MAULE Star Rocket M-8-235, Maintenance Manual

Page 1: ...E 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 PC SMM Tel 229 985 2045 Fax 229 890 2402 985 2048 www mauleai...

Page 2: ...thereof which shall within one 1 year after delivery of such airplane to the original purchaser be returned to Maule with trans portation charges prepaid and which upon Maule s examination shall discl...

Page 3: ...r ME406 406HM ELT 14 Weighing Procedure 16 Rigging Procedures 18 Lubrication 20 Fabric Repairs 21 SECTION III MAJOR COMPONENT PARTS Wings 22 Lift Struts 22 Fuselage 22 Movable Surfaces and Controls 22...

Page 4: ...f color coding paint for elevator horns and cables Added Inspection for ME406 406HM ELT Added Periodic Maintenance for ME406 406HM ELT Added weighing procedures Added set up for installation of rudder...

Page 5: ...ol Systems Dual controls wheels rudder pedals and brakes All con trols directly cable driven Fuel control shut off valve is at the left lower side panel Mechanical flap and trim controls are at the ce...

Page 6: ...FLUID CAPACITIES AND SPECIFICATIONS a Main Fuel Tanks Inboard 100 Octane Right Main Tank 21 5 or 23 8 gallons total Left Main Tank 21 5 or 23 8 gallons total Note 1 5 gallons unusable fuel per 21 5 ga...

Page 7: ...ing product such as Mirror Glaz will keep the glass clean and help polish out minor scratches Experience has shown that airplanes based at coastal airports or where there is an other wise corrosive at...

Page 8: ...t and hard or impossible to re move Set stains should be removed carefully with a clean cloth dampened in denatured alco hol Stains caused by shoe polish can best be removed with turpentine However su...

Page 9: ...or Brackett air filter 7 Inspect all engine engine mount attach bolts 8 Inspect all engine fuel and oil lines for general condition and security 9 Check all engine compartment electrical connections a...

Page 10: ...fle extensions for security and cracking 5 Clean gascolator screen 6 Re torque bolts attaching engine mount to fuselage engine to engine mount Visually inspect mount structure for condition See Engine...

Page 11: ...only Inject into strut approximately one quart of Valoil or Lionoil Multi purpose L 1 Linseed Oil Paralketone LPS 3 Randolph Tube Oil No 315 Tubeseal Lineoil or any other preservative oil conforming t...

Page 12: ...e there is concern about the condition of the main landing gears or their attachments 12 Remove all inspection covers plates and inspect all visible control cables pul leys bellcranks electrical wires...

Page 13: ...one rubber to seal tube from moisture Inspect the struts for dents corrosion or punctures and replace if necessary Reinstall struts with new hardware and document in aircraft records NOTE Double strut...

Page 14: ...the 5 year life rating of the battery pack ELT Battery removal CAUTION The battery pack contains electrostatic sensitive parts Take ESD precautions before handling Damage may happen to the exposed ele...

Page 15: ...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 2 Lay the battery pack on the work surface w...

Page 16: ...ng near the root Adjust the height of the tailwheel until the aircraft is level 3 Measure the following distances a Wheel base L the horizontal distance from the tailwheel weight point center of axle...

Page 17: ...ms of equipment as marked on the accompanying Equipment Lists The certificated empty weight is the above weight less 24 lbs drainable oil for the O 540 engine or above weight less 16 lbs drainable oil...

Page 18: ...abricate two equal length spacers 1 inch minimum length which can be placed on the bolt heads Place a 48 inch level across the two spacers and block under the landing gear to center the bubble Longitu...

Page 19: ...be supported while the front strut is being adjusted For rear strut adjustment see section on washout CAUTION Be sure that the strut fork is not extended more than1 inch of threads from the strut end...

Page 20: ...ropriate length a 2x4 wooden block works fine is ideal to hold the given distance during the rudder rigging process Install rudder cables and related hardware Check the rudder travel for 21 1 right an...

Page 21: ...e rudder LUBRICATION 1 Main wheel bearings Use aircraft quality bearing grease 2 Hydraulic brake reservoirs Use Texaco Aircraft Hydraulic Oil 15 conforming to MIL H 5606E or equivalent 3 Control Colum...

Page 22: ...than the repair patch size Allow this to dry for approximately 15 minutes 8 Apply a second coat of the thinned urethane adhesive and lay the patch in the wet bed of adhesive smoothing the edges while...

Page 23: ...ures are cause for replacement of the strut FUSELAGE The fuselage is a welded truss type structure having an integral vertical tail fin Chrome molybdenum steel 4130 is used for all tube members contro...

Page 24: ...ATORS 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...

Page 25: ...ack or a small bottle jack placed under the lower end of the spring gear leg 3 Remove brake calipers by removing two 2 brake bolts 4 Raise wheel using a hoist with a cable sling placed under the lower...

Page 26: ...MAULE AEROSPACE TECHNOLOGY INC MAINTENANCE MANUAL FOR M 8 235 Rev B 26 41...

Page 27: ...proper level is no closer than inch to top of cylinder Add oil if needed Bleeding brake system may be done as follows 1 Fill reservoir if necessary 2 Replace plug in reservoir 3 Connect a clear plast...

Page 28: ...in step 1 above as necessary for achieving this spring expansion 6 Recheck operation per Steps 1 and 2 CAUTION Push parking brake knob completely against Instrument panel for OFF position MAINTENANCE...

Page 29: ...e pads and thus will always drag slightly Do not be concerned unless this drag is noticeable while taxiing Probable Cause Corrective Action 1 Foreign matter in system 1 If dirt is found in the system...

Page 30: ...nly one 1 or two 2 shims will be required to remove any bearing clearance Too many shims will cause the bearings to drag when the nut is tightened C ASSEMBLY 1 Grease pack roller bearings A5 and lock...

Page 31: ...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 FIGURE 1 7 Thread on nut...

Page 32: ...if the wheel has no tendency to shimmy POWER PLANT SYSTEM The power plant system consists of the engine engine mount propeller cowl engine con trols exhaust air intake system and fuel system ENGINE En...

Page 33: ...or 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 again...

Page 34: ...ground return to the battery All wiring in the airplane is fabricated into harnesses which are groups of related wires tied together Most of the harnesses originate at circuit breakers on the main bu...

Page 35: ...TOR AND ALTERNATOR CONTROL SYSTEM To protect the alternator and battery from an overcharge the voltage regulator should be checked for a charging voltage of 13 7 to a maximum of 14 0 volts with the en...

Page 36: ...NUAL FOR M 8 235 Rev B 36 41 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 sche...

Page 37: ...NUAL FOR M 8 235 Rev B 37 41 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 sche...

Page 38: ...MAULE AEROSPACE TECHNOLOGY INC MAINTENANCE MANUAL FOR M 8 235 Rev B 38 41...

Page 39: ...NCE MANUAL FOR M 8 235 Rev B 39 41 Electrical Schematic 28 Volt The wire numbering system has been designed to ease tracing a faulty wire The cir cuit tracing code is as shown below in the schematic W...

Page 40: ...MAINTENANCE MANUAL FOR M 8 235 Rev B 40 41 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...

Page 41: ...e 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...