (Cont’d) Wings: Airfoil Modified USA 35-B Chord 63 inches Incidence +30 minutes 1.2 degrees Dihedral Sweepback None Areas: 173.7 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-8-235 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-8-235 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 *S/n 15006C may have sealed struts when delivered. CAUTION: Item (a)(4) of AD# 98-15-18 is very misleading as Maule never drills holes in struts to at- tach cuffs, door clips or any hardware and it is illegal to do so since there are no approved holes in the wing struts under the TC data.
  • 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. 13. 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 16. 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-8-235 23. Ensure that all applicable Airworthiness Directives and Maule Service Letters and Bulletins that are mandatory have been complied with. 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-...
  • Page 15 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 • On or before the battery replacement (expiration) date. • There is any evidence of corrosion or leakage of any cell or on the small interface board and connector. 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.

  • Page 16: Weighing Procedure

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 WEIGHING PROCEDURE DETAILED CALCULATIONS OF EMPTY WEIGHT AND EMPTY WEIGHT CENTER OF GRAVITY: PROCEDURE: 1. Place each of the wheels on a scale with the tailwheel elevated to place the airplane in approximately the flight attitude.
  • Page 17 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 = net Tailwheel wt. (T) of _________________ Lbs. Total Weight as Weighed (W) = __________________ Lbs. Weighing Procedure (Cont’d) The above empty weight includes unusable fuel of 27.6 lbs. at 24 inches and 12 quarts of...

  • Page 18: Rigging Procedures

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 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 19 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 To check dihedral angle at the front spar, remove both top wing root fairings to expose the front spar attach bolts. Stretch a string along the top of the wing above the front spar, from wingtip to wingtip, and draw it tight.
  • Page 20 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 Adjust the first notch (0°) flap position to be aligned with the aileron trailing edge with the ailerons centered. Check the flap travel with flap handle at fully retracted (handle down) posi- tion for negative 7° ±1° up, and 24° ±3° down for second notch, 40° ±3° down for third notch and 48°...

  • Page 21: Lubrication

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 This tab is interconnected with the aileron system to automatically coordinate aileron and rudder controls for simplified handling in the air. (It may be used as a rudder trim tab to make the airplane trim in cruise.) This tab may be adjusted by changing to the position of the tab cables where they attach to the aileron cables located just over the front doors on the inside of the airplane.

  • Page 22: Major Component Parts

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 Trim the damaged area to a rectangular or circular shape. 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 23: Lift Struts

    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 24: Landing Gear, Wheels And Brakes

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 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 25 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 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. No maintenance is required. However, since the landing loads are taken on these mem- bers, they are stressed and should be inspected frequently for damage and corrosion.
  • Page 26 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 26/41 Rev. B...
  • Page 27 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 28 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 With rudder pedals in neutral position, set cable housing to 2 ¼” dimension as shown on drawing below. Pull the parking brake knob out until the nicopress comes in contact with the cable housing.

  • Page 29: Maule Sfs P8 Tailwheel

    Use only the recommended hydraulic fluid. 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-...
  • Page 30 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 A. DISASSEMBLY 1. Remove cap (74B) - may be pried off with flat side of a screwdriver. 2. Hold the fork (69B) and loosen the nut (A1). 3. With the nut removed, carefully remove the fork spindle from the rest of the assembly.
  • Page 31 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 6. Slide the lock pin subassembly over the threaded end of the fork spindle being careful to keep the parts together. It will be necessary to retract lock pin (13AB) slightly to clear wear plate (75B) as the assemblies are brought together.

  • Page 32: Power Plant System

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 8. Install cap (74B) with soft mallet. Check wheel rotation. There must be no play in the bearings. Wheel should rotate with a slight drag. 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 33 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 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 34: Fuel System

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 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 35 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 If the battery is the sealed type with the base being integrally vented, tubes attached to the case vent the battery to the fuselage bottom. Battery caps should be kept tight to prevent elec- trolyte spillage.

  • Page 36: Electrical Schematic

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 Electrical Schematic (14V) (Circa before 1999) 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 37: Electrical Schematic

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 Electrical Schematic (14V) (Circa 1999 and 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 38 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 38/41 Rev. B...

  • Page 39: Electrical Schematic

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 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 40 MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 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) 40/41 Rev. B...

  • Page 41: Airworthiness Limitations Section

    MAULE AEROSPACE TECHNOLOGY, INC. MAINTENANCE MANUAL M-8-235 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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